Engine 4JJ1

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

Service Marketing Department
ENGINE MECHANICAL (4JJ1)
6A-1
ENGINE
ENGINE MECHANICAL
(4JJ1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4JJ1) . . . . . . . . . . . . . . 6A-3
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3
Work procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6A-7
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-20
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 6A-21
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-26
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6A-28
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31
Torque specifications . . . . . . . . . . . . . . . . . . . . 6A-33
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . 6A-34
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-38
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-38
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-40
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-46
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-48
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54
Valve Stem Seal and Valve Spring . . . . . . . . . . . 6A-55
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Head Disassembly . . . . . . . . . . . . . . . . . . . . . . 6A-64
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Head Reassembly . . . . . . . . . . . . . . . . . . . . . . 6A-70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-72
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-80
Piston and Connecting Rod . . . . . . . . . . . . . . . . 6A-82
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-82
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-83
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-87
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-90
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-91
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-93
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-95
Gear Case Assembly . . . . . . . . . . . . . . . . . . . . . 6A-96
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97
Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . 6A-99
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100
Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-102
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102
Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 6A-103
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
6A-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104

Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-105
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-105
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-105
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-106
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-107
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-117
Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6A-119
Service Precautions . . . . . . . . . . . . . . . . . . . . 6A-119
Functional Check . . . . . . . . . . . . . . . . . . . . . . 6A-120
Oil Filter Element. . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-121
Oil Filter Assembly and Oil Cooler . . . . . . . . . . 6A-123
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-123
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-123
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-124
Crank Case and Oil Pan . . . . . . . . . . . . . . . . . . 6A-126
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-126
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-126
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-128
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-131
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-135
Oil Pressure SW . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-138
Circuit check. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-138
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6A-139
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-139
6A-3
ISUZU DIESEL ENGINE (4JJ1)

Service Precautions
Matters that
maintenance
require
Matters that require attention in specifically dealing

with this engine.
attention
in
terms
of
To prevent damage to the engine and ensure reliability

of its performance, pay attention to the following in
maintaining the engine:
When lifting up or supporting the engine, do not
apply a jack on the oil pan.
When taking down the engine on the ground, do
not make the bearing surface of the oil pan touch
the ground directly. Use a wooden frame, for
example, to support the engine with the engine
foot and the flywheel housing.
Because there is only a small clearance between
the oil pan and the oil pump strainer, it can damage
the oil pan and the oil strainer.
When the air duct or air cleaner is removed, cover
the air intake opening to prevent foreign matter
from getting into the cylinder. If it gets
contaminated, it can considerably damage the
cylinder and others while the engine is operating.
When maintaining the engine, never fail to remove
the battery earth cable. If not, it may damage the
wire harness or electrical parts. If you need
electricity on for the purpose of inspection, for
instance, watch out for short circuits and others.
Apply engine oil to the sliding contact surfaces of
the engine before reassembling it. This ensures
adequate lubrication when the engine is first
started.
When valve train parts, pistons, piston rings,
connecting rods, connecting rod bearings or
crankshaft journal bearings are removed, put them
in order and keep them.
When installing them, put them back in the same
location they were removed from.
Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust is clinging
to them. Then, apply the designated liquid gasket
to each place anew before assembly.
Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes has elapsed, remove the
existing liquid gasket and apply a new liquid
gasket.
When assembling or installing parts, fasten them
with the prescribed tightening torque so that they
are installed properly.
Holes or clearances in the fuel system, which serve as

a passage of fuel, including the inside of the injector,
are made with extreme precision. For this reason, they
are highly sensitive to foreign matter and if it gets in, it
can lead to an accident on the road, for instance; thus,
make sure that foreign matter is prevented from getting
in.
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.
Work procedure
The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
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.
6A-4
How to read the model
LNW71BMF000101
Legend
1. Engine Model (Stamped)
2. Engine Number (Stamped)
Explanation of functions and operations
Electronic engine control

With the control unit, the range from injection to air
intake/exhaust, including fuel injection quantity,
injection timing, intake air restriction, EGR, and idling
rpm, is controlled.
Piston
The piston is aluminum-alloy and a thermal flow piston
with a strut cast, while the combustion chamber is a
round reentrant type.
Cylinder head
The cylinder head is aluminum-alloy and there are 4
valves per cylinder. The angular tightening method of
the cylinder head bolt further increases reliability and
durability.
3. Front
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail
that measures such high-pressure fuel and a fuel
injector that turns it into a fine spray and injects it. Each
is controlled via ECM based upon various signals,
while injection timing or fuel injection quantity is
controlled under every possible driving condition.
6A-5
Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the
fuel injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.
Fuel filter with sedimenter

It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system
The preheating system consists of the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.
Lubrication system
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.
Functional inspection
Inspection/adjustment of valve clearance
1. Inspection of valve clearance
Remove the injection nozzle harness assembly.
Remove the leak off hose.
Remove the cylinder head cover.
Rotate the crankshaft and make the No.1
cylinder compression top dead center (TDC).
Check TDC using a mirror etc.
LNW76ASH001101
Legend
1. Crankshaft Damper Pulley
2. Mirror
3. TDC Mark
Insert a 0.15 mm (0.006 in) thickness gauge
between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw of
the rocker arm. When the movement of the
thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.
Valve clearance
mm (in)
Intake valve
0.15 (0.006)
Exhaust valve
0.15 (0.006)
NOTE:
Adjust while cold.
2. Adjustment of valve clearance
6A-6
Loosen each adjusting screw of the rocker arm

completely.
Insert a 0.15 mm (0.006 in) thickness gauge

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

adjust a valve clearance with { mark given on
the table and if the No. 4 cylinder is the
compression TDC, adjust that with mark.
Install the cylinder head cover.
Refer to Cylinder Head Cover.
Install the leak off hose.
Install the fuel injector harness assembly.
Turn on the starter to inspect compression

pressure.
Measure each cylinder one by one.
Compression pressure inspection

Warm up the engine.
Remove a minus terminal of the battery.
Remove the all glow plugs.
NOTE:
When the harness connector is removed, ECM judges
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear the
memory of the ECM.
(For how to clear the memory of the ECM, refer to
ENGINE CONTROL SYSTEM Section)
Install the minus terminal of the battery.
Turn on the starter to emit foreign matter within the
cylinders.
Install an adapter and the gauge of the
compression gauge with the special tool.
NOTE:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
Remove the compression gauge with the special
tool.
Remove the minus terminal of the batteries.
Install the glow plugs.
Install the minus terminal of the batteries.
A list of defective phenomena
Engine does not turn over.

Engine turns over but does not start.
Excessive black exhaust smoke.
Excessive white exhaust smoke.
Engine knocking.
Abnormal engine rotation.
Abnormal battery charging.
Turbocharger trouble shooting.
Trouble Shooting
LNW76ASH001201
Compression gauge: 5-8840-2675-0

Gauge adapter: 5-8840-2815-0
Engine does not turn over
Condition
Possible Cause
Correction
Condition
Possible Cause
Correction
Starter motor does not rotate
Dead or weak battery
Charge battery
Replace battery
Incomplete circuit
Connect
Repair
Starter motor brushes stuck, worn,

or broken
Replace brushes
Starter motor internal damage
Repair motor
Ring gear abrasion
Replace ring gear
Magnetic switch (starter motor) not

properly adjusted
Adjust
Starter motor not meshed with

flywheel
6A-7
6A-8

Condition
Starter motor pinion meshed with

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

Condition
Fuel is not delivered to fuel supply
pump
Fuel is delivered to fuel supply

pump
Insufficient or unstable fuel delivery

volume
Possible Cause
Correction
Air in fuel system
Bleed air from fuel system
Air entering fuel pipe
Replace pipe and bleed air from

fuel system
Empty fuel tank
Replenish fuel
Clogged strainer (fuel suction)
Clean or replace strainer
Clogged fuel pipe
Clean or replace pipe
Feed pump malfunction
Replace pump
Use of wrong fuel for prevailing

temperatures
Drain existing fuel and replace with

appropriate fuel
Clogged fuel filter
Replace filter
Loose injection pipe connections
Tighten connections
Loose
or
connectors
Tighten and/or replace connectors
broken
electrical
Bad rotational sensor
Replace sensor
Engine control system malfunction
System diagnosis
Air in fuel system
Feed pump malfunction
Repair pump
Loose
or
connectors
broken
electrical
Tighten and/or replace connectors
Clogged fuel filter
Replace filter
System diagnosis
Excessive black exhaust smoke

Condition
Possible Cause
Correction
Bad injection timing
System diagnosis
Bad fuel injector condition
Carbon deposit at nozzle tip
Clean fuel injector assembly
Sticking nozzle
Replace fuel injector assembly
System diagnosis

Condition
Insufficient compression pressure
Possible Cause
Correction
Excessive valve clearance
Adjust clearance
Sticking valve stem (valve open)
Repair or replace valve
Damaged valve spring
Replace spring
Valve seat abrasion
Repair valve seat
Compression leakage
damaged piston ring
6A-9
due
to
Replace piston ring
Damaged gasket
Replace gasket
Piston scoring
Replace piston
Water in fuel

new fuel
Poor fuel quality

new fuel
Clogged intake pipes
Clean or replace pipes
Clogged air cleaner element
Clean or replace element
Malfunction detected by engine

control system
Defective sensor
Replace sensor
System diagnosis
EGR valve and/or intake throttle

valve malfunction
Intake throttle valve sticking
EGR valve sticking
Exhaust brake valve sticking
System diagnosis
Damaged turbocharger blade
Replace turbocharger
Rough turbocharger shaft rotation
Oil leakage from oil seal
Broken actuator
Defective booster sensor
Replace sensor
Fuel condition
Poor engine aspiration
Turbocharger malfunction
Excessive white exhaust smoke

Condition
Possible Cause
Correction
Bad injection timing
System diagnosis

control system
Defective sensor
Replace sensor
Control unit malfunction
Replace unit
System diagnosis
Excessive valve clearance
Adjust clearance
Sticking valve stem (valve open)
Damaged valve spring
Replace spring
Valve seat abrasion
Repair valve seat
Insufficient compression pressure
Compression leakage
damaged piston ring
Fuel condition
due
to
Replace piston ring
Damaged gasket
Replace gasket
Piston scoring
Replace piston
Water in fuel

new fuel
6A-10

Condition
Excessive oil consumption
Possible Cause
Correction
Worn or damaged piston ring(s)
Replace ring(s)
Defective valve stem oil seal
Replace oil seal
Defective turbocharger oil seal
Clogged turbocharger oil return

pipe
Repair pipe
Engine knocking
Condition
Possible Cause
Correction
Bad timing
System diagnosis

control system
Defective sensor
Replace sensor
Control unit malfunction
Replace unit
System diagnosis
Fuel condition
Poor quality fuel

new fuel
Poor engine aspiration
Clogged intake pipes
Clean or replace pipes
System diagnosis
Foreign material in cylinders
Engine overhaul
Scored pistons and/or bearings
Replace pistons and/or bearings
Engine break-down
Abnormal engine rotation

Condition
Engine speed cannot be increased
Engine speed unstable
Turbocharger malfunction
Possible Cause
Correction
Defective control unit
Replace unit
System diagnosis
Defective control unit
Replace unit
System diagnosis
Clogged fuel filter element
Replace element
Defective fuel injector(s)
Replace fuel injector assembly
Water in fuel

new fuel
Air in fuel system
Exhaust brake valve sticking
Damaged turbocharger blade
Rough turbocharger shaft rotation
Broken actuator
Defective booster sensor
Replace sensor
Abnormal battery charging

Condition
No charging
Possible Cause
Correction
Open or shorted wiring and/or

connectors
Repair or replace wiring and/or

connectors
Defective generator
Repair or replace generator
Defective battery
Replace battery

Condition
Insufficient charging
Excessive charging
6A-11
Possible Cause
Correction
Open or shorted wiring and/or

connectors
Repair or replace wiring and/or

connectors
Defective generator
Loose generator drive belt
Adjust belt tension or replace belt
Defective battery
Replace battery
Shorted wiring
Repair or replace wiring
Defective generator
Defective battery
Replace battery
Turbocharger Troubleshooting
Condition
Possible Cause
Engine has less than normal power
Air leakage from intake pipe rubber

hose
Repair
Air leakage from intake cover
Repair
Clogged intercooler cooling section
Clean
Clogged air cleaner element
Clean or replace
Intake throttle valve stuck
Repair or replace
Turbine and
(Interference)
Blue exhaust smoke
Noisy turbocharger operation
Excessive rotating part wear
Correction
housing
contact
Replace
Excessive carbon deposit near

turbine exhaust port that interferes
with turbine
Clean or repair
Rough turbine shaft rotation
Repair or replace
Damaged turbine blade
Repair or replace
Oil leakage from turbocharger oil

seal
Repair or replace
Clogged turbocharger oil return

pipe
Repair
Clogged
passages
Repair or replace
center
housing
oil
Engine oil deterioration
Change engine oil
Gas leakage from intake or exhaust

system
Repair
Turbine and
(Interference)
Repair or replace
housing
contact
Damaged turbine blade
Replace
Turbine shaft bearing abrasion or

scoring
Repair or replace
Engine oil deterioration
Change engine oil
Clogged turbocharger oil feed pipe
Repair
Low engine oil pressure
Repair
Main Data and specifications

Item
Type
Engine model 4JJ1

Diesel/4-cycle/water cooling-type in-line DOHC
6A-12

Item
Engine model 4JJ1
Combustion chamber type
Direct injection type
Cylinder liner type
Liner less
Number of cylinders -cylinder
mm (in)
4-95.4 (3.76) 104.9 (4.13)
bore X strokes
Displacement
cc (cu.in)
Compression ratio
2999 (183)
17.5
Compression pressure
MPa (psi)/rpm
Idling speed
rpm
Valve clearance
Intake
3 (435)/200
700 25
0.15 (0.006) (cold)
mm (in) Exhaust
0.15 (0.006) (cold)
Ignition type
Compressed ignition
Injection order
1-3-4-2
Lubricating system
Lubricating type
Pressure delivery type
Oil pump type

Volume of lubricating oil
Gear type
L (qts)
Oil filter type
10 (10.6)
Full flow filter (cartridge type)
Oil cooling type
Built-in-type, water cooling
Cooling system
Cooling type
Water cooling type
Radiator type
Corrugated fin (pressure type)
Water pump type
Centrifugal, belt drive type
Thermostat type
Wax-type units
Thermostat valve-opening temperature
C (F)
85 (185)
Volume of coolant
L (qts)
10 (10.6) (incl. radiator)
Fuel system
Injection pump type
Fuel supply pump common rail type
Injection nozzle type
Electronic control injector

6-hole
Fuel pump type
Into the fuel tank type
Charging system
Generator type
Power output
AC type
V-A
Regulator type
IC
Starting system
Engage magnet type
Starter type
Power output
Preheat system type
24 - 50 , 24 - 80
Reduction type
V-kW
24 - 4.0, 24 - 4.5
Glow plug

Item
Glow plug standard voltage/electric current
Special Tools
Illustration
Tool Number/ Description
5-8840-2822-0
Valve clearance adjust
nut wrench
5884028220
5-8840-2675-0
Compression gauge
5884026750
5-8840-2815-0
Compression gauge
adapter
5884028150
Engine model 4JJ1

V-A
23 - 3.5
6A-13
6A-14
Engine Assembly
Removal
NOTE:
Instructions for engine removal
Be sure to lock the vehicle's wheels in a fixed
position.
Use an engine hoisting attachment that can
adequately sustain the engine's weight.
Do not get underneath the engine while the engine
is being lifted.
Do not insert fingers into any location where they
may be caught.
1.
2.
3.
4.
Detach the negative cable from the battery.

Drain the coolant.
Remove the starter.
Remove the front exhaust pipe.
2
1
LNW76ASH000201
7. Remove the air intake pipe with the hoses.

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

Refer to Transmission section.
6. Disconnect the air intake hose.
Disconnect the PCV hose (1) from the air intake
hose (2).
Disconnect the air intake hose (2) from the
turbocharger side.
Do not disconnect the air intake hose from the
air cleaner side.
LNW76ASH000301
8. Disconnect the two connectors from the ECM.

Disconnect the connector from the boost
sensor.
the intake throttle valve.
pipe.
6A-15
NOTE:
The bracket on the right side of the engine(1) is used
as an engine hanger when the engine is lifted.
2
1
3
LNW76ASH000501
10. Disconnect the radiator upper hose.

Disconnect the hose from the radiator side.
11. Detach the A/C compressor.
Detach the A/C compressor drive belt.
Detach the compressor from the A/C
compressor bracket.
Fix the compressor and hose in an appropriate
position with wire etc.
12. Disconnect the engine ground cable from the
frame.
13. Disconnect the vacuum hose.
Disconnect the hose(1) from the vacuum pump
side(2).
LNW76ASH000701
16. Remove the cooling fan assembly.

Remove the cooling fan and the fan clutch.
17. Disconnect the power steering pump.
Disconnect the power steering pump with its
hose attached from the engine side.
Fix the pump and hose in an appropriate
18. Disconnect the heater hose (1) from the heater
pipe (2).
1
2
LNW76ASH000601
14. Disconnect the radiator lower hose.

Disconnect the hose from the engine side.
15. Disconnect the fan guide bracket.
Remove the bolts(3).
LNW76ASH000801
19. Install an engine hanger (1).

Special tool
Engine Hanger: 5-8840-2823-0
Install the engine hanger to the rear left side of
the engine.
6A-16
NOTE:
The FR engine hanger is not used for this engine.
Fit hoist wire to the engine hanger and hoist the

engine.
Operate the hoist and move the engine into the
installation position.
2. Fit the engine mounts.
Align the engine mounts to the engine mounting
cross member holes, and once fitted , tighten to
the specified torque.
Tightening torque:
Front independent suspension model
122 Nm (12.4 kgm / 90 lb ft)
Front rigid suspension model
94 Nm (9.6 kgm / 68 lb ft)
3. Fit the fuel hose.
LNW76ASH000901
20. Engine Mounts

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

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

Operate the hoist slowly, and raise the engine
until it is above and protruding from the chassis
frame.
Installation
1. Fit the engine assembly.
6A-17
11. Fit the fan guide.

2
2
1
3
1
3
LNW76ASH000601
8. Attach the engine earth cable to the frame.

9. Fit the A/C compressor.
Fit the A/C compressor, and tighten to the
specified torque.
Attach the drive belt, and adjust the belt's
tension with the tension pulley adjustment belt.
Refer to "Drive Belt" section in the "Cooling
System" chapter for details concerning belt
tension adjustment.
By hand, press the center part of the belt with a
force of 98N (10kg / 142psi), and check with a
scale that the degree of deflection is within the
specified range. Also, check that the belt is not
damaged.
LNW76ASH000701
12. Fit the radiator upper hose.

13. Fit the air intake pipe and hose.
Fit the pipe and the hose between the intake
throttle valve and the intercooler.
Connect the boost sensor connector.
Use new clips. Tighten the clip according to the
marking.
Tightening torque: 6 Nm (0.6 kgm / 52 lb in)
A/C Compressor Belt Degree of Deflection:

(5.5 - 7.3 mm / 0.2165 - 0.2874 in) (new belt)
(7.6 - 9.2 mm / 0.2992 - 0.3622 in) (used belt)
After adjusting belt tension, tighten the tension
pulley's lock nut.
10. Fit the cooling fan Assembly.
Tighten the fan clutch to the fan pulley at the
specified torque.
LNW76ASH000501
14. Connect the ECM harness connector.

Fit the pipe and the hose between the
turbocharger and the intercooler.
marking.
6A-18

17. Remove the engine hanger.
Remove the engine hanger from the rear left
side of the engine.
18. Fit the transmission assembly.
Refer
to
removal
procedure
for
"TRANSMISSION".
19. Install the front exhaust pipe and gaskets.
a. Tighten temporarily.
b. Tighten turbocharger side.
c. Tighten the clamp.
d. Tighten DPD side.
LNW76ASH000301
16. Fit the air intake hose (2).

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

Tightening torque:127 Nm (13.0 kgm / 94 lb ft)
21. Replenish the coolant.
22. Reattach the negative cable to the battery.
LNW76ASH000201
Special Tools
Illustration
5-8840-2823-0
Engine Hanger
5884028230
6A-19
Engine Mount
Components
LNW76AMF000101
Legend
1. Engine Mount
Removal
1. Remove the engine assembly.
Refer to Engine Assembly.
2. Remove the engine mount.
Before removing the engine mount, hang the
engine with a hoist.
Remove the nuts fastened to the engine foot
and engine mount.
Remove the nuts fastened to the engine mount
on the chassis frame side.
Hoist the engine assembly slightly to remove
the engine mount.
LNW46ASH002501
6A-20
Installation
1. Install the engine mount and tighten up with the
specified torque.
The nuts on the chassis frame side
Tightening torque:
Front independent suspension model
122 Nm (12.4 kgm / 90 lb ft)
Front rigid suspension model
94 Nm (9.6 kgm / 68 lb ft)
The nuts on the engine foot side
LNW76ASH001501
2. Install the engine assembly.

Torque Specifications
51 (5.2/ 38)
40 (4.1 / 30)
94 (9.6/69)
LNW76AMF000201
6A-21
Cylinder Head Cover

Components
1
4
9
LNW71BLF000401
Legend
1. Oil Filler Cap
2. Oil Filler Cap Gasket
3. Engine Cover
4. Cylinder Head Cover
5. Bolt
Removal
1. Remove the engine cover.
Remove the oil filler cap before removing the
engine cover.
6.
7.
8.
9.
Head Cover Mounting Rubber

Oil Seal
Head Cover Gasket
Nut
6A-22

NOTE:
Do not reuse the leak-off hose clips (1).
LNW76ASH002201
2. Remove the fuel injector connector (2) and the

leak-off hose(1).
LNW76ASH002101
3. Disconnect the blow-by hose.

4. Remove the cylinder head cover.
1
RTW76ASH000101
LNW71BSH000401
5. Remove the nozzle seal cover from the cylinder

head cover.
Remove from the lower side of cylinder head
cover.
6. Remove the cam end gasket (1).
Remove the liquid gasket that has adhered to
cylinder head completely.
6A-23
Apply attaching cam end gasket. Apply the

liquid gasket (ThreeBond TB-1207B or
equivalent).
1
1
2
RTW56ASH020501
Installation
RTW56ASH022701
1. Install the nozzle seal cover.

Insert from the lever side of cylinder head
cover.
Apply soapy water or engine oil to the surface
of cylinder head cover side.
Insert the nozzle seal cover as far as it will go.
2. Install the cam end gasket.
Apply the liquid gasket (ThreeBond TB-1207B
or equivalent) and mount.
Legend
1. 3.0 - 5.0 mm (0.118 - 0.197 in)
2. 3.0 - 5.0 mm (0.118 - 0.197 in)
3. Install the cylinder head cover.
Tighten the bolts and a nut in order shown in
the illustration.
3
12
11
10
1
3
13
14
15
LNW76ASH001701
RTW56ASH020601
Legend
1. Cam End Gasket
2. Apply The Liquid Gasket
3. 2.0 to 3.0 mm (0.079 to 0.118 in)
4. Install the blow-by hose.

5. Install the leak-off hose and the fuel injector
connector.
6. Install the engine cover.
Install the oil filler cap after installing the engine
cover.
6A-24
Intake Manifold
Components
1
2
3
4
LNW71BLF000101
Legend
1. Intake Manifold Gasket
2. Intake Manifold
3. EGR Valve Assembly Gasket
Removal
Remove the oil filler cap before removing the
engine cover.
4. EGR Valve Assembly

5. Intake Throttle Assembly Gasket
6. Intake Throttle Assembly
6A-25
6. Remove the intake throttle connector(2) and the

EGR valve connector(1).
LNW76ASH002201

sensor.
pipe.
LNW71BSH001101
7. Remove the injection pipe (No.1 to 4).

1
LNW71DSH000101
LNW76ASH000501
3. Remove the A/C compressor.

Remove the A/C belt.
Disconnect the A/C compressor
connector.
4. Remove the A/C compressor bracket.
5. Remove the engine oil level guide tube.
harness
8. Remove the intake manifold and gasket.

Remove the intake manifold with the EGR valve
and the intake throttle.
9. Remove the EGR valve (2) from the intake
manifold (1).
6A-26
10. Remove the intake throttle (3) from the intake

manifold (1).
1
6. Install the engine level guide tube.

7. Install the A/C compressor bracket.
8. Install the A/C compressor.
Install the A/C belt.
9. Install the intake air pipe and hose.
marking.
3
LNW71BSH001001
Installation
1. Install the EGR valve to the intake manifold.
2. Install the intake throttle to the intake manifold.
3. Install the intake manifold.
a. Install the gasket and the intake manifold and
tighten temporarily.
b. Tighten the bolts and nuts in the order
described in the drawing.
5
1
3
8
6
10
LNW71BSH000901
4. Install the injection pipe (No.1 to 4).

5. Connect the intake throttle connector and EGR
valve connector.
LNW76ASH000501
10. Connect the boost sensor connector.

Install the oil filler cap after installing the engine
cover.
6A-27
25(2.5/18)
27(2.8/20)
27(2.8/20)
25(2.5/18)
25(2.5/18)
10(1.0/87lbin)
LNW76ALF000101
6A-28
Turbocharger
Service Precautions
While carrying out maintenance, take appropriate

measures to prevent foreign materials from
entering into the turbine housing, compressor
housing, or oil inlets/outlets.
After servicing the turbocharger, pour clean engine
oil (3-5 cc) into the pipe connecting port before
installing the oil pipe.
The turbocharger is a high precision component

and cannot be disassembled (spins at approx.
100,000 rpm). If any damage whatsoever, such as
dents and scratches, is discovered on the turbo
charger's fins or housing, the entire turbo charger
must be replaced.
Components
4
2
5
LNW71JLF000101
Legend
1. Turbocharger Assembly
2. Oil Feed Pipe
3. Turbocharger Duct
4. Exhaust Adaptor
5. Water Feed Pipe

6. Water Return Pipe
7. Oil Return Pipe

Removal
6A-29
6. Remove the heat protector (1).
1. Drain the coolant.

2. Remove the front exhaust pipe and exhaust brake.
LNW71JSH000301
LNW76ASH000101
3. Remove the following parts.

a. Inlet hose (5)
b. PCV hose (2)
c. Air duct (1)
d. Right side noise cover (6)
e. Fan guide bracket (3)
f. Water feed pipe and VGS vacuum hose (4)
7.
8.
9.
10.
Remove the oil feed pipe.

Remove the water return pipe.
Remove the oil return pipe.
Remove the turbocharger assembly from the
exhaust manifold.
LNW71JSH000101
Inspection
Visual and noise inspection
LNW71BSH000101
4. Remove the AC generator.

Disconnect the generator terminals.
5. Remove the exhaust adapter from
turbocharger.
Remove the adapter's bracket (3).
Remove the exhaust adapter (2).
the
The turbine housing outlet's adaptor and the

compressor housing inlet's rubber hose must be
removed before a visual inspection on the turbocharger
can take place.
The turbocharger can not be disassembled or adjusted.
Check the turbocharger for abnormal noise during
operation.
6A-30
Check the compressor cover and turbine housing

for scratches and/or cracks caused by contact with
the fin.
Check the inner surface of the housing for oil
leakage.
Check the turbine exhaust port for excessive
carbon deposits that may interfere with the fin.
Turn the turbine shaft by hand and check for
dragging or sticking conditions.
Move the shaft and check for excessive clearance
in axial and radial directions.
Axial play on the wheel shaft

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

between wheel shaft and bearing.
Clearance
mm
(in)
Standard
Limit
0.08 - 0.1
(0.0031-0.0039)
0.17(0.0067)
Legend
1. Waste Gate Actuator
2. Waste Gate Hose
3. Pressure Gauge (General Tool)
3. Use the pressure gauge pump to apply pressure
(load) to the waste gate actuator (the engine must
be off).
6A-31
4. Note the pressure at which the control rod moves 2

mm (0.078 in). This pressure must be within the
specified limit.
Control rod pressure range:
kPa (mmHg / psi)
143 - 154 (1068 - 1158 / 20.7 - 22.4)

Actuator operation (EURO 4 Specification)
1. Install a vacuum pump (2) to the actuator (1) as
shown in the illustration.
2
LNW71JSH000101
2. Install the oil return pipe.

Install the O-rings into both sides of the oil
return pipe, and tighten the bolt to the specified
torque.
Tightening torque
Turbocharger side:
Crank case side:
LNW71JSH000201
2. Operate the vacuum pump and apply vacuum

pressure to the actuator.
kPa (mmHg / psi)
Working
vacuum
pressure
Reference
44 (330 / 6.38)
3. Place a vernier caliper on the end of the control rod

of actuator.
Release the vacuum pressure and check the
control rod moves.
Measure the length of the control rod moving.
10 Nm (1.0 kgm / 87 lbin)

25 Nm (2.5 kgm / 18 lbft)
3. Install the water return pipe.

Tighten the water return pipe's eye bolt to the
specified torque.
Tightening torque: 23 Nm (2.3 kgm / 17 lbft)
4. Install the oil feed pipe.
Install the eye bolt to the oil feed pipe on the top
of turbocharger, and tighten the bolt to the
specified torque.
Tightening torque: 39 Nm (4.0 kgm / 29 lbft)
5. Install the exhaust adapter to the turbocharger,
and tighten to the specified torque.
Tightening torque: 27 Nm (2.8kgm / 20 lbft)
6. Fit the heat protector and tighten with the bolt.
Tightening torque: 10 Nm (1.0 kgm / 87 lbin)
Standard length
7 mm (0.28 in)
Installation
1. Install the turbocharger assembly.
Install the gaskets and turbocharger assembly,
and tighten to the specified torque.
Tightening torque
Nut
25 Nm (2.5 kgm / 18 lbft)
Bolt
27 Nm (2.8 kgm / 20 lbft)
6A-32

c. Tighten the clamp.
1

d. Tighten DPD side.
LNW71JSH000301
Legend
1. Heat Protector; Turbocharger
2. Exhaust Adapter
3. Exhaust Adapter Bracket
7. Install the AC generator.
8. Install the following parts.
a. Water feed pipe and VGS vacuum hose (4)
b. Fan guide bracket (3)
c. Right side noise cover (6)
d. Air duct (1)
e. PCV hose (2)
f. Inlet hose (5)
LNW71BSH000101
9. Install the front exhaust pipe and gaskets.

a. Tighten temporarily.
b. Tighten turbocharger side.
6A-33
Torque specifications
10 (1.0/87 lbin)
10 (1.0/87 lbin)
22.5 (2.2/16)
27 (2.8/20)
25 (2.5/1.8)
27 (2.8/20)
25 (2.5/1.8)
10 (1.0/87 lbin)
25 (2.5/1.8)
LNW76ALF001001
6A-34
Exhaust Manifold
Components
1
2
3
4
5
6
Legend
1. EGR Cooler
2. Heat Protector; EGR Cooler
3. Heat Protector; Exhaust Manifold
4. Gasket
Removal
2. Remove the turbocharger assembly.
Refer to "Turbocharger".
5.
6.
7.
8.
Exhaust Manifold
Gasket
Turbocharger Assembly
Gasket
LNW71BLF000601

3. Remove the EGR cooler heat protector.
Limit
6A-35
0.5 (0.02)
NOTE:
If the plane surface exceeds the limit, replace it.
LNW71FSH000101
4. Remove the EGR cooler.

Disconnect the rubber hoses of the water
pipe(IN, OUT) from the EGR cooler.
Remove the EGR cooler and the gasket from
the exhaust manifold.
5. Remove the exhaust manifold heat protector.
LNW21BSH006601
Check a crack in the exhaust manifold visually.

Carefully inspect the turbocharger for abrasion
and/or excessive wear. Make any necessary
adjustments, repairs, and/or part replacements.
Installation
1. Install the exhaust manifold.
Put the gasket in to install the exhaust manifold.
Tighten in order described in the drawing.
LNW71BSH000701
6. Remove the exhaust manifold.

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

Manifold installation plane surface
Standard
mm (in)
0.3 (0.01) or lower
Tightening torque: 25 Nm (2.5 kgm / 18lb ft)

3. Install the EGR cooler.
6A-36
a. Put the gasket in to install the EGR cooler.

b. Temporary tightening order.
123456
c. Fully tightening order.
345126
Tightening torque
Bolt, Nut (1 - 5) : 27 Nm (2.8 kgm / 20 lb ft)
Bolt (6) : 52 Nm (5.3 kgm / 38 lb ft)
6
4
1
2
LNW71FSH000201
4. Connect the rubber hoses to the water pipe(IN,

OUT) of the EGR cooler.
5. Install the EGR cooler heat protector.
6. Install the turbocharger.
Refer to Turbocharger.
6A-37
52(5.3/38)
27(2.8/20)
27(2.8/20)
25(2.5/18)
25(2.5/18)
52(5.3/38)
LNW76ALF000701
6A-38
Timing Gear Train

Components
5
6
8
9
10
11
12
1
13
RTW56ALF001101
Legend
1. Oil Pump Gear
2. Crankshaft Gear
3. Idle Gear D
4. Exhaust Camshaft Gear
5. Intake Camshaft Gear
6. Idle Gear D Sprocket
7. Timing Chain
Removal
1. Drain the engine coolant.
2. Remove the radiator upper hose.
8.
9.
10.
11.
12.
13.
Injection Pump Sprocket

Injection Pump Gear
Idle Gear A
Vacuum Pump Gear
Power Steering Oil Pump Gear
Idle Gear C
6A-39
9. Remove the cover of the gear case cover(1).
3. Remove the fan guide bracket.

2
1
3
LNW76ASH000701
Legend
1. Fan Guide Bracket(RH)
2. Fan Guide Bracket(LH)
3. Bolt
LNW76ASH003201
10. Remove the gear case cover.
4. Remove the cooling fan and fan pulley.
RTW56ASH019701
11. Install the M6 bolt to the idle gear A.
RTW56ASH025401
5. Remove the A/C compressor drive belt and fan

belt.
6. Remove the crank pulley.
NOTE:
Do not reuse the crank pulley bolt and washer.
7. Remove the power steering pump with hose.
8. Remove the vacuum pump.
Remove the vacuum pipe bracket and vacuum
pipe.
Remove the oil pipe (feed side and return side)
of vacuum pump.
6A-40
12. Remove the idle gear A and idle gear A flange, idle
gear A shaft.
14. Remove the crankshaft gear.
RTW56ASH021501
RTW56ASH011301
13. Remove the idle gear C and idle gear C shaft.
Disassembly
1. Remove the scissor gear assembly.
Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Use snap ring pliers to remove the scissor gear
assembly.
4
3
2
1
RTW56ASH011401
RTW56ASH022001
Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A
Reassembly
1. Install the scissor gear assembly.

Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Press against the pin on the left side of the idle
gear A spring to make a gap on the right side of
the spring. Push the spring into place.
Align the sub gear pin with the hole in the right
side of the idle gear A spring. Press the subgear into place.
6A-41
If the measurement exceeds the limit, replace

either the idle gear or the thrust collar.
End clearance of the idle gear
mm (in)
Standard
0.080 - 0.155 (0.003 - 0.006)
Limit
0.20 (0.008)
Measure an end clearance of the idle gear

before removing the idle gear B.
3. External diameter of the idle gear shaft.
Use a micrometer to measure an external
diameter of each idle gear shaft.
the shaft.
4
3
2
1
External diameter of the idle gear A shaft

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

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

ring.
Inspection
1. Measurement of idle gear backlash
Apply a dial gauge on the teeth of the idle gear
to be measured and move the gear to right and
left lightly to read how much the dial gauge
shook (never fail to fix the gear).
the idle gear.
Backlash of the idle gear
mm (in)
Standard
0.10 - 0.17 (0.004 - 0.006)
Limit
0.30 (0.01)
Measure backlash of the idle gear before

removing the idle gear A.
2. Measurement of end clearance of the idle gear.
Insert a thickness gauge between the idle gear
and the thrust collar to measure a clearance.
RTW56ASH021601
4. Clearance between the idle gear and the idle gear

shaft
Measure an inside diameter of the idle gear
bush to calculate a clearance between the idle
gear and the idle gear shaft.
6A-42

either the idle gear or the shaft.
Clearance between the idle gear A and
the shaft
Apply engine oil to the bolt screw thread and

seat, and temporarily tighten together with the
flange (tighten fully in later process).
mm (in)
Standard
0.025 - 0.075 (0.0010 - 0.0030)
Limit
0.200 (0.0079)
Clearance between the idle gear C and

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

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

the idle gear shaft is to be put together.
Install the idle gear A and idle gear A flange,
idle gear A shaft at the position shown in the
figure.
Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).

Align the oil hole of the cylinder body (2) with
the oil hole of the idle gear A shaft (3).
Install the flange so that the front mark (1) face
toward the front.
6A-43
Attach, aligning with the gear crank: idle A and

timing mark.
3
LNW71BSH000501
RTW56ALH000301
5. Tighten the bolts of idle gear A and idle gear C to

Tightening torque:
idle gear A: 32 Nm (3.3 kgm / 24 lb ft)
idle gear C: 59 Nm (6.0 kgm / 44 lb ft)
6A-44
2
RTW56ASH011701
Legend
1. Idle Gear A Bolt
2. Idle Gear C Bolt
RTW56ASH012101
8. Install the vacuum pump.
6. Remove the M6 bolt from the idle gear A.

7. Install the gear case cover.
or equivalent).
1

Install the oil pipe (feed side and return side) of
vacuum pump.
Install the vacuum pipe bracket and vacuum
pipe.
9. Install the power steering pump.
Tighten the nut to the specified torque.
10. Install the cover of the gear case cover
11. Install the crank pulley.
Tightening torque: 294 Nm (30 kgm / 217 lb ft)
12. Install the A/C compressor drive belt and fan
belt.Refer to drive belt tension check procedure for
Heating and air conditioning and Engine cooling in
this manual.
13. Install the cooling fan.
14. Install the fan guide bracket.
15. Install the radiator upper hose.
16. Replenish the engine coolant.
RTW56ASH020101
Legend
1. Apply the liquid gasket
Install the gasket in slot of the gear case cover.
Tighten the bolts to the specified torque.
6A-45
130 (13.3 / 96.2)
8 (0.8 / 69lb in)
294 (30 / 217)

32 (3.3 / 24)
59 (6.0 / 43)
LNW76ALF000601
6A-46
Camshaft Assembly
Components
7
6
5
4
2
RTW56ALF000901
Legend
1. Snap Ring
2. Sub Gear
3. Knock Pin
4. Damper Spring
Removal
1. Rotate the crankshaft to make the No.1 cylinder
compression TDC.
5. Camshaft Gear and Camshaft

6. Cam Cap
7. Bolt
6A-47
4. Remove the baffle plate.

1
2
1
LNW76ASH001101
RTW56ASH006301
Legend
2. Mirror
3. TDC Mark
Legend
1. Baffle Plate

Refer to "Cylinder Head Cover".
3. Install the M5 lock bolt of fixing sub gear.
5. Remove the camshaft bearing cap and camshaft.

Check the engraved making on the camshaft
bearing caps.
1E
2E
3E
4E
1I
5E
2I
3I
4I
5I
RTW56ASH018401
RTW56ASH007101
6A-48
RTW56ASH013801
Disassembly
1. Remove the sub gear assembly.
Clamp the camshaft in a vise. Insert soft metal
protectors (aluminum) between the vise
surfaces and the camshaft.
Use a camshaft gear tool (5-8840-2591-0) to
turn sub gear to right direction to remove the
M5 bolt.
LNW76ASH002501
2. Remove the camshaft gear.

Use a press and socket to remove the camshaft
gear.
2
3
RTW56ASH006501
Legend
1. Press
2. Socket
3. Camshaft Gear
LNW76ASH002601
Use snap ring pliers to remove the scissor gear

assembly.
NOTE:
Take care not to damage the camshaft cams and
journals.
3. Remove the dowel pin.

4. Inspect the camshaft visually.

Check if the journal and cam parts of the
camshaft are worn or damaged, if so, replace it.
6A-49
Use a micrometer to measure the height of the

cam lobe.
If the height of the cam lobe is at the limit or
less, replace the camshaft.
Height of the cam lobe
mm (in)
Inlet
Exhaust
Standard
40.6 (1.60)
40.6 (1.60)
Limit
39.6 (1.56)
39.6 (1.56)
LNW21BSH020201
5. Inspect an end clearance of the camshaft.

Use a thickness gauge to measure an end
clearance of the camshaft gear and the
camshaft bracket.
the camshaft gear or the camshaft.
End clearance of the camshaft
mm (in)
Standard
0.050 - 0.170 (0.002 - 0.007)
Limit
0.25 (0.009)
NOTE:
Measure an end clearance of the camshaft before
disassembling.
LNW21BSH020401
7. Check if the camshaft journal is worn.

Use a micrometer to measure wear which is not
even with a diameter of the camshaft journal.
If the measured uneven wear exceeds the limit,
replace the camshaft.
External diameter of the camshaft journal
part
Standard
29.909 - 29.930 (1.1775 - 1.1783)
Limit
29.809 (1.1736)
Partial wear of the camshaft journal part

Limit
RTW56ASH013901
6. Check if the cam lobe is worn.
mm (in)
mm (in)
0.05 (0.0019)
6A-50

b. Read the difference between the inside
diameter of the camshaft bearing and the
diameter of the camshaft journal.
If the measured oil clearance exceeds the limit,
replace the camshaft bearing.
Clearance of the journal part
mm (in)
Standard
0.030 - 0.112
(0.0012 - 0.0044 )
Limit
0.15 (0.0059 )
LNW21BSH020501
8. Check if the camshaft is bent.

Place the camshaft on a V block to measure a
bend with a dial gauge.
Rotate the camshaft slowly to measure how
much the dial indicator shook. If it exceeds the
limit, replace the camshaft.
Bent of the camshaft
Limit
mm (in)
0.05 (0.0019 )
LNW21BSH054601
Reassembly
1. Install the dowel pin.
2. Install the camshaft gear.
LNW21BSH020601
9. Measure a camshaft journal oil clearance.

a. Measure an inside diameter of the camshaft
bearing with a dial gauge.

Align the knock pin with the slot in the camshaft
gear. Use a press to install the camshaft gear to
the camshaft.
6A-51
Align the sub gear pin (2) with the hole in the
right side of the camshaft gear spring (3). Press
the sub-gear into place.
2
3
RTW56ASH006601
Legend
1. Camshaft
2. Dowel Pin
3. Camshaft Gear
3. Install the sub gear assembly.
Clamp the camshaft in a vise. Insert soft metal
protectors (aluminum) between the vise
surfaces and the camshaft. Press against the
pin on the left side of the camshaft gear spring
(3) to make a gap on the right side of the spring.
Push the spring into place.
LNW76ASH002401
Legend
1. Snap Ring
2. Sub Gear
3. Spring
4. Camshaft Gear
Use snap ring pliers to snugly install the snap
ring.
LNW76ASH002501
4. Tighten sub gear setting bolt.

Use a camshaft gear tool (5-8840-2591-0) to
turn sub gear to right direction until it aligns with
the M5 bolt hole between camshaft driven gear
and sub gear.
6A-52
Tighten the M5 bolt to a suitable torque to

prevent the sub gear from moving.
3
RTW56ASH007001
LNW76ASH002601
Installation
compression TDC.
Legend
3. Idle Gear D
3. Camshaft bearing caps, tighten ten bolts on one
side bank to the specified torque.
Apply engine oil to camshaft journal and
bearing surface of camshaft bearing caps.
2
1E
2E
3E
4E
1I
5E
2I
3I
4I
5I
LNW76ASH001101
Legend
2. Mirror
3. TDC Mark
2. Install the camshaft assembly.
Align timing mark on intake camshaft and
exhaust camshaft to idle gear D.
RTW56ASH018401

4. Check that the alignment marks (camshaft bearing
cap and camshaft) (1) are aligned.
6A-53
Apply engine oil over the screw part and tighten

up the bearing cap with the prescribed torque.
Tightening torque: 18 Nm (1.8kgm / 13 lb ft)
5. Remove the M5 lock bolt of fixing sub gear.
6. Adjustment of valve clearance.
Refer to installation procedure for inspection /
adjustment of valve clearance in this manual.
7. Install the baffle plate.
Tightening torque: 10 Nm (1.0 kgm/87 lb in)

RTW56ASH006901
Nm(kgm/lb ft)
18 (1.8/13)
10 (1.0kgm/87lb in)
Lubricate with engine oil
RTW56AMF001701
6A-54
Special Tools
Illustration
5-8840-2591-0
Camshaft gear tool
6A-55
Valve Stem Seal and Valve Spring

Components
2
3
2
3
4
7
8
14
13
12
11
10
9
RTW56ALF001301
Legend
1. Exhaust Rocker Arm Shaft Assembly
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Fuel Injector Assembly
6. Fuel Injector Clamp Bolt
7. Fuel Injector Clamp
Removal
1. Remove the cylinder head assembly.
Refer to "Cylinder Head".
2. Remove the valve stem end cap.
3. Remove the split collar.
8.
9.
10.
11.
12.
13.
14.
Pin
Spring Lower Seat
Valve Stem Oil Seal
Valve Spring
Spring Upper Seat
Split Collar
Valve Stem End Cap
To prevent the valve from falling into the

cylinder, move the piston to TDC.
6A-56
Use a replacer to compress the valve spring to

remove the split collar.
Special tool
NOTE:
Do not reuse the oil seal.
7. Remove the spring lower seat.
Valve spring replacer: 5-8840-2818-0

Pivot: 5-8840-2819-0
Inspection
Inspect the valve spring
NOTE:
Check the valve spring visually and if there is clear
damage or wear, replace it.
1. Free length
Measure free length of the spring and if it is
shorter than the prescribed limit, replace the
spring.
Free length of the valve spring IN / EX
mm (in)
Standard
49.04 (1.93) / 57.57 (2.27)
Limit
48.15 (1.89) / 56.52 (2.23)
1
RTW56ASH012301
Legend
1. Valve spring replacer
2. Pivot
4. Remove the spring upper seat.
Remove the special tool to remove the upper
seat.
5. Remove the valve spring.
Put the removed valve springs in order by cylinder
number.
6. Remove the valve stem oil seal.
Use pliers to remove the oil seal.
LNW21BSH017001
2. Valve spring squareness.

Use a surface plate and a square to measure
the valve spring squareness.If the measured
value exceeds the specified limit, the valve
spring must be replaced.
Valve spring squareness IN / EX
Limit
RTW56ASH012401
mm (in)
2.1 (0.083) / 2.5 (0.098)
6A-57
Installation
1. Install the spring lower seat.
2. Install the valve stem oil seal.
Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
NOTE:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
Special tool
Valve stem seal installer: 5-8840-2817-0
LNW21BSH017101
3. Tension
Use a spring tester to compress the spring to
the installation height. Measure tension of the
compressed spring. If the measurement is
lower than the limit, replace the spring.
Installation length mm (in)
Tension of the valve spring
37.80 (1.488)
N (kg / lb)
Inlet / Exhaust
Standard
213 (21.7 / 157) /

409 (41.7 / 301)
Limit
188 (19.2 / 138) /

370 (37.7 / 272)
RTW56ASH013701
3. Install the valve spring.

4. Install the spring upper seat.
5. Install the split collar.
Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home
position.
Use a replacer to compress the valve spring
and install the split collar.
Special tool
Pivot: 5-8840-2819-0
LNW21BSH056701
6A-58

NOTE:
Move it up and down to check if it moves smoothly.
1
RTW56ASH012301
Legend
2. Pivot
Special Tools
Illustration
5-8840-2818-0
Valve spring replacer
5884028180
5-8840-2819-0
Pivot assembly
5884028190
5-8840-2817-0
Valve stem seal installer
5884028170
6. Install the valve stem end cap.

7. Install the cylinder head assembly.
6A-59
Cylinder Head
Components
3
4
5
6
7
8
LNW71BLF000901
Legend
1. Timing Chain Tensioner
2. Glow Plug
3. Intake and Exhaust Valves
4. Fuel Injector Assembly
NOTE:
To avoid electric shock;
Set the switch to the 'OFF' position and disconnect
battery negative cable before checking or repairing the
fuel injector, wiring or/and connectors.
Removal
5.
6.
7.
8.
Fuel Injector Clamp

Cylinder Head
Timing Chain Guide
Timing Chain Tension Lever
2. Remove the turbocharger.

6A-60
3. Remove the EGR cooler heat protector.
LNW76ASH000501
LNW71FSH000101

5. Remove the water by pass pipe (1).
7.
8.
9.
10.
Remove the LH noise cover.

Remove the radiator upper hose.
Remove the A/C compressor drive belt.
Remove the A/C compressor.
Remove the compressor from the A/C
compressor bracket.
Fix the compressor and hose in an appropriate
12. Remove the A/C compressor adjust pulley.
1
RTW56ASH008401

sensor.
pipe.
1
LNW76CSH001101
Legend
1. Bolt
2. Nut
14. Remove the oil level gauge tube.
6A-61
19. Remove the harness connector of camshaft

position sensor (1), water temperature sensor (2).
15. Remove the injection pipes (NO.1 to 4).

1
LNW71DSH000101
16. Disconnect the heater hose.

Disconnect the heater hose from the cylinder
block side.
17. Remove the fan guide bracket (LH).
18. Remove the noise shield cover (1) from the lower
timing chain cover.
LNW76CSH001801
20. Remove the timing chain cover.

a. Remove the lower cover (2).
b. Remove the upper cover (1).
1
2
LNW76CSH001001
RTW56CSH001401
21. Remove the fuel injector.

Refer to Fuel Injector in FUEL SYSTEM
section.
22. Remove the glow plug connector.
23. Remove the glow plug .
6A-62
24. Install M5 bolts to the sub gear of the camshaft.
26. Remove the camshaft bearing cap.
1E
2E
3E
4E
1I
5E
2I
3I
4I
5I
RTW56ASH007101
25. Remove the baffle plate (1).
RTW56ASH018401
27. Remove the camshaft.
RTW56ASH006301
RTW56ASH013801

28. Remove the timing chain tensioner (1) and gasket
(2).
6A-63
30. Remove the timing chain tension lever pivot.
2
1
RTW56ASH019401
LNW71BSH001401
29. Remove the idle gear D.

Timing chain is dropped behind.
31. Remove the timing chain from the supply pump

sprocket.
32. Remove the chain guide bolt from the cylinder
head.
RTW56ASH022101
RTW56ASH019501
33. Remove the rocker arm shaft assembly.

NOTE:
Keep the removed rocker arm shaft assembly properly
so that they may be put back to the original place.
6A-64

2
3
2
3
2
10
14
18
15
11
13
17
16
12
RTW56ASH012201
Legend
2. Bolt (Long)
3. Bolt (Short)
5. Front
RTW56ASH008601
36. Remove the cylinder head assembly.

Remove the cylinder head assembly with the
exhaust manifold and the intake manifold.
Remove the cylinder head gasket.
NOTE:
Pay full attention so as not to drop the parts in the gear
case of the front part of the cylinder head or a hole into
which oil pours back in the front.
34. Remove the cylinder head gear case bolts (2) and
nuts (1).
2
1
NOTE:
Replace the head gasket with a new one once it is
removed.
Head Disassembly
1.
2.
3.
4.
5.
Remove the intake manifold assembly.

Remove the exhaust manifold assembly.
Remove the water outlet pipe.
Remove the valve stem cap.
Remove the split collar.
Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Pivot: 5-8840-2819-0
RTW56ASH020801
35. Remove the cylinder head bolts.

Loosen the cylinder head bolts in the order
described in the drawing.
NOTE:
Do not reuse the cylinder head bolts.
6A-65
9. Remove the valve stem oil seal.
1
RTW56ASH012301
RTW56ASH012401
Legend
2. Pivot
6. Remove the spring upper seat
7. Remove the valve spring.
Put the removed valve springs in order by
cylinder number.
8. Remove the intake and exhaust valve.
Put the removed valves in order by cylinder
number.
10. Remove the spring lower seat.

11. Remove the valve guide.
Use the valve guide replacer to press out the
valve guides from the bottom side of the
cylinder head.
Special tool
Valve guide remover and installer:
5-8840-2816-0
RTW56ASH008701
LNW21BSH016801
6A-66

2. The cylinder head lower surface warpage is more
than the limit, it should be replaced.
12. Remove the cam end gasket (1).

1
RTW56ASH020501
RTW56ASH008901
13. Remove the oil seal.

Cylinder Head Lower Face Warpage
mm (in)
Standard
0.05 (0.002) or less
Limit
0.20 (0.0079)
NOTE:
The cylinder head lower face cannot be reground.
RTW56ASH008801
A
E
Inspection
Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is
discovered during inspection.
Cylinder Head Lower Face Warpage
1. Use a straight edge and a thickness gauge to
measure the four sides and the two diagonals of
the cylinder head lower face.
LNW61ASH003901
Cylinder Head Height (H) (Reference)

Standard
mm (in)
143.4 (5.646)
6A-67
Exhaust Manifold Warpage

Use a straight edge and a thickness gauge to measure
the manifold cylinder head fitting face warpage.If the
measured values exceed the specified limit, the
manifold must be replaced.
Exhaust Manifold Warpage
H
mm (in)
Standard
0.05 (0.002) or less
Limit
0.20 (0.008)
RTW56ASH017401
Manifold Fitting Face Warpage

Use a straight edge and a thickness gauge to measure
the manifold cylinder head fitting face warpage.Regrind
the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit
but less than the maximum grinding allowance.If the
measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.
Manifold Fitting Face Warpage
LNW21BSH001601
mm (in)
Standard
0.05 (0.002) or less
Limit
0.20 (0.008)
Maximum Grinding Allowance
0.40 (0.016)
Valve Stem Cap

Make the necessary part replacements.If excessive
wear or damage is discovered during inspection.
Valve Stem Outside Diameter
Measure the valve stem diameter at three points.If the
measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Valve Stem Outside Diameter
RTW56ASH017501
mm (in)
Intake Valve
Exhaust Valve
Standard
6.955 - 6.970
(0.2738 - 0.2744)
6.939 - 6.949
(0.2732 - 0.2736)
Limit
6.935
(0.2730)
6.920
(0.2724)
6A-68

Valve Thickness
Measure the valve thickness.If the measured value is
less than the specified limit, the valve and the valve
guide must be replaced as a set.
Intake and Exhaust Valve Thickness
mm (in)
Standard
1.3 (0.051)
Limit
1.1 (0.045)
LNW21BSH017301
Valve Stem and Valve Guide Clearance

1. Measure the valve stem outside diameter.Refer to
the item "Valve Stem Outside Diameter".
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as
a set.
LNW21BSH017801
Valve Stem Clearance
mm (in)
Intake Valve
Exhaust Valve
Standard
0.030 - 0.060
(0.0012 - 0.0023)
0.038 - 0.068
(0.0015 - 0.0027)
Limit
0.200
(0.008)
0.250
(0.0098)
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Valve Depression
LNW61ASH004001
mm (in)
Standard
0.5 (0.02)
Limit
2.5 (0.098)
6A-69
Use a seat cutter to minimize the scratch and other

roughness (15/45/75 degree-blade), thereby
returning the contact width to the standard value.
2
150
90
30
LNW61ASH004101
Valve Contact Width

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

Remove carbon from the surface of the valve
insert seat.
Attach compound in the valve insert seat.

Insert the valve into the valve guide.
Attach compound on the valve seat surface, rotate
the valve and hit it lightly to grind it, and confirm
that it has even contact all round.
6A-70
NOTE:
Remove compound completely after grinding.
Install the valve seat insert

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

Arc-weld the entire inner diameter of the valve seat
insert.
Cool the valve seat insert for two to three minutes.
Contraction due to cooling makes it easier to
remove the valve seat insert.
Remove the valve seat insert, using a screw driver.
Be sure not to harm the cylinder head.
LNW21BSH018601
Legend
1. Washer
2. Valve Seat Insert
3. Press
Head Reassembly
1. Install the oil seal.
Install on the surface of the injection pipe insert.
Hammer it in so that the seal does not incline.
NOTE:
Be sure not to harm the Lip.
Special tool
Injection pipe oil seal installer: 5-8840-2820-0
LNW21BSH056001
Legend
1. Arc-Weld
2. Valve Seat Insert
3. Screw Driver
RTW56ASH008801
6A-71
RTW56ASH009001
Height from the upper surface of the cylinder head

to the edge surface of the valve guide;
1
NOTE:
When replacing the valve guide, it must be replaced
together with the valve.
1
2
RTW56ASH009101
Legend
1. Cylinder Head
2. Injection Pipe Oil Seal Installer
2. Install the valve guide.
Hammer in the valve guide from the upper
surface of the cylinder head, using the valve
guide installer.
Special tool
Valve guide remover and installer:
5-8840-2816-0
RTW56ASH023001
Legend
1. 12.6 0.1 mm (0.50 0.0039 in)
2. Cylinder Head
3. Install the valve spring lower seat.
4. Install the valve stem oil seal.
Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
6A-72
NOTE:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
Use a replacer to compress the valve spring

and install the split collar.
Special tool
Special tool
Pivot: 5-8840-2819-0
Valve stem seal installer: 5-8840-2817-0
1
RTW56ASH013701
5. Install the intake and exhaust valve.

Apply engine oil on the valve stem part and
install the valve.
RTW56ASH012301
Legend
2. Pivot
NOTE:
Move it up and down to check if it moves smoothly.
9. Install the valve stem end cap.
10. Install the exhaust manifold assembly.
Refer to Exhaust Manifold.
11. Install the intake manifold assembly.
Refer to Intake Manifold.
Installation
1. Select the cylinder head gasket.
LNW21BSH018801
6. Install the valve spring.

7. Install the valve spring upper seat.
8. Install the split collar.
Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home
position.

Cylinder Head Gasket Selection
Cylinder head gasket is determined by the piston head
projection from the cylinder body upper surface, in
order to improve engine performance.
Three types of gasket are provided with difference of
thickness. Select the appropriate one out of three
grades of gasket, according to the following procedure.
Before measurement, clear off carbon from the piston
head and cylinder body surface and also clean the
place where the gasket was installed.
6A-73
4. Obtain the maximum value in the four cylinders.

5. Determine the gasket grade required to the
maximum value described above in accordance
with the following table.
LNW61ASH004301
Cylinder Head Gasket Combination mm(in)
LNW21BSH068001
1. Use a dial indicator to measure the piston

projection amount.
2. Refer to the illustration for the piston head
projection measuring positions. All measuring
positions should be as close as possible to the
cylinder block.
Gasket Grade Mark Piston Projection Gasket Thickness

A
0.067-0.117
(0.0026-0.0046)
0.95
(0.0374)
0.117-0.167
(0.0046-0.0066)
1.00
(0.0394)
0.167-0.217
(0.0066-0.0085)
1.05
(0.0413)
RTW76ASH000301
2
RTW36ASH001701
3. Measure the points 1, 2, 3, 4 and obtain two

differences 1-2 and 3-4 on each cylinder. Calculate
the average value of the piston head projection on
each cylinder.
6A-74

Use a torque wrench and angle gauge to
tighten the head bolts in the order described in
the drawing.
Tightening torque:
1st step = 70 Nm (7.1 kgm / 51 lb ft)
2nd step = 70 Nm (7.1 kgm / 51 lb ft)
3rd step = 60 (degrees)
4th step = 60 (degrees)
17
13
14
10
12
16
RTW56ASH009501
18
NOTE:
Difference of each piston projection must be equal or
within 0.05 mm (0.002 in).
6. Select the gear case gasket.
This should be of the same grade as cylinder
gasket is chosen.
7. Apply liquid gasket (ThreeBond 1207B or
equivalent) at the two locations .
11
15
RTW56ASH009701
Special tool
Angle gauge: 5-8840-0266-0
11. Install the cylinder head gear case bolts (2) and
nuts (1).
Tighten the bolts and nuts to the specified
torque.
2
1
2
1
RTW56ASH020901
8. Install the cylinder head gasket and gear case

gasket within 5 minutes of application of the liquid
gasket.
9. Install the cylinder head assembly.
Wipe the cylinder head assembly lower face.
Install the cylinder head assembly, adjusting the
dowel of the cylinder block.
10. Install the cylinder head bolt.
Please use new cylinder head bolt.
RTW56ASH020801
12. Install the rocker arm shaft assembly.

Apply the engine oil.

Attach the rocker arm shaft assembly in
sequence from No.1 to No.4.
6A-75

compression top dead center (TDC).

2
3
4
LNW76ASH001101
RTW56ASH012201
Legend
2. Bolt (Long)
3. Bolt (Short)
5. Front
13. Install the water by pass pipe.Apply soapy water to
the O-ring.Tighten the bolt to the specified torque.
Legend
2. Mirror
3. TDC Mark
17. Install the timing chain with idle gear D.
Apply the engine oil bolt thread and seat.
Tightening torque: 59 Nm (6.0 kgm/43 lb ft)

14. Install the chain guide bolt from cylinder
head.Tighten the bolt to the specified torque.
RTW56ASH021801
RTW56ASH019501
15. Install the tension lever.
6A-76
Align the timing marks at two locations as

shown.
1
19. Hold the latch(3) depressed.

Insert the plunger(2).
Attach the hook(4) to the pin(1) to hold the plunger
in place.
1
RTW56ASH020301
Legend
1. Timing Chain
2. Timing Mark
3. Blue Link
4. Yellow Link
LNW71BSH001501
20. Install the timing chain tensioner (1) and gasket

(2). Tighten the bolt to the specified torque.
18. Install the timing chain tension lever pivot.Tighten

the bolt to the specified torque.
2
1
LNW71BSH001401
RTW56ASH019401
21. Unlock the tensioner hook.

Press the place of the arrow in the figure.
The hook is opened. The plunger pushes the
tension lever.
RTW56ASH020401

Align timing mark on intake camshaft and
exhaust camshaft to idle gear D.
6A-77
RTW56ASH013801
24. Align mark (1) on camshaft to mark on camshaft

bearing cap.
Align mark on intake camshaft and exhaust
camshaft to mark of bearing cap.
3
RTW56ASH007001
Legend
3. Idle Gear D
23. Install the camshaft bearing cap.
Apply engine oil to all of the cylinder head
journals.
RTW56ASH006901
25. Remove the M5 lock bolt from the camshaft Gear.

26. Turn the crank pulley two rotation (720CA)
Align mark on camshaft to mark on camshaft
bearing cap.
6A-78
31. Install the noise cover.

Refer to procedure for fuel system in this manual.
32. Inspection and adjustment of valve clearance.
Refer to procedure for service precautions in this
manual.
33. Install the fuel injector.Refer to procedure for fuel
system in this manual.
34. Install the baffle cover.Refer to procedure for
camshaft in this manual.
35. Install the cam end gasket.
or equivalent).
3
RTW56ASH020701
Legend
3. Idle Gear D
2
RTW56ASH020601
Legend
1. Cam End Gasket
2. 2.0 to 3.0 mm (0.078 to 0.118 in)

37. Install the glow plug. Tighten the glow plug to the
specified torque.
4
RTW56ASH020301
Legend
1. Timing Chain
2. Timing Mark
3. Dark Plate
4. Yellow Plate
27. Apply liquid gasket to timing chain cover upper.
28. Install the timing chain cover upper.
29. Apply liquid gasket to timing chain cover lower.
30. Install the timing chain cover lower.

38. Install the glow plug connector. Tighten the nuts to
39. Install the fuel injection pipe.
Attachment order No.2No.1No.3No.4
40. Tighten the fuel injector clamp bolt to the specified
torque.
41. Tighten the injection pipe to the specified torque.
42. Install the fuel injection pipe clip .Tighten the nut to

43. Install the engine oil level gauge guide.
Apply engine oil to the O-ring. Tighten the bolt
to the specified torque.
44. Install the A/C compressor bracket.Tighten the bolt
45. Install the A/C compressor adjust pulley. Tighten
the bolt (1) and nut (2) to the specified torque.
Tightening torque: bolt 25 Nm (2.6 kgm/19 lb ft) (Dry)
Tightening torque: nut 41 Nm (4.2 kgm/30 lb ft)
1
LNW76CSH001101
46. Install the A/C compressor and connector.

Tighten the bolt to the specified torque.
47. Connect each connector.
Barometric Sensor
EGR Valve
Glow plug
Water temperature sensor
Camshaft Position sensor
Throttle Assembly
48. Install the exhaust front pipe.
Refer to procedure for exhaust system
manual.
49. Install the EGR cooler.
manual.
50. Install the EGR cooler water pipe.
manual.
51. Install the EGR cooler heat protector.
manual.
in this
in this
in this
in this
6A-79

Refer to procedure for Engine cooling in this
manual.
53. Install the A/C drive belt.
Refer to Procedure for Intake Manifold in this
manual.
56. Install the Turbocharger.
6A-80
70(7.1/51)
25(2.5/18)
70(7.1/51)
18(1.8/13)
60
60
2(0.2/17lb in)
25(2.5/18)
10(1.0/87lb in)
26(2.7/20)
25(2.5/18)
27(2.8/20)
LNW76ALF000801
Special Tools
Illustration
Illustration
5-8840-2820-0
Injection pipe oil seal
installer
5884028200
5-8840-2816-0
Valve guide remover and
installer
5884028160

Illustration
5-8840-2817-0
Valve stem seal installer
5884028170
5-8840-2818-0
Valve spring replacer
5884028180
5-8840-2819-0
Pivot
5884028190
5-8840-0266-0
Angle gauge
6A-81
6A-82
Piston and Connecting Rod

Components
2
1
5
RTW56ALF001601
Legend
1. Piston Pin Snap Ring
2. Piston Pin
3. Piston Ring
Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
3. Remove the camshaft assembly.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
4. Piston
5. Connecting Rod
6. Bearing
5. Remove the gear case assembly.

Refer to "Gear Case Assembly".
6. Remove the oil pan.
Refer to "Oil Pan and Crank Case" .
7. Remove the connecting rod cap.
NOTE:
Sort the removed bearings according to cylinders by
using tags.
LNW21BSH004901
8. Remove the piston and connecting rod.

Remove carbon on the upper side of the
cylinder block with a scraper.
Pull out the piston and connecting rod towards
the cylinder head.
NOTE:
Be sure not to damage the oil jet and cylinder block
when pushing out the connecting rod.
6A-83
LNW21BSH005101
2. Remove the snap ring.

3. Remove the piston pin.
NOTE:
Sort the disassembled piston pins, pistons and
connecting rods together in the same order as the
cylinders.
9. Remove the connecting rod bearing.

NOTE:
Sort the bearings in the order of cylinders when reusing
them so that they are not confused with the bearings of
other cylinders.
Disassembly
1. Remove the piston ring.
Use ring pliers to remove the piston ring.
NOTE:
Sort the piston rings in the same order as the cylinders
when reusing them so that they are not confused with
the pistons and piston rings of other cylinders.
LNW21BSH005201
4. Remove the connecting rods from the piston.

5. Piston
Carefully clean carbon that is adhered to the
head of the piston and the groove of the piston
ring.
NOTE:
Do not use a wire brush to clean the piston because it
scratches the piston.
Visually inspect the piston for cracks, burns and other
excessive wear, and replace it if there is any
abnormality.
6A-84
6. Measure the gap between the piston and the inner

diameter of the cylinder bore.
Inner diameter of the cylinder block.
Use a cylinder bore dial indicator to measure
the cylinder block inner diameter both in the
thrust and radial directions in the designated
position.
Measurement position (from the upper surface
of the cylinder block) 20 mm (0.79 in)
Measure the cylinder block inner diameter
based on the average value of the actual
measurement values on 2 positions.
Cylinder block inner diameter
Measurement position (from the bottom surface

of the piston) 11.00 mm (0.43 in).
mm (in)
95.421 - 95.450 (3.75673 - 3.75787)
RTW56ASH023101
Legend
1. 11 mm (0.43 in)
1
Gap between the piston and the inner

diameter of the cylinder block
Standard
mm (in)
0.082 - 0.100 (0.0032 - 0.0039)
NOTE:
If it is found that the gap between the cylinder block
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder block.
LNW21BSH039801
Legend
1. 20 mm (0.79 in)
2. Radial
3. Thrust
Piston outside diameter
Use a micrometer to measure the outside
diameter of the piston in the right angle to the
piston pin in the designated position.
7. Piston replacement
The head of the piston has a marking of grade
A, B or C.
The mark shows the grade of the piston.
If oversize pistons are installed, rebore the
cylinder block.
Refer to "Cylinder Block".
Piston Grade (Service Part)
mm (in)
95.340 - 95.369 (3.75354 - 3.75469)
95.350 - 95.379 (3.75394 - 3.75508)
95.360 - 95.389 (3.75433 - 3.75547)
6A-85
Push the piston ring into the cylinder bore until

it reaches the measuring point 1 or 2 where the
cylinder liner bore is the smallest.Do not allow
the piston ring to slant to one side or the other.
It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 20 mm (0.8 in)
2
LNW76ASH001401
Legend
1. Grade
2. Front Mark Cut
8. Inspect the piston ring.

Insert the piston ring horizontally (in the position
it would assume if it were installed to the piston)
into the cylinder liner.
LNW61ASH004401
LNW61ASH004501
LNW21BSH034801
Use a thickness gauge to measure the piston

ring gap.
If the measured value exceeds the specified
limit, the piston ring must be replaced.
Piston ring gap
mm (in)
Standard
Limit
1st compression ring
0.27 - 0.51
(0.0106 - 0.0200)
1.50
(0.059)
2nd compression ring
0.42 - 0.66
(0.0165 - 0.0260)
1.50
(0.059)
6A-86

0.27 - 0.56
(0.0106 - 0.220)
Oil ring
1.50
(0.059)
Measure the clearance between the piston ring

groove and the piston.
Remove carbon in the piston ring groove.
Put the piston ring in the piston ring groove, use
a thickness gauge to measure the gap between
them.
If the clearance between the piston ring groove
and the piston exceeds the limit, replace the
piston and the piston ring.
Piston ring and piston ring groove
clearance
mm (in)
Standard
Limit
1st compression ring
2nd compression ring
0.05 - 0.09
(0.0020 - 0.0035)
1.50
(0.059)
Oil ring
0.03 - 0.07
(0.0012- 0.0028)
1.50
(0.059)
LNW21BSH009601
Inspect to make sure that there is a resistance

to the extent which the piston can push the
piston pin lightly in normal temperatures.
If it feels a large looseness or instability in
normal temperatures, replace the piston or
piston pin.
*Measurement is impossible
LNW21BSH009701
LNW21BSH009501
9. Inspect the piston pin.

Visually inspect the piston pin for cracks,
scratches and other damages, and replace it if
necessary.
Use a micrometer to measure the outer
diameter of the piston pin. If the measured
value exceeds the limit, replace the piston pin.
Piston pin outer diameter
mm (in)
Standard
33.995 - 34.000 (1.33838 - 1.33858)
Limit
33.970 (1.33740)
Measure the bush of the small edge of the

connecting rod. If the clearance of the bush
inner diameter and the pin diameter exceeds
the limit, replace the bush or connecting rod
assembly, and the pin.
Piston pin and connecting rod small end
bushing clearance
mm (in)
Standard
0.008 - 0.020 (0.0003 - 0.0008)
Limit
0.05 (0.0020)
LNW21BSH009801
10. Measure the clearance between the piston and the

piston pin.
Apply engine oil on the piston pin. Use your
finger to push it in the piston hole and rotate it.
If the pin smoothly rotates without instability, the
clearance is normal. If there is instability,
measure the clearance.
If the clearance
exceeds the limit, replace the piston and the
piston pin.
LNW21BSH010401
12. Measure the bearing oil clearance.

Install the bearing to the connecting rod big
end.
Tighten the bearing cap to the two step of
angular tightening method.
Use an inside dial indicator to measure the
connecting rod bearing inside diameter.
Connecting rod bearing cap bolt torque:
Piston pin and piston pin hole clearance
mm (in)
Standard
0.008 - 0.019 (0.0003 - 0.0007)
Limit
0.04 (0.0016)
11. Measure the connecting rod alignment.

Use a connecting rod aligner to measure the
torsion and parallel level of the big end hole and
the small end hole. If the measured value
exceeds the limit, replace it.
Connecting rod alignment
(par length of 100 mm (3.94 in))
6A-87
mm (in)
1st step
29.4 (3.0 / 22)
2nd step
45 deg
If the clearance between the measured bearing

inside diameter and the crank pin exceeds the
specified limit, the bearing and/or the
crankshaft must be replaced.
Crank pin and bearing clearance
mm (in)
Standard
0.029 - 0.083 (0.0011 - 0.0026)
Limit
0.10 (0.0039)
mm (in)
Standard
Limit
Distortion
0.08 (0.003) or less
0.20 (0.008)
Parallelism
0.05 (0.002) or less
1.50 (0.006)
Reassembly
1. Install the piston.
2. Install the connecting rod.
Install it so that the front mark of the head of the
piston, and the connecting rod forging mark
(projecting) on the connecting rod, both face in
the same direction.
Install the snap ring of one side.
6A-88

Insert the expander coil into the oil ring groove
so that there is no gap on either side of the
expander coil before installing the oil ring.
1
3
1
2
3
LNW41BSH003701
Legend
1. Front Mark
2. Forging Mark (Projecting)
RTW56ASH023201
3. Apply enough engine oil on the piston pin, push it

in the piston and the connecting rod small edge.
4. Use snap ring pliers to install the snap ring.
NOTE:
Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.
LNW61ASH004601
5. Use ring pliers to install the piston ring.

Install the piston rings in the order shown in the
illustration.
Install 2nd and 1st compression rings in this
order so that the marks "2N" and "N" face
upward.
Legend
1. Compression Ring 1st
2. Compression Ring 2nd
3. Oil Ring
4. Expander
Installation
1. Install the connecting rod bearing.
Install the bearing on the connecting rod, and
apply engine oil on the bearing.
2. Install the piston and connecting rod assembly.
Apply enough engine oil on the piston ring, ring
groove and piston side surface.
Dislocate the piston ring end gap so that (1) is
1st ring, (3) is 2nd ring and (2) is oil ring, as
shown in the drawing.
With the piston front mark cut facing forward,
use the piston ring compressor to insert the
piston in the cylinder liner.
NOTE:
Be sure not to make the connecting rod touch the oil
jet when pushing in the piston.
Be sure not to harm the inside of the cylinder block
when pushing in the piston.
6A-89
Special tool
Piston ring compressor: 5-8840-9018-0
LNW21BSH011401
LNW21BSH072201
3. Install the connecting rod cap.

Install the bearing on the connecting rod cap
and apply engine oil.
Install the cap, matching the numbers (1, 2, 3,
and 4) of the caps and connecting rods.
LNW61ASH004801
Apply engine oil on the screw part and the

setting face of the tightening bolt and tighten it
with the designated torque.
Tightening torque:
1st step = 29.4 Nm (3.0 kgm / 22 lb ft)
2nd step = 45 (degrees)
Special tool
Angle gauge: 5-8840-0266-0
NOTE:
Make sure that the crankshaft smoothly rotates.
4. Install the oil pan.

Refer to "Oil Pan and Crank Case".
5. Install the gear case assembly.
6. Install the cylinder head.
6A-90
Nm(kgm/lb ft)
1st STEP
2nd STEP
29.4(3.0/22)
45
Lubricate with engine oil
RTW56AMF001801
Special Tools
Illustration
5-8840-9018-0
Piston ring compressor
5884090180
5-8840-0266-0
Angle gauge
6A-91
Flywheel
Components
5
3
2
1
10
8
9
LNW71BMF000601
Legend
1. Pressure Plate Assembly
2. Driven Plate
3. Pilot Bearing
4. Washer
5. Flywheel
Removal
1. Remove the starter.
2. Remove the transmission assembly.
Refer to "transmission assembly removal and
installation".
3. Remove the clutch pressure plate.
Remove the pressure plate installation bolts in
the order shown in the drawing.
Remove the pressure plate from the flywheel.
6.
7.
8.
9.
Bearing Stopper
Flywheel Housing
Flywheel (Smoother E)
Flexible Plate
6A-92

In the case of A/T car, after loosening the
flywheel installation bolts, remove the washer,
flexible plate, flywheel and sleeve in this order.
10
4
1
5
3
LNW21BSH002501
4. Remove the driven plate.

Remove the driven plate from the flywheel
along with the clutch aligner (1).
5. Install the crankshaft stopper in the starter
installation part of the flywheel housing.
NOTE:
Make sure that the stopper is applied with the ring gear
and installed properly.
Special tool
LNW21BSH072801
7. Remove the pilot bearing.

Remove the pilot bearing from the flywheel.
Crankshaft stopper: 5-8840-0214-0
2
3
LNW21BSH029301
LNW21BSH007701
6. Remove the flywheel.

Gradually loosen the flywheel installation bolts
in the order shown in the drawing so that the
flywheel does not rotate.
After loosening the bolts, remove the stopper
and remove the flywheel.
Special tool
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
8. Remove the ring gear.
Put a bar on the ring gear and hit it with a
hammer to remove it.
6A-93
Depth = From the pressure installation surface to

the friction surface.
LNW21BSH012001
LNW21BSH011901
Inspection
1. Visual inspection
Inspect the flywheel friction surface for cracks
and damages, and replace it if it has
abnormality.
Inspect the tooth part of the ring gear, replace
the ring gear if it has damage or serious wear.
2. Measurement of the friction surface
Measure the depth of the friction surface of the
flywheel.
Adjust it if the measured value is within the
standard value and the limit.
If the measured value exceeds the limit, replace
the flywheel.
Depth of the friction surface of the flywheel
Standard
12 (0.4724)
Limit
13 (0.5118)
mm (in)
3. Flywheel installation bolts.

There is no damage in appearance.
Exchange for a new part if damage is
extensive.
Installation
1. Install the pilot bearing
Place the crankshaft pilot bearing right angle
across the crankshaft bearing installation hole.
Tap around the edges of the crankshaft pilot
bearing outer races with a brass hammer to
drive the bearing into the crankshaft bearing
installation hole.
2. Install the ring gear.
Heat the ring gear evenly with a gas burner to
invite thermal expansion. Do not allow the
temperature of the gas burner to exceed 200C
(390F).
Install the ring gear when it is sufficiently
heated. The ring gear must be installed with the
chamfer facing the clutch.
NOTE:
Install the ring gear so that the side with a pattern
faces forward.
Shrink fit the ring gear to the flywheel.Make sure
that flywheel and ring gear adhesion is complete.
6A-94
LNW21BSH002601
LNW21BSH012101
3. Install the flywheel.

Install the flywheel of the crankshaft, tighten
them in the order shown in the illustration.
Apply molybdenum disulfide on the screw part
and setting face of the bolt.
Install the crankshaft stopper on the starter
installation part of the flywheel housing.
Tightening torque:
1st step = 59 Nm (6.0 kgm / 43 lb ft)
Legend
1. Clutch Aligner
5. Install the clutch pressure plate.
Install the pressure plate on the flywheel so that
the installation hole of the pressure plate
matches with the dowel pins of the flywheel.
Tighten the pressure plate in the order shown in
the drawing.
Tightening torque: 51Nm (5.2 kgm / 38 lb ft)
2nd step = 60 - 90 (degrees)

Special tool
Crankshaft stopper: 5-8840-0214-0
9
1
10
8
8
6
2
2
LNW21BSH002501
LNW71BSH001301
4. Install the driven plate.

Use a clutch aligner to install the driven plate on
the flywheel.
6. Install the transmission assembly.

Refer to "transmission assembly removal and
installation".
7. Install the starter.
6A-95
59(6.0/43)
60
to 90
51(5.2/38)
59(6.0/43)
60
to 90
LNW76AMF000301
Special Tools
Illustration
5-8840-2230-0
Crankshaft stopper
5884022300
5-8840-0266-0
Angle gauge
6A-96
Gear Case Assembly

Components
3
4
LNW76ALF000301
Legend
1. Adjust Plate
2. Generator
Removal
Refer to Cylinder Head.
3. Remove the adjustment bracket of generator.
4. Remove the vacuum pump and pipe.
Refer to removal procedure for brake in this
manual.
3. Gasket
4. Gear Case Assembly
5. Remove the power steering pump.

Refer to removal procedure for power steering in
this manual.
6. Remove the water pump.
Refer to removal procedure for water pump in this
manual.
7. Remove the fuel supply pump.
Refer to removal procedure for fuel supply pump in
this manual.

8. Remove the crankshaft pulley.
Refer to removal procedure for crankshaft front oil
seal in this manual.
Refer to removal procedure for gear case cover in
this manual.
10. Remove the idle gear A and idle gear A shaft, idle
gear C and idle gear C shaft.
Refer to Timing Gear Train.
11. Remove the oil pump.
Refer to Oil Pump.
12. Remove the timing gear case (1) and gasket (2).
Install the timing gear case to match with the

dowel pins, install bolts them in the order shown
in the illustration.
Do not remove the bolts(11) when maintaining.
11
10
11
2
4
6
2
7
2
2
9
1
RTW76ASH001201
Installation
1. Install the gasket of the timing gear case.
Apply liquid gasket (ThreeBond 1207B or
equivalent) on the joint (1) of the cylinder block
and the crank case.
RTW56ASH016301
2. Install the timing gear case.
11
6A-97
LNW76ASH002701
Legend
1. Gear Case Assembly
2. Bolt L = 20 mm (0.79 in)
3. Bolt L = 60 mm (2.36 in)
4. Bolt L = 45 mm (1.77 in)
5. Bolt L = 35 mm (1.38 in)
6. Bolt L = 16 mm (0.63 in)
7. Bolt L = 20 mm (0.79 in)
8. Bolt L = 25 mm (0.98 in)
9. Nut
10. UP
10. Bolt
Tighten the bolts and nuts to the specified
torque.
3. Install the oil pump.
Refer to Oil Pump.
4. Install the idle gear C shaft and idle gear C, idle
gear A shaft and idle gear A.
Refer to Timing Gear Train.
Refer to removal procedure for gear case cover in
this manual.
6. Install the crankshaft pulley.
Refer to removal procedure for crankshaft front oil
seal in this manual.
7. Install the fuel supply pump.
Refer to installation procedure for fuel supply
pump in this manual.
8. Install the water pump.
Refer to installation procedure for water pump in
this manual.
6A-98

Refer to removal procedure for power steering in
this manual.
10. Install the vacuum pump and pipe.
Refer to removal procedure for brake in this
manual.
11. Install the adjustment bracket of generator.

25 (2.5/18)
25 (2.5/18)
51 (5.2/38)
25 (2.5/18)
LNW76ALF000401
6A-99
Crankshaft Front Oil Seal

Components
7
6
2
1
LNW76AMF000401
Legend
1. Bolt
2. Washer
4. Crankshaft Front Oil Seal
5. Gear Case Cover

6. Slinger
7. Crankshaft Gear
Removal
1. Remove the radiator.
Refer to Radiator in ENGINE COOLING section.
2. Remove the fan assembly.
Remove the fan assembly unscrewing four
mounting nuts.
LNW61BSH003601
6A-100

Tighten the bolt as far as it will go.
3. Remove the fan belt.

4. Remove the crankshaft pulley.
Special tool
NOTE:
Do not reuse the crankshaft pulley bolt and the washer.
5. Remove the crankshaft front oil seal.
Use the special tool to remove the front oil seal.
Oil seal and slinger installer: 5-8840-2855-0

The length from the surface of the crankshaft gear to
the surface of the slinger:
Special tool
Remover: 5-8840-0027-0
Put a rod and a wooden piece etc. as shown in
the illustration. And pull the rod to the front
slowly, and remove the crankshaft front oil seal.
5.8 - 6.2 mm (0.228 - 0.244 in)
2
1
3
LNW76ASH002901
LNW76ASH002801
Legend
1. Rod
2. Remover
3. Wooden Piece
7. Remove the slinger.
Remove the slinger with a screwdriver etc.
avoiding damage to the surface of the
crankshaft gear.
Legend
1. Bolt
2. Washer
3. Slinger Installer
4. Slinger
5. Crankshaft Gear
6. Crankshaft
3. Install the crankshaft front oil seal.
Use the special tool to install the front oil seal.
Use only one of the special tools when the oil
seal is installed.
NOTE:
The slinger does not need to be replaced if there are no
scratches nor damages.
Special tool
Installation
The length from the surface of the crankshaft gear to

the surface of the oil seal:
1. Install the slinger.

Use the special tool to install the slinger.
Oil seal and slinger installer: 5-8840-2855-0
14.75 - 15.25 mm (0.581 - 0.600 in)

4
2
LNW76ASH003001
Legend
1. Bolt
2. Washer
3. Front Oil Seal Installer
4. Gear Case Cover
5. Front Oil Seal
6. Slinger
7. Crankshaft Gear
8. Crankshaft
Apply engine oil to the lip of the oil seal.
4. Install the crankshaft damper pulley.
Install the crankshaft pulley aligning with the
key on the crankshaft.
Hold the flywheel ring gear stationary to prevent
the crankshaft from turning when tightening the
damper pulley bolt.
Tighten in the sequence shown.
Take care not to damage the crankshaft
damper pulley boss.
Tightening torque: 294 Nm (30 kgm/217 lb ft)
5. Install the fan belt.
Refer to "Engine Cooling"
6. Install the radiator.
Refer to Radiator in ENGINE COOLING section.
6A-101
6A-102
294(30/217)
LNW76AMF000501
Special Tool
Illustration
5-8840-0027-0
Remover
5-8840-2855-0
Oil seal and slinger
installer
5884028550
6A-103
Crankshaft Rear Oil Seal

Components
LNW71BLF000501
Legend
1. Starter
2. Transmission Assembly
3. Clutch Pressure Plate
4. Driven Plate
Removal
Refer to "Flywheel".
With the oil seal pushed in deep, install the
special tool as shown in the illustration and
remove the oil seal.Oil Seal Remover: 5-88402360-0
5.
6.
7.
8.
Flywheel
Crankshaft Rear Oil Seal
Transmission Assembly
Flexible Plate
6A-104

Use an oil seal install to install the crankshaft
rear oil seal.
Oil Seal Installer: 5-8840-2359-0
12.50.3mm
(0.490.01in)
LNW76ASH002301
Installation
RTW56ASH022901
1. Install the crankshaft rear oil seal.
Special Tools
Illustration
5-8840-2359-0
Oil seal installer
5-8840-2360-0
Oil seal remover

Refer to "Flywheel".
6A-105
Crankshaft
Components
RTW56ALF002601
Legend
1. Upper Bearing
2. Thrust Bearing
3. Gear
Removal
3. Remove the camshaft.
4. Crankshaft
5. Lower Bearing
6. Bearing Cap
5. Remove the fuel supply pump and common rail.

Refer to "Fuel Supply Pump and Common Rail" in
the fuel system section.
6. Remove the front cover.
Refer to "Front Cover".
7. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
6A-106

Refer to "Water Pump" in the Cooling System
Section.
9. Remove the timing gear train.
Refer to "Timing Gear Train".
Refer to "Oil Pump".
11. Remove the gear case assembly.
12. Remove the crankshaft gear.
18. Remove the thrust bearing.

19. Remove the upper crankshaft bearings.
Disassembly
1. Remove the crank angle sensor rotor.
RTW56ASH016801
Legend
1. Crank Angle Sensor Rotor
2. Bolt
LNW61ASH005501
13. Remove the crank case.

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

17. Remove the crankshaft assembly.
6A-107
RTW56ASH016701
Legend
1. Crank Angle Sensor Rotor
2. Bolt
Inspection
1. Thrust clearance
Measure the crankshaft end play at the center
journal of the crankshaft.
Do this before removing the crankshaft bearing
caps. If the measured value exceeds the
specified limit, the crankshaft thrust bearing
must be replaced.
Axial play of the crankshaft
Standard
mm (in)
0.10 (0.004)
NOTE:
Measure the thrust clearance before dismounting.
LNW61ASH005701
2. Main bearing clearance

Remove the crankcase.Set out disassembled
main bearings in the order of the numbers.
Remove the crankshaft. Remove the main
bearings.
Clean the crankshaft journal and upper and
lower bearings.
Check the bearings for damage or excessive
wear.
If you find damage or excessive wear, replace
the bearings in pairs.
Place the upper bearings and the crankshaft on
the cylinder block. Install the crankshaft so that
it is horizontal.
NOTE:
Turn the crankshaft about 30 degrees to allow the
bearings to settle in.
Place Plastigage on the crankshaft journal as
shown.
6A-108
Place the lower bearings at original positions on

the bearing cap.
#1,#2,#4,#5
0.030 - 0.054 (0.0012 - 0.0021)
#3
0.042 - 0.066 (0.0016 - 0.0026)
LNW61ASH005801
Install the bearing cap and tighten bolts to the

specified tightening torque.
Tighten the bearing cap in the sequence shown
using a torque wrench and an angle gauge.
10
LNW21BSH024401
If the journal oil clearance exceeds the limit,

replace the main bearings altogether or the
crankshaft.
Remove the Plastigage from the bearings and
the crankshaft.
Inspection of the crankshaft
Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil
seal contact surface for excessive wear and
damage.
Check the oil port for clogging.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowly
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
Crankshaft run-out
LNW21BSH038701

NOTE:
Do not turn the crankshaft after you have tightened the
bearing cap.
Loosen the bolts and gently remove the bearing
cap.
Measure the widest part of the Plastigage
flattened by tightening the bearing cap to
determine the clearance.
Journal oil clearance
mm (in)
Standard
mm (in)
0.05 or less (0.0020 or less)
6A-109
NOTE:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
should not polish the surface of the crankshaft.
Crankshaft bearing selection
Crankshaft bearing selection is based on the
measured diameters of the crankshaft journals
and the bearing inserts.
Match the crankshaft bearing housing grade
marks and the crankshaft journal grade marks
in the table below to determine the correct
crankshaft bearing size.
Crankshaft bearing housing grade marks 1, 2 or
3 are stamped on the rear right hand side of the
cylinder body.
LNW21BSH024501
4. Measure the journal and the crank pin diameters

and uneven wear.
Measure outer diameters of the journal and the
pin and calculate differences between the
maximum and the minimum values. Take
measurements at four positions for both the
journal and the pin.
LNW76ASH003101
Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5
LNW21BSH024601
Crankshaft Outside Diameter
mm (in)
Standard
Limit
Journal
69.917 - 69.932
(2.7526 - 2.7532)
69.91
(2.7524)
Pin
52.915 - 52.930
(2.0833 - 2.0839)
52.9
(2.083)
The crankshaft journal grade marks (1 or -, 2 or

--, 3 or ---) are stamped on each crankshaft
journal web. The crankshaft journal and bearing
clearance must be the same for each position
after installation of the crankshaft and the
crankshaft bearings.
NOTE:
The crankshaft journal mark No. 4 is stamped on
crankshaft No. 4 journal web front side or rear side.
6A-110
RTW56ASH017201
Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5
NOTE:
Be careful about difference in the shape of the bearings
when installing them.
73.97573.982
(2.91242.9127)
1
2
1 or
-
69.92769.932
(2.75302.7532)
2 or
--
69.92269.927
(2.75282.7530)
3 or
---
69.91769.922
(2.75262.7528)
6A-111
Bearing Selection Table (#3)

mm (in)
RTW56ASH017301
Legend
1. Lot No
2. Size Code
Crankshaft
Bearing Housing
Grade
Mark
Diameter
Bearing Selection Table (#1, #2, #4, #5)
Crankshaft Journal Crankshaft

Bearing
Grade
Size
Code
Diameter
Mark
1 or
-
69.92769.932
(2.75302.7532)
2 or
--
69.92269.927
(2.75282.7530)
3 or
---
69.91769.922
(2.75262.7528)
1 or
-
69.92769.932
(2.75302.7532)
2 or
--
69.92269.927
(2.75282.7530)
3 or
---
69.91769.922
(2.75262.7528)
mm (in)
Crankshaft
Bearing Housing
Grade
Mark
Diameter
73.99274.000
(2.91312.9134)
73.98373.991
(2.91272.9130)
Crankshaft Journal Crankshaft

Bearing
Grade
Size
Code
Diameter
Mark
1 or
-
69.92769.932
(2.75302.7532)
2 or
--
69.92269.927
(2.75282.7530)
3 or
---
69.91769.922
(2.75262.7528)
1 or
-
69.92769.932
(2.75302.7532)
2 or
--
69.92269.927
(2.75282.7530)
3 or
---
69.91769.922
(2.75262.7528)
73.99274.000
(2.91312.9134)
73.98373.991
(2.91272.9130)
6A-112
73.97573.982
(2.91242.9127)
1 or
-
69.92769.932
(2.75302.7532)
2 or
--
69.92269.927
(2.75282.7530)
3 or
---
69.91769.922
(2.75262.7528)
2. Install the crankshaft assembly.Apply an ample

coat of engine oil to the crankshaft journals and the
crankshaft bearing surfaces before installing the
crankshaft.
Installation
1. Install the crankshaft upper bearing.
The crankshaft upper bearings have an oil hole
and an oil groove. The lower bearings do not.
Carefully wipe any foreign material from the
upper bearing.
Locate the position mark applied at
disassembly if the removed upper bearings are
to be reused.
NOTE:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.
LNW21BSH038301
LNW61ASH006101
3. Install the thrust bearing.

Apply an ample coat of engine oil to the thrust
bearings before installation. Install the thrust
bearings to the crankshaft center journal.
The thrust bearing oil grooves must be facing
the sliding faces.
LNW21BSH037401
4. Install the lower crankshaft bearing.

Before the crankshaft bearing installation,
select the appropriate bearings in accordance
with the description in CRANK BEARING
SELECTION of INSPECTION AND REPAIR.
5. Install the bearing cap.

Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
The bearing cap numbers must be facing up.
6A-113
8. Install the crankshaft gear.
RTW56ASH017001
LNW21BSH038601
Tighten the crankshaft bearing cap bolts to the

specified torque a little at time in the sequence
Crankshaft Bearing Cap Torque
Nm (kgm / lb ft)
166 (16.9 / 122)

Check to see the crankshaft turns smoothly by
rotating it manually.
NOTE:
Confirm that the crankshaft turns smoothly.
10
LNW21BSH038701
6. Install pistons and connecting rods.

7. Install the crank case.
Refer to "Crank Case and Oil Pan".
9. Install the gear case assembly.

11. Install the timing gear train.
Refer to "Timing Gear train".
Section.
13. Install the front cover.
15. Install the fuel supply pump and common rail.
Refer to "Fuel Supply Pump and Common Rail".
19. Mount the engine assembly on the chassis.
6A-114
166(16.9/122)
Nm(kgm/lb ft)
12Nm(1.2kgm/104 lb in)
RTW56AMF001301
6A-115
Cylinder Block
Components
1
RTW76ASF000101
Legend
1. Cylinder Block
Removal
3. Remove the camshaft assembly.
5. Remove the fuel supply pump and fuel rail
assembly.
Refer to "Fuel Supply Pump and Fuel Rail
Assembly" in FUEL SYSTEM section.
6. Remove the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
7. Remove the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
8. Remove the crankshaft rear oil seal.
Refer to "Oil Pan".
Section.
11. Remove the front cover.
12. Remove the timing gear train.

14. Remove pistons and connecting rods.
15. Remove the crankshaft.
Refer to "Crankshaft"
16. Remove the piston cooling pipe.
RTW76ASH001101
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
6A-116
Be careful not to damage the cylinder block.

2. Carefully remove the liquid gasket on the
crankcase mounting surface.
3. Clean up the cylinder block.
4. Visually inspect the cylinder block.
Conduct color check and hydraulic (or
pneumatic) test and if you find a crack or other
damage, replace the cylinder block.
Standard
95.421 - 95.450 (3.7567 - 3.7579)
Limit
95.48 (3.7590)
6. Cylinder Reboring.
Select oversize pistons to fit the largest cylinder
bore (previously measured).
At a point 11 mm (0.43 in) above the lower
edge of the piston skirt, measure the piston
diameter at a right angle to the piston pin.
Calculate the additional cylinder boring required
for each cylinder.
RTW76ASH000801
5. Cylinder block wear measurement.

Use a cylinder indicator to measure the cylinder
bore at measuring point (1) in the thrust (2-2)
and axial (3-3) directions of the crankshaft.
Measuring Point (1): 20 mm (0.79 in).
If the measured value exceeds the specified
limit, the cylinder block must be replaced or
rebored.
RTW56ASH023101
Legend
1. 11 mm (0.43 in)
Formula
Boring inside diameter = D + C - H E
D = Piston outside diameter
(Measured Oversize Piston)
C = Piston and cylinder bore clearance
0.082 - 0.100 mm (0.0032 - 0.0039 in)
H = Honing allowance
0.03 mm (0.0012 in) or less
E = Boring machine error
Piston size
2
3
3
2
LNW21BSH039801
Cylinder block bore diameter
mm (in)
mm (in)
Standard
95.340 - 95.389 (3.7535 - 3.7555)
Oversize(0.25)
95.590 - 95.639 (3.7634 - 3.7653)
Oversize(0.50)
95.840 - 95.889 (3.7732 - 3.7752)
Oversize(0.75)
96.090 - 96.139 (3.7831 - 3.7850)
Bore and hone the cylinders individually as

required.
Once again, measure each cylinder bore.
Each cylinder bore remainder
mm (in)
6A-117
Installation
0.02 (0.0008) or less.

7. Cylinder block upper face warpage.
Use a straight edge (1) and a thickness gauge
(2) to measure the four sides and the two
diagonals of the cylinder body upper face.
If the measured values exceeds the limit, the
cylinder body must be replaced.
1. Install the piston cooling pipe.

Align the dowel pin of the piston cooling pipe
with the pin hole on the cylinder block and
tighten with the relief valve.
Tightening torque:
Relief valve 30 Nm (3.1 kgm / 22 lb ft)
bolts M8 25 Nm (2.5 kgm / 18 lb ft)
Cylinder block upper face warpage
mm (in)
Standard
0.05 or less (0.002 or less)
Limit
0.20 (0.079)
bolts M6 8 Nm (0.8 kgm / 69 lb in)

NOTE:
Be careful not to deform or damage the piston cooling
pipe nozzle.
LNW61ASH006501
Cylinder body height (H) (Reference)

Standard
mm (in)
262.945 - 263.055 (10.352 - 10.356)
LNW71BSH000301
RTW76ASH001101
2. Install the crankshaft.

Refer to "Crankshaft".
3. Install pistons and connecting rods.
5. Install the timing gear train.
6. Install the front cover.
Section.
8. Install the oil pan.Refer to "Oil Pan".
10. Install the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
11. Install the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
6A-118
12. Install the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump and Fuel Rail
Assembly" in FUEL SYSTEM section.

16. Mount the engine assembly on the chassis.
Refer to "Engine Assembly.
30 (3.1/22)
25 (2.5/18)
8 (0.8/69lb in)
LNW71BSF000301
6A-119
Lubrication System
Service Precautions
During each disassembly, remove the old gasket
adhering to each part and mating part completely
using a scraper at the location, where the fluid
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton
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.
Explanations on functions and operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating system diagram
4. Oil Press.
SW
Warning
Lamp
Oil Gallery
Oil Filter & Cooler Assembly
Oil Filter
Oil Cooler
2. Relief
Valve
1. Relief
Valve
3. Relief
Valve
Turbocharger
Crankshaft
Bearing
5. Regulating
Valve
Piston
Cooling Jet
Vacuum
Pump
Camshaft
Bearing
Idler Gear
Shaft
Connecting
Rod Bearing
Timing Gear
Timing Chain
Oil Jet
Oil Pump
Rocker Arm
Oil
Strainer
Oil Pan
LNW76ALF000201
Legend
1. Oil Pump Relief Valve Operating Pressure: 490 686 kPa (5.0 - 7.0 kg/cm2 / 71 - 100 psi)
2. Oil Cooler Relief Valve Opening Pressure: 176 216 kPa (1.8 - 2.2 kg/cm2 / 26 - 31 psi)
6A-120
3. Oil Filter Relief Valve Opening Pressure: 80 120 kPa (0.8 - 1.2 kg/cm2 / 11 - 17 psi)
4. Oil Pressure Switch Operating Pressure: 29.4 49.0 kPa (0.3 - 0.5 kg/cm2 / 4.3 - 7.1 psi)
5. Regulating Valve: 176 - 216 kPa (1.8 - 2.2 kg/

cm2 / 26 - 31 psi)
Functional Check
Engine oil
Oil pressure check
Ensure the car is on level ground. Before starting the

engine or when 30 minutes or more have elapsed after
stopping the engine, check the engine oil volume using
the level gauge. The volume is appropriate if the engine
oil is between the upper and lower limits of the level
gauge. Replenish the engine oil, if level is below the
lower limit. Also, check for contamination of the engine
oil.
1. Check whether the engine oil is contaminated with

dirt, light oil, or water. If contaminated with dirt,
light oil, or water (after examining the cause and
taking the appropriate measures for light oil or
water contamination), replace the oil.
2. Check the engine oil level. The oil level should be
between the two holes of the level gauge. If the oil
level is insufficient, replenish it.
3. Remove the oil pressure switch on the nipple.
4. Install the oil pressure gauge on the nipple.
5. Warm the engine.
6. Measure the oil pressure, to check whether it is
more than 400 kPa (4 kg/cm2 / 58 psi) at 3600
rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
10. Start the engine and check for oil leakage.
ADD
FULL
RTW56ASH015701
Legend
1. Lower Limit
2. Upper Limit
Engine oil leakage
In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
6A-121
Oil Filter Element

Components
1
2
3
6
4
8
9
10
LNW71HSF000101
Legend
1. Oil Cooler
2. Oil Filter Element
3. Gasket
4. Plate
5. Spring
Removal
1. Place a tray under the oil filter.
2. Remove the drain plug, and oil in the filter is
drained.
3. Remove the center bolt, and remove the element
in the case.
NOTE:
Do not reuse the two O-rings and the gasket.
Installation
1. Install the oil filter element.
Apply grease(Besco L2, L3 or equivalent) or
engine oil to the O-rings and the gasket.
Tighten the bolt and the drain plug using the
specified torque.
Tightening torque:
Center bolt 44 Nm (4.5 kgm / 33 lb ft)
Drain plug 24 Nm (2.4 kgm / 17 lb ft)
6.
7.
8.
9.
10.
Center Bolt
O-ring
O-ring
Drain Plug
Oil Filter Case
6A-122
44(4.5/33)
25(2.5/18)
LNW76ASF000101
6A-123
Oil Filter Assembly and Oil Cooler

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

2. Remove the exhaust manifold.
Refer to Exhaust Manifold.
1
RTW56ASH008401
6A-124

Disassembly
4. Remove the water intake pipe (1).
1. Remove the element mounting nuts(1).

2
RTW56ASH012601
Legend
1. Water Intake Pipe
2. Bracket
3. Bracket
4. Bolt
RTW56ASH012901
2. Remove the element (1).

3. Remove the gasket (2).
5. Remove the oil cooler and oil filter.

1
2
RTW56ASH013001
LNW71HSH000101
Reassembly
1. Install the gasket on the element.
2. Install the element.
3. Tighten the element fixing nuts using the specified
torque.
Installation
1. Install the oil filter and cooler.
Install the O-ring on the oil filter and cooler,
apply grease.

Apply the liquid gasket and mount within 5
minutes. Apply liquid gasket (ThreeBond TB1207C or equivalent) to the flange surface
groove (cylinder block). Bead diameter must
be between 2 and 3 mm (0.008 and 0.012 in).
Refer to the illustration for the offset position
(no more than 1 mm (0.004 in)).
6A-125
Tighten the bolts to the specified torque in the

order shown in the illustration.
10
1 11
1
3
12
2
22
22 20
17
19
18
16
15
14
13
LNW76ASH002001
2
LNW76ASH001801
Legend
1. Liquid Gasket
2. O-ring
Align the oil filter and cooler holes with the
cylinder block studs. Install the oil cooler to the
cylinder clock.
2. Install the water intake pipe.

After applying soapy water to O-ring, set it on
water intake pipe and insert into the oil
cooler.Tighten the bolts to the specified torque.
3. Install the water by pass pipe.
After applying soapy water to O-ring, set it on
by pass pipe and insert into the cylinder
head.Tighten the bolts to the specified torque.
4. Install the bracket of generator.

5. Install the adjustment bracket of generator.
1
2
4
LNW76ASH001901
Legend
1. Bolt 35 mm X 11
2. Bolt 70 mm X 4
3. Bolt 90 mm X 2
4. Nut X 2

6. Install the generator.
Refer to Installation procedure for generator in this
manual.
7. Install the exhaust manifold.
Refer to Installation procedure for turbocharger
and exhaust manifold in this manual.
6A-126
Crank Case and Oil Pan

Components
LNW76ALF000501
Legend
1. Flywheel Housing
2. Cylinder Block
3. Oil Strainer
Removal
2. Remove the oil level gauge guide tube.
3. Remove the heater pipe and hose.
4. Crank Case
5. Oil Pan
6A-127
9. Remove the retainer.
1
2
LNW76ASH001301
RTW76ASH002001
Legend
1. Retainer
2. Bolt

Refer to Flywheel.
6. Remove the flywheel housing.
10. Remove the crank case.
3
1
2
LNW71BSH001601
Legend
1. Bolt
2. Bolt
3. Nut
8. Remove the timing gear case.
Refer to Timing Gear Case.
RTW56ASH021901
Legend
1. O-ring
2. Crank Case
NOTE:
Take care not to damage an O-ring.
6A-128
Disassembly
1. Remove the oil strainer.
3
2
1
2
1
RTW56ASH015301
RTW66ASH009201
Legend
2. Oil Strainer
3. Bolt
4. Crank Case
Legend
1. 2.0 - 3.0 mm (0.079 - 0.118 in)
2. 4.0 - 5.0 mm (0.157 - 0.179 in)
2. Install the oil pan.
Apply the liquid gasket (ThreeBond TB-1207B or
equivalent)and mount within 5 minutes.
Reassembly
Install the oil strainer.
Install the packing on the strainer.
Installation
1. Install the crank case.
Apply the liquid gasket (ThreeBond TB-1207C
or equivalent) and mount within 5 minutes.
RTW56ASH015201
Legend
1. 2.0 mm (0.079 in)
2. 3.0 mm (0.118 in)
3. Install the retainer.
Apply the liquid gasket (ThreeBond TB-1207C
or equivalent) and mount within 5 minutes.
6A-129
4. Install the heater pipe and hose.
2
1
RTW56ASH017701
LNW76ASH001301
Legend
1. 2 - 2.5 mm (0.079 - 0.098 in)
2. 2 - 2.5 mm (0.079 - 0.098 in)
5. Install the timing gear case.

Refer to Timing Gear Case.
7. Install the Flywheel housing.
Tightening torque:
Bolt (1) : 106 Nm (10.8 kgm / 78 lb ft)
Bolt (2) : 82 Nm (8.4 kgm / 61 lb ft)
1
Bolt (1) : 51 Nm (5.2 kgm / 38 lb ft)

2
RTW76ASH002001
Legend
1. Retainer
2. Bolt
2
LNW71BSH001601

Refer to Flywheel.
9. Install the oil level gage guide tube.
Apply the engine oil to the O-ring.
6A-130

106(10.8/78)
51(5.2/38)
25(2.5/18)
25(2.5/18)
82(8.4/61)
25(2.5/18)
22(2.2/16)
44(4.5/33)
LNW76ALF000901
6A-131
Oil Pump
Components
2
1
RTW66AMF000701
Legend
1. Bolt
Removal
2. Oil Pump Assembly
6A-132
8. Remove the noise cover (1).
2
1
3
LNW76ASH000701
Legend
1. Fan Guide Bracket (RH)
2. Fan Guide Bracket (LH)
3. Bolt
4. Remove the fan and fan clutch.
Loosen the fan clutch nuts.
Remove the fan together with the fan clutch.
Take care not to damage the radiator core.
5. Remove the fan drive belt and pulley.
Loosen the tension adjust bolt on the generator
and A/C.
Remove the fan drive belt with the fan pulley.
6. Disconnect the power steering pump.
7. Remove the vacuum pump.
Remove the vacuum pipe bracket and vacuum
pipe.
Remove the oil pipe (feed side and return side)
of vacuum pump.
RTW56CSH001401
9. Remove the crank pulley.

NOTE:
Do not reuse the crank pulley bolt and washer.
10. Remove the cover of the gear case cover(1).
LNW76ASH003201

6A-133
4. Install the spring pin.
RTW56ASH019701
RTW56ASH015901
Legend
1. Spring Pin
2. Spring Seat
3. Spring
4. Valve
Inspection
NOTE:
Think to match direction of ditch of gear when
assembling it.
1. Measure the clearance between the driven gear/
drive gear shaft and the bush.
Measure the outside diameter of the driven
gear shaft using a micrometer.
RTW56ASH020001
Legend
1. Oil Pump
Disassembly
1.
2.
3.
4.
Remove the spring pin.

Remove the spring seat.
Remove the spring.
Remove the valve.
Reassembly
1. Install the valve.
2. Install the spring.
3. Install the spring seat.
Outside diameter of the driven gear shaft/

drive gear shaft
mm (in)
Standard
15.989 - 16.000 (0.62949 - 0.62992)
Limit
15.900 (0.62598)
6A-134

Measure the width size the driven gear/drive
gear.
RTW56ASH025601
Measure the inside diameter of the bushes of

the cylinder block using the dial gauge.
If the clearance between the driven gear shaft/
drive gear shaft and bush exceeds the limit,
replace the oil pump assembly.
Clearance between the driven gear shaft/
drive gear shaft and bush
mm (in)
Standard
0.04 - 0.07 (0.0016 - 0.0028)
Limit
0.20 (0.0079)
RTW56ASH025501
Measure the Depth size of the gear case

housing surface and the oil pump housing gear
case side.
Depth size the gear case housing surface
Standard
mm (in)
14.500 - 14.527 (0.5709 - 0.5719)
RTW56ASH014801
RTW56ASH014701
2. Measure the clearance between the gear side

surface and the gear side surface of the oil pump
housing.
Clearance between the gear side surface

and the gear side surface of the oil pump
housing
mm (in)
Standard
0.065 - 0.109 (0.0026 - 0.0043)
Limit
0.20 (0.0079)

Installation
6A-135

Apply engine oil to the oil pump attachment
gearbox.
RTW56ASH012101
3. Install the cover of the gear case cover.

4. Install the crank pulley.
RTW56ASH020001
Legend
1. Oil Pump
Installed pump gear should be smooth to rotate.
Apply the liquid gasket (Threebond TB-1207B
or equivalent) mount within 5 minutes.
1

5. Install the noise cover.
6. Install the vacuum pump.
Tighten the nuts to the specified torque.
Install the oil pipe (feed side and return side) of
vacuum pump.
Install the vacuum pipe bracket and vacuum
pipe.
Tighten the nuts to the specified torque.
8. Install the fan drive belt and pulley.
Install the fan drive belt with the fan pulley.
9. Install the fan and fan clutch.
RTW56ASH020101
Legend
1. Apply The Liquid Gasket in Area
Install the gasket in the slot of the gear case
cover.

10. Adjust the drive belt of generator and A/C
compressor.
Apply tension to the fan drive belt by moving
the generator.
6A-136
Apply a force of 98 N (10 kg / 22 lb) to the drive

belt mid portion to check the drive belt
deflection.
Generator drive belt deflection
New belt
5 - 6 (0.20 - 0.24)
Reuse belt
7 - 8 (0.28 - 0.32)
A/C compressor drive belt deflection

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

mm (in)
mm (in)
6A-137
Oil Pressure SW
Components
LNW76AMF000601
Legend
1. Oil Pressure SW
2. Gasket
Removal
1. Remove the oil pressure SW.
2. Remove the nipple; oil pressure warning SW and
gasket.
Installation
1. Install the nipple; oil pressure warning SW and
gasket.
2. Install the oil pressure SW.
3. Nipple; Oil Pressure Warning SW
6A-138
Inspection
Check the continuity between the switch terminal and
the body grounding in a no-load condition.If there is no
connectivity, replace with normal parts.
LNW21HSH003301
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
LNW21HSH003401
Air Cleaner Element

Removal
1. Remove the air cleaner cover fixing bolt.
2. Remove the air cleaner element assembly.
Cleaning
Dry type element
Rotate the element with your hand while applying
compressed air to the inside of the element. This
will blow the dust free.
Compressed air pressure
kPa (kg/cm2 /psi)
690 (7 / 100)
LNW46ASH003201
Installation
1. Install the air cleaner element assembly.
2. Install the air cleaner cover.
6A-139
MEMO
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ENGINE COOLING (4JJ1)
ENGINE
ENGINE COOLING
(4JJ1)
TABLE OF CONTENTS
Main Data and Specifications . . . . . . . . . . . . . . . . 6B-2
Main Data and Specifications. . . . . . . . . . . . . . . 6B-2
General Description . . . . . . . . . . . . . . . . . . . . . . 6B-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-7
Draining and Refilling Cooling System . . . . . . . . . 6B-8
Draining and Refilling Cooling System. . . . . . . . 6B-8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9
Removal and Installation . . . . . . . . . . . . . . . . . . 6B-9
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-11
Removal and Installation . . . . . . . . . . . . . . . . . 6B-11
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-13
Removal and Installation . . . . . . . . . . . . . . . . . 6B-13
Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15
Radiator Core. . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15
Flushing the Radiator . . . . . . . . . . . . . . . . . . . . 6B-15
Cooling System Leakage Check . . . . . . . . . . . 6B-15
Engine coolant change . . . . . . . . . . . . . . . . . . 6B-17
Fan Clutch with Cooling Fan . . . . . . . . . . . . . . . . 6B-18
Inspection and Repair . . . . . . . . . . . . . . . . . . . 6B-18
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-19
6B-1
6B-2
Main Data and Specifications

Main Data and Specifications
Description
Item
M/T
Cooling system
Smoother
Engine coolant forced circulation
Water pump type
Centrifugal impeller type
Pump to crankshaft speed ratio
(To 1)
Delivery volume
lit (US/UK gal)/min
1.25
240 (63.1/53.3)
Pump speed at 5600 rpm

Water temperature at 30C (86F)
Pump bearing type
Double row shaft
Thermostat type
Wax pellet with jiggle valve
Valve initial opening temperature
C (F)
85 (185)
Valve full opening temperature
C (F)
100 (212)
Valve lift at fully open position
mm (in)
10 (0.39)
Radiator
Tube type corrugated
Heat radiation capacity
kW
91.2
Heat radiation area
m2
(ft2)
10.9 (117.3)
Radiator front area
m2 (ft2)
0.242 (2.6)
Radiator dry weight
N (kg/lb)
Radiator cap valve opening pressure
kPa (psi)
Engine coolant capacity
lit (U.S pint)
6.7 (7.1)
Engine coolant total capacity
lit (U.S pint)
10 (10.6)
125.5 (12.8 / 28.2)
128.5 (13.1 / 28.9)
93.3 122.7 (13.5 17.8)
6B-3
General Description
Coolant Flow
Turbocharger
EGR
Cooler
Cylinder head
Thermostat
Reservoir
Tank
Radiator
Oil cooler
Cooling fan
Water
pump
Cylinder block
Car heater
RTW76BLF000301
The engine cooling system consists of the radiator, the

water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for
smooth engine operation, the coolant is circulated by
the water pump and thermostat through the bypass
pipe and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value,
the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the
radiator.
The thermostat will be fully open when the coolant
temperature reaches specified value. All of the coolant
is now circulating through the radiator for effective
engine cooling.
6B-4
Water Pump
RTW56BSF000101
A centrifugal type water pump forcefully circulates the

coolant through the cooling system.
The water pump is not disassembled type.
Thermostat
RTW56BSF000201
A wax pellet type thermostat is used.
6B-5
Radiator
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of the coolant, the radiator is
fitted with a cap in which the valve is operated at 93.3
122.7 kPa (0.95 1.25 kg / cm2 / 13.5 17.8 psi)
pressure. (No oil cooler provided for M/T)
Freezing
temperature
guideline
Mix ratio
Liter (qts)
Engine
coolant
Concentration
of engine
coolant
Tap
water
-18C (-0.4F) 3.5 (3.7)
6.5 (6.9)
35%
-25C (-13F)
4.2 (4.4)
5.8 (6.1)
42%
-35C (-31F)
5.0 (5.3)
5.0 (5.3)
50%
-40C (-40F)
5.3 (5.6)
4.7 (5.0)
53%
2. Engine coolant density measurement

Methods for measuring specific gravity
Measure the specific gravity and the
temperature of the cooling water using an antifreeze specific gravity meter and thermometer.
Take precautionary measures as the boiled
cooling water may gush out at high
temperatures if the cap is removed.
LNW76BSH002801
Use a deep container to suit the height of the

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

0
10 20 30 40 50
FREEZING TEMPERATURE (C)
LNW46BSH001001
Legend
1. Anti-Freeze Specific Gravity Meter
2. Radiator
-10
-20
Fix the temperature of the cooling water being

measured in the range of 0 to 50 C (32 to
122 F).
-30
-40
-50
LNW46BSH001301
6B-6
SPECIFIC GRAVITY
Measure the temperature and specific gravity

and determine the concentration from the table
given below.
1100
1090
1080
1070
1060
1050
1040
1030
1020
1010
1000
60%
50%
40%
30%
20%
10%
0 10 20 30 40 50 60 70
TEMPERATURE (C)
LNW46BMH000101
Coolant scooping method
Measure the concentration using the coolant
scoop.
6B-7
Diagnosis
Diagnosis
Condition
Engine overheating
Possible Cause
Correction
Low Engine Coolant level
Replenish
Thermo meter unit faulty
Replace
Faulty thermostat
Replace
Faulty Engine Coolant temperature

sensor
Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap
Replace
Low engine oil level or use of

improper engine oil
Replenish or change oil
Clogged exhaust system
Clean exhaust system or replace

faulty parts
Faulty Throttle Position sensor
Replace throttle valve assembly
Open or shorted Throttle Position

sensor circuit
Repair or replace
Damaged cylinder head gasket
Replace
Engine overcooling
Faulty thermostat
Replace
Engine slow to warmup
Faulty thermostat
Replace
Thermo unit faulty
Replace
6B-8
Draining and Refilling Cooling System

Draining and Refilling Cooling System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
"MIN" and "MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the
"MAX" line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole,
and the EC should also be free from oil.Replace the EC
if excessively dirty.
1. Completely drain the cooling system by opening
the drain plug at the bottom of the radiator.
2. Remove the radiator cap.
Press the radiator upper hose(1) 2 to 3 times as

shown in the illustration. If the coolant level is
down caused by the air was bled, poor the coolant
again.
2
1
WARNING:
To avoid the danger of being burned, do not remove the
cap while the engine and radiator are still hot. Scalding
fluid and steam can be blown out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water,
then drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC.
Procedure for filling with coolant (in case of full
change)
Confirm that the engine has cooled.

Open the radiator cap and the reserve tank cap.
Unscrew the air bleeding bolt(2).
Pour the coolant up to the filler neck.
LNW76BSH002901
Pour the coolant up to the "MAX" line in the

reserve tank.
Tighten the air bleeding bolt firmly.
Close the radiator cap and the reserve tank cap
and start the engine. Stop the engine after running
for about 2 to 3 minutes at the idling rpm. Open the
radiator cap again and replenish if the water level
is low.
WARNING:
Do not loosen or remove the radiator cap when the
temperature of the cooling water is high. Steam or
boiling water will gush out and you may be burnt. To
open the radiator cap, cover the cap with a thick cloth
when the cooling water is cool, release the pressure by
slowly turning the cap, and then remove the cap.
After tightening the radiator cap, warm up the
engine by running it at about 2000 rpm.
When the pointer of the thermometer crosses the
median and the thermostat has activated, run at
idling rpm for another 5 minutes, then stop the
engine and leave it as-is.
After the engine has cooled down sufficiently,
check the water level in the filler neck part and
replenish if necessary. If the level is extremely low,
check for leaks in the cooling water conduit system
and reserve tank hose.
6B-9
Water Pump
Removal and Installation
b. Remove the fan drive belt with the fan pulley.
Read this Section carefully before performing any

removal and installation procedure. This Section gives
you important points as well as the order of operation.
Be sure that you understand everything in this Section
before you begin.
Removal
2. Radiator Upper Hose
a. Partially drain the engine coolant.
b. Remove the radiator upper hose.
3. Water Outlet Pipe
a. Disconnect the turbocharger-cooling pipe from
the outlet pipe.
b. Loosen the fixing bolt and remove the water
outlet bolt.
4. Fan guide bracket
2
1
RTW56ASH025401
7. Water Pump
a. Remove the water pump bolts and nuts.
b. Remove the water pump.
LNW76ASH000701
Legend
1. Fan Guide Bracket RH
2. Fan Guide Bracket LH
3. Bolt
5. Fan and Fan Clutch
a. Loosen the fan clutch nuts.
b. Remove the fan together with the fan clutch.
Take care not to damage the radiator core.
6. Fan Drive Belt and Pulley
a. Loosen the tension adjust bolt on the generator.
RTW56BSH000201
Inspection and Repair

The water pump is not disassembled type.Make
necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump
assembly must be replaced.
Cracks in the water pump body.
Coolant leakage from the sealed unit.
Excessive radial play or abnormal noise in the fan
center when rotated by hand.
Excessive thrust play in the fan center (Standard
play: less than 0.2 mm (0.0078 in)).
6B-10
Cracks or corrosion in the impeller.
d. Apply a force of 98 N (10 kg/22 lb) to the drive

belt mid-portion to check the drive belt
deflection.
Installation
1. Water Pump
Fan Drive Belt Deflection
mm (in)
New belt
5 - 6 (0.20 0.24)
Reuse belt
7 - 8 (0.28 0.32)
3. Fan guide bracket

4. Water Outlet Pipe.
a. Install the water outlet pipe to the thermostat
housing.
b. Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque:
RTW56BSH000201
a. Install the water pump with a new gasket.

b. Tighten bolts and nuts to specified torque.
Water Pump Bolt/Nut Torque:
25 Nm (2.5 kgm /18 lb ft)
2. Fan Drive Belt and Pulley and Fan and Fan Clutch.
RTW56ASH025401
a. Install the fan drive belt and fan pulley and fan
and fan clutch.
b. Tighten the nuts to specified torque.
Fan Clutch Nut Torque: 8 Nm (0.8 kgm /69 lb in)
c. Apply tension to the fan drive belt by moving
the generator.
25 Nm (2.5 kgm /18 lb ft)

c. Connect the turbocharger-cooling pipe to outlet
pipe.
5. Radiator Upper Hose.
a. Connect the radiator upper hose to the water
outlet pipe.
b. The knob of clamp shall be directed to
horizontal.
c. Replenish the engine coolant.
6B-11
Thermostat
before you begin.
2. Heat the water.Stir the water constantly to avoid

direct heat being applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature:
C (F)
85 (185)
Removal
a. Partially drain the engine coolant.
b. Remove the radiator upper hose.
c. Remove the engine harness clip.
3. Water Outlet Pipe
a. Disconnect the turbocharger-cooling pipe from
outlet pipe.
b. Loosen the fixing bolt and remove the water
outlet bolt.
4. Thermostat
Remove the thermostat from the thermostat
housing.
Take care not to damage the thermostat.
4. Check the thermostat full opening temperature.

C (F)
Thermostat Full Opening Temperature:

100 (212)
Valve Lift At Fully Open Position:
mm (in)
10 (0.39)
1
2
LNW61BSH003501
LNW71CSH000401
Legend
1. Jiggle Valve
2. Thermostat
Operating Test of Thermostat
1. Completely submerge the thermostat in water.
Legend
1. Agitating Rod
2. Thermometer
3. Wooden Piece
6B-12
Installation
1. Thermostat
Install the thermostat.
Mount the jiggle valve with the valve facing engine
front.
1
2
2
LNW71CSH000401
Legend
1. Jiggle Valve
2. Thermostat
2. Water Outlet Pipe.
a. Install the water outlet pipe with a new gasket to
the thermostat housing.
b. Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque:
25 Nm (2.5 kgm /18 lb ft)
c. Connect the turbocharger-cooling pipe to outlet
pipe.
d. Install the engine harness clip.
3. Radiator Upper Hose.
a. Connect the radiator upper hose to the water
outlet pipe.
b. The knob of the clamp should be directed to the
horizontal side.
c. Replenish the engine coolant.
6B-13
Radiator
Radiator and Associated Parts
5
LNW76BLF001901
Legend
1. Reserve Tank Hose
3. Radiator & Intercooler
Removal
1. Disconnect battery ground cable.
2. Loosen the drain plug to drain the engine coolant.
After draining the coolant, tighten the drain
plug.
4. Fan Guide
5. Radiator Lower Hose
6B-14
LNW46BSH000401
Legend
1. Radiator Drain Plug
the turbocharger side.
pipe.
LNW76ASH000501
6. Remove the radiator upper hose on the radiator

side.
7. Remove the radiator lower hose on the radiator
side.
8. Remove the coolant reserve tank hose from the
radiator side.
2
1
3
LNW76ASH000701
LNW76ASH000301
4. Disconnect the ECM harness connector.

sensor.
pipe.
Legend
1. Fan Guide Bracket RH
2. Fan Guide Bracket LH
3. Bolt
10. Remove the inter cooler.
6B-15
11. Take care to avoid damage to the radiator core

from the fan blade, and remove the brackets on
the right and left sides of the radiator.
Simultaneously remove the radiator.
LNW21BSH000201
Radiator Core
LNW76BSH003001

Radiator Cap
Measure the valve opening pressure of the
pressurizing valve with a radiator filler cap
tester.Replace the cap if the valve opening pressure is
outside the standard range.
Valve opening pressure:
93.3 122.7 kPa (0.95 1.25 kg / cm2 / 13.5 17.8
psi)
Cap tester: 5-8840-0277-0
Adapter: 5-8840-2603-0
Check the condition of the vacuum valve in the center
of the valve seat side of the cap. If considerable rust
or dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.
Valve opening vacuum:
1.96 4.91 kPa (0.02 0.05 kg / cm2 / 0.28 0.71 psi)
1. A bent fin may result in reduced ventilation and

overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the
fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator

Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all signs of scale and rust.
Cooling System Leakage Check

Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196
kPa (2.0 kg / cm2 / 28.5 psi) with a cap tester:
Leakage from the radiator.
Leakage from the coolant pump.
Leakage from the water hoses.
Check the rubber hoses for swelling.
6B-16

6. Mount the radiator upper hose.
7. Pour engine coolant up to filler neck of radiator,
and up to MAX mark of reserve tank. Important
operation (in case of 100% engine coolant change)
procedure for filling with engine coolant.
Confirm that the engine has cooled.
Open the radiator cap and the reserve tank
cap.
Unscrew the air bleeding bolt(2).
Pour the coolant up to the filler neck.
Press the radiator upper hose(1) 2 to 3 times as
shown in the illustration. If the coolant level is
down caused by the air was bled, poor the
coolant again.
LNW21BSH000301
Installation
1. Ensure that no damage occurs to the radiator core
because of the fan brade.Mount the brackets on
the left and right sides of the radiator on the frame
according to the figure.
Tightening Torque: 26 Nm (2.6 kgm /19 lb ft)
LNW76BSH002901
2
5
4
LNW46BSH000101
Legend
1. Flange nut
2. Rubber
3. Stud Bolt
4. Bracket
5. Bracket on the Radiator Side
6. Washer
2. Install the intercooler.
4. Mount the reserve tank hose of the coolant on the
radiator.
5. Mount the radiator lower hose.
Pour the cooling water up to the "MAX" line in

the reserve tank.
Tighten the air bleeding bolt firmly.
Close the radiator cap and the reserve tank cap
and start the engine. Stop the engine after
running for about 2 to 3 minutes at the idling
rpm. Open the radiator cap again and replenish
if the water level is low.
WARNING:
Do not loosen or remove the radiator cap when the
temperature of the cooling water is high. Steam or
boiling water will gush out and you may be burnt. To
open the radiator cap, cover the cap with a thick cloth
when the cooling water is cool, release the pressure by
slowly turning the cap, and then remove the cap.
After tightening the radiator cap, warm up the
engine by running it at about 2000 rpm.
When the pointer of the thermometer crosses
the median and the thermostat has activated,
run at idling rpm for another 5 minutes, then
stop the engine and leave it as-is.

After the engine has cooled down sufficiently,
check the water level in the filler neck part and
replenish if necessary. If the level is extremely
low, check for leaks in the cooling water conduit
system and reserve tank hose.
1
LNW76BSH000101
Legend
1. Reserve Tank
2. MAX Line (Upper Limit)
3. MIN Line (Lower Limit)
Engine coolant change

Refer to change procedure for Draining and Refilling
Cooling System in this section.
6B-17
6B-18
Fan Clutch with Cooling Fan

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

Warm up the bimetal of the fan clutch by using the
heat gun until the temperature gets to about
85C(185F) when measured with the thermistor.
Then confirm that the fan clutch can be turned with
considerable effort (clutch torque).
If the fan clutch rotates more readily at this time,
this indicates that the silicone grease is leaking
internally.
Replace the fan clutch with a new one.
Heat gun
Thermistor
LNW61BSH003701
3. Clearance between fan and fan guide

The clearance in three places must be 3mm(0.118
in) or more.
RTW56ASH025401
LNW71CSH000501

Special Tools
Illustration
5-8840-02770-0
Cap tester
5-8840-2603-0
Adapter
5884026030
6B-19
MEMO
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FUEL SYSTEM (4JJ1)
ENGINE
FUEL SYSTEM
(4JJ1)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . .6C-2
Work procedure . . . . . . . . . . . . . . . . . . . . . . . . .6C-2
Fuel System Check . . . . . . . . . . . . . . . . . . . . . .6C-7
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . .6C-9
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-9
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .6C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-10
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-14
Torque Specifications . . . . . . . . . . . . . . . . . . . .6C-16
Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . . . .6C-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-17
Fuel Pressure Limiter . . . . . . . . . . . . . . . . . . . . .6C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-18
Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . .6C-19
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-22
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .6C-24
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-28
Fuel Sedimenter Switch . . . . . . . . . . . . . . . . . . .6C-34
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-34
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-35
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-36
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-37
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-38
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6C-39
6C-1
6C-2
FUEL SYSTEM (4JJ1)
Fuel System
Service Precautions
If parts are to be replaced (fuel hose, fuel pipe,

etc.) do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with
new ones.
Parts of the fuel system such as the internal part of the

fuel injector, and holes and clearances that form
passages for fuel are finished to a very high degree of
accuracy. They are therefore highly sensitive to foreign
matter and the entry of foreign matter could cause
damage to the fuel passage. Therefore, effective
measures should be taken to prevent the entry of
foreign matter.
If a 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 a 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.
Work procedure
The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
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.
Fuel system diagram
7
5
11
10
8
LNW71DSF000101
Legend
1. Fuel Rail
2. Pressure Limiter
3. Leak Off Pipe
4. Fuel Injector
5. Fuel Return Pipe
6. Fuel Feed Pipe
7.
8.
9.
10.
11.
Fuel Tank
Priming Pump
Fuel Filter With Sedimenter
Recirculation valve
Fuel Supply Pump
FUEL SYSTEM (4JJ1)
6C-3
Fuel Rail Assembly
2
1
RTW76CLF000601
Legend
1. Pressure Limiter
2. Fuel Rail Pressure Sensor
6C-4
FUEL SYSTEM (4JJ1)
Fuel Supply Pump
LNW71DLF000101
Legend
1. Fuel Temperature Sensor
2. Suction Control Valve
3. High Pressure Pipe
4. Camshaft Key
5. Camshaft Nut
FUEL SYSTEM (4JJ1)

Fuel Injector
6C-5
Fuel Filter
5
2
4
LNW76CSH000101
Legend
1. Element
2. Case
3. Drain Plug
4. Switch Connector
Functional Check
RTW76CMH000201
Legend
1. Terminal
2. Fuel Injector ID Code
3. Two Dimensional Barcode
4. Parts Number
5. Part for Mounting the Injection Pipe
6. O-ring
Air Bleeding
1. Before starting the engine
a. Fit a tray below the fuel filter (below the air
bleed plug).
b. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
near the plug overflows.
c. Tighten the plug, and operate the priming pump
more than 10 times until it is filled with fuel.
d. Tighten the plug firmly and wipe the fuel in the
surrounded area. Operate the priming pump
(10 to 15 times) till it is filled with fuel and then
send fuel to the engine.
2. After starting the engine
a. Start the engine by rotating the starter without
depressing the accelerator pedal.
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly rotate the idling control knob clockwise
and maintain it for 3 minutes.
d. Fully depress the accelerator pedal and
increase the rotations to maximum.(Repeat this
operation several times)
e. Rotate the idling knob counterclockwise and
return to idling more.
6C-6
FUEL SYSTEM (4JJ1)
NOTE:
If the air bleeding work is insufficient then it could lead
to faults in the engine. Therefore, the procedures after
starting the engine should always be implemented.
Water drain
A warning lamp will light up if water above the specified
volume collects in the sedimenter. In such cases, drain
out the water by performing the following operations:
Set a container at the tip of the plastic hose.
Loosen the air bleeding plug and the drain plug.
Discharge the water.

Tighten the drain plug after discharging the water.
Tighten the air bleeding plug to the specified
torque.
Tightening torque : 7.5 Nm (0.7 kgm/26 lb in)
Ignition switch is turned ON for 15 seconds check
for fuel leakage.
Check that the warning lamp in the meter is off.
Trouble Shooting
Problems with starting

Condition
Problems with starting
Possible Cause
Correction
Fuel tank is empty
Fill the tank.
Air has entered the fuel system.
Bleed the air.
Fuel line is clogged or damaged.

Connection to the fuel line is loose.
Repair or replace the fuel line. Retighten the connection.
Fuel filter element is clogged.
Replace the cartridge.
Fault in the feed pump
Replace the fuel supply pump.
Regulating valve is open.
Replace
Sticking of the fuel injector
Replace the fuel injector.
Defective engine control system
Diagnose
system.
the
engine
control
Hunting during idling

Condition
Hunting during idling
Possible Cause
Correction
Bleed air from the fuel system.
Leakage or clogging of the fuel

system
Repair or replace the fuel system.
Drops of water have entered the

fuel system.
Replace the fuel.
Replace the fuel filter element kit.
Diagnose
system.
the
engine
control
Insufficient horsepower
Condition
Insufficient horsepower
Possible Cause
Correction
Bleed air from the fuel system.
Leakage or clogging of the fuel

system
Repair or replace the fuel system.
Water mixes in the fuel system
Replace the fuel.
Replace the element kit.
Diagnose
system.
the
engine
control
FUEL SYSTEM (4JJ1)
6C-7
Maximum engine speed is too low

Condition
Possible Cause
Maximum engine speed is too low
Correction
Fuel line is clogged or damaged.
Repair or replace the fuel line.
Diagnose
system.
the
engine
control
Engine does not stop

Condition
Possible Cause
Engine does not stop
Correction
Diagnose
system.
the
engine
control
Exhaust gas is blue or black

Condition
Possible Cause
Exhaust gas is blue or black.
Reduction
in
injection-valve
opening pressure or defective
atomizing status
System diagnosis.
Fuel System Check

Description
Conforms to a fuel leak. Engine acceleration raises fuel
pressure and which increases the leak. Leak could be
in the following pipes and locations.
Between injectors and fuel rail.
Between fuel rail and fuel supply pump.
Between fuel supply pump and fuel filter.
Between fuel filter and fuel tank.
Between pressure limiter and fuel tank.
Between injector over flow and leak off pipe.
Diagnostic Aids
Check the following items.
Air in the fuel line
Step
1
Correction
Action
Check the fuel quantity.
Was a problem found?
Clogged fuel filter

Fuel pipe malfunction (Crushing, breakage,
clogging, disconnection, etc.)
Fuel tank malfunction
Injector malfunction
Fuel supply pump malfunction
Pressure limiter malfunction
An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
the insulation. Check for poor connections or a
damaged harness.
Inspect the ECM harness and connector for improper
mating, broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
ECU may set a DTC, if there is adequate air in fuel line.
Schematic Reference: Engine Controls Schematics
Value(s)
Yes
No
Go to Step 2
Add fuel and go to

Step 2
Go to Step 7
Go to Step 3
Go to Step 4
Check the fuel quality.
1.
Discharge the fuel from fuel tank
2.
Replenish the tank with specified fuel
3.
Bleed the air from the fuel system
4.
Start the engine
Could the engine be started?

3
Bleed the air from fuel system. Refer to Fuel

System Air Bleeding in this section.
Is the action complete?
6C-8
Step
FUEL SYSTEM (4JJ1)

Action
Check the main fuel filter for clogging.
Clean, repair, or replace as required.
Notice: Replacement of a fuel filter is
checking to a dealer.
Value(s)
Go to Step 6
Go to Step 7
Verify repair

Rebleed the air from the fuel pipe. Refer to
Fuel System Air Bleeding in this section.
Go to Step 5

Check the fuel tank.
If a problem is found, clean, repair, or replace
as necessary.
Foreign material (Clogged suction port)
Bent or cracked suction pipe
Fuel tank distortion
Fuel tank improper installation
Clogged fuel cap hole
Water
No

Check the fuel line for damage and leakage.
Clean, repair, or replace as required.
Crushed areas
Breakage
Cracks
Loose connections
Yes
FUEL SYSTEM (4JJ1)
6C-9
Fuel Filter Assembly

Components
1
2
Legend
1. Bolt
2. Fuel Feed Hose
Removal
1. Disconnect the sedimenter harness connector.
2. Remove the feed hose and the return hose from
the fuel filter and plug it so that the fuel does not
flow out.
3. Remove the bolts for mounting the fuel filter.
4. Remove the fuel filter assembly.
Installation
1.
2.
3.
4.
5.
Install the fuel filter assembly.

Install the bolts for mounting the fuel filter.
Install the feed hose and the return hose.
Connect the sedimenter harness connector.
Bleed out the air.
Refer to "Fuel System".
LNW76CSF000101
3. Fuel Return Hose

4. Sedimenter Harness Connector
6C-10
FUEL SYSTEM (4JJ1)
Fuel Filter Element

Removal
1. Remove the fuel in the element case.
a. Loosen the drain plug at the bottom of the
element case.
b. When the air breather of the body is loosened,
the is run out from the drain plug.
2. Remove the harness of the water warning switch.
3. Remove the element case from the body by
rotating the case in a counterclockwise direction,
using a socket (width of double socket: 29mm(a)).
After removing the case, confirm that the float at
the inside bottom can move up and down
smoothly.
If foreign materials, sludge or other dirty materials
are deposited at the bottom of the case, remove it
clearly.
4. Remove the O-ring of the body by pulling out the
element downward.
5. If foreign material is attached on the surface of the

body inner circumference, wipe it with clean cloth.
1
2
3
4
7
8
a
BLW61DMH000101
Legend
1. Cap
2. Air bleeder
3. Filter body
4. O-ring
5. Fuel filter element
6. Element case
7. O-ring
8. Drain plug
9. Wiring connector
Installation
1. Place the O-ring, packaged with the element kit,
into the groove on the outer circumference of the
body.
Careful handling of the O-ring is needed to prevent
being damaged by the threaded area of the body.
2. Apply a thin layer of fresh diesel fuel on the
gaskets, inside and outside of the element, and
then insert the gasket until it hits the end.
NOTE:
Be careful not to insert any foreign materials into the
four holes (clean side) next to the inside gasket.
FUEL SYSTEM (4JJ1)
6C-11
5. Tighten the drain plug of the element case, and

reconnect the connector of the water warning
switch.
Tightening torque:
0.4 Nm (0.04 kgm / 3.47 lb in)
6. After starting the engine, check each section for no
looseness.
4
3
MFW61DLH000101
Legend
1. Salient for socket
2. Float
3. Outside gasket
4. Inside gasket
5. Clean side hole
6. Element kit
7. O-ring grove
3. Apply a thin layer of fresh diesel fuel on the inner
circumference of the element case (or the O-ring
section at the body side). Turn the element in a
clockwise direction until it hits to the body carefully.
Biting with the O-ring must be
avoided.
No hitting of the element to the case means that
the element does not have compete insertion.
Turn the element and push it in again.
4. Tighten the element case with a torque wrench.
6C-12
FUEL SYSTEM (4JJ1)
Fuel Injector
Components
5
3
2
6
LNW76CLF000201
Legend
1. Cylinder Head Cover
The fuel system consists of many tiny holes and
spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injector.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injector during the
removal and installation procedure.
4. Fuel Injector
5. Fuel Injection Pipe
6. Fuel Injection Pipe Clip
NOTE:
To avoid electric shock: Set the switch to the 'OFF'
position and disconnect the battery negative cable
before checking or repairing the fuel injector, wiring or/
and connectors.
Removal
Refer to Cylinder Head Cover in ENGINE
MECHANICAL section.
FUEL SYSTEM (4JJ1)

2. Remove the injection pipe sleeve nut (1) from the
injector.
1
6C-13
4. Mark each fuel injector with the number of the

cylinder from which it was removed. Store the fuel
injector in a safe place. Position the fuel injector so
that the nozzle is protected.
NOTE:
If a fuel injector is replaced, cross off the replaced
injector ID codes on the label with a marking pen
etc.
If all fuel injectors are replaced, remove the fuel
injector ID code label from the engine cover.
1
2
3
4
LNW71DSH000101
4JJ1
51 16 1A 25 1A 24 17 17 00 14 00 52
51 19 13 OF OF OF 00 09 09 09 00 54
51 39 39 2C 1C 23 13 14 00 OF 00 57
51 19 19 18 00 17 00 00 00 00 00 44
3. Remove the injector.

NOTE:
Do not reuse the clip, gasket and bolt.
LNW76CSH001701
1
5
RTW66CSH000101
Legend
1. Fuel Injector
2. Leak Off Pipe
3. Clip
4. Gasket
5. Washer
NOTE:
Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
will result in injector failure.
Legend
1. 1st Cylinder Injector ID Code
2. 2nd Cylinder Injector ID Code
3. 3rd Cylinder Injector ID Code
4. 4th Cylinder Injector ID Code
5. Engine Cover
6. Injector ID Code Label
6C-14
FUEL SYSTEM (4JJ1)
Installation
1. Install the new gasket and O-ring to each fuel
injector.
2
4. Temporarily tighten the clamp bolts.

5. Apply a thin coat of engine oil to the outer surface
of the fuel injector side sleeve nuts.
6. Install the fuel injector pipes to the position shown
in the illustration.
7. Use a spanner to carefully tighten the sleeve nuts
until the fuel injector pipes contact the fuel injector
and fuel rail.
8. Tighten the fuel injector pipe clips to the specified
torque.
5
RTW66CSH000101
Legend
1. Fuel Injector
2. Leak Off Pipe
3. Clip
4. Gasket
5. Washer
2. Install the fuel injector clamps. Refer to the

illustration.
Apply Engine oil to the threads and seating
surfaces of the clamp bolts.
2
3
LNW76CMH000101
Legend
1. Fuel Injector
2. Pipe Clip
9. Tighten the injection pipes to the specified torque.
Tightening torque
Injector Side: 30 Nm (3.1 kgm / 22 lb ft)
Fuel rail side: 25 Nm (2.5 kgm / 18 lb ft)
RTW56CSH000601
Legend
1. Fuel Injector
3. Install the fuel injector clamps to the cylinder head.
FUEL SYSTEM (4JJ1)

2
LNW76CSH000501
Legend
1. Clamp Bolt
2. Sleeve Nut
10. Tighten the fuel injector clamp bolts to the
specified torque.
11. Tighten the engine oil level gauge guide tube.
Refer to Cylinder Head Cover in ENGINE
MECHANICAL section.
13. Program the Fuel Injector ID Codes
Refer to Programming in ENGINE CONTROL
SYSTEM section.
SAMPLE
5F 05 00
FB 00 F7
1
08 F5 19
FF 04 49
RTW76ESH002601
Legend
1. Fuel Injector ID Code
2. Fuel Injector
6C-15
6C-16
FUEL SYSTEM (4JJ1)
30(3.1/22)
26(2.7/20)
25(2.5/18)
8(0.8kg m/69lb in)
LNW76CLF000101
FUEL SYSTEM (4JJ1)
6C-17
Fuel Pressure Sensor

Removal
Installation
1. Disconnect the fuel pressure sensor harness

connector (1).
1
LNW76CSH001601
2. Remove the fuel pressure sensor.

NOTE:
Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.
RTW76CSH000101
Legend
1. Fuel Rail
3. Fuel Pressure Limiter
1. Install the fuel pressure sensor.

2. Connect the fuel pressure sensor harness
connector.
6C-18
FUEL SYSTEM (4JJ1)
Fuel Pressure Limiter

Removal
Installation
1. Remove the leak off pipe and hose (1).

NOTE:
system.
1. Install the fuel pressure limiter.

2. Install the fuel leak off pipe and hose (1) using the
mounting eyebolt using the specified torque.
1
LNW76CSH000401
2. Remove the fuel pressure limiter.

NOTE:
system.
RTW76CSH000101
Legend
1. Fuel Rail
LNW76CSH000301
FUEL SYSTEM (4JJ1)
6C-19
Fuel Rail Assembly

Components
1
5
2
7
LNW76CLF000301
Legend
1. Injection Pipe (#1 to #4)
2. Fuel Feed Pipe Assembly
3. Injection Pipe Clip
4. Fuel Rail
Parts of the fuel system such as the internal part of the
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter
and the entry of foreign matter could cause damage to
the fuel passage. Therefore, effective measures should
be taken to prevent the entry of foreign matter.
5. Fuel Rail Bracket

6. Space Rubber
7. Fuel Leak Off Pipe
Removal
sensor.
pipe.
6C-20
FUEL SYSTEM (4JJ1)
LNW76ASH000501
2. Remove the noise cover left side.

Disconnect the dropping register connector and
remove the noise cover.
3. Disconnect the fuel rail pressure sensor harness
connector (1).
LNW76CSH000701
6. Remove the leak off pipe and hose (1).

NOTE:
system.
1
LNW76CSH001601
4. Remove the engine oil level gage guide tube.

5. Remove the fuel hose (1).
NOTE:
system.
LNW76CSH000401
7. Remove the fuel feed pipe assembly (1) for supply

pump.
NOTE:
system.
FUEL SYSTEM (4JJ1)
LNW76CSH000801
8. Disconnect the injection pipe sleeve nut (1).

NOTE:
system.
6C-21
LNW76CSH001201
Legend
1. Fuel Rail
3. Space Rubber
Disassembly
1. Remove the fuel pressure limiter.
2. Remove the pressure sensor.
LNW76CSH000601
9. Remove the fuel rail and fuel rail bracket.

NOTE:
Do not grasp the pressure sensor, during the fuel
rail removal procedure.
Take care not to damage the connector unit of the
pressure sensor.
RTW76CSH000101
Legend
1. Fuel Rail
Reassembly
1. Install the fuel pressure limiter.
6C-22
FUEL SYSTEM (4JJ1)
2. Install the fuel pressure sensor.

4. Install the fuel feed pipe assembly (1) for supply

pump and tighten the bolts to the specified torque.
Installation
1. Tighten the space rubber, fuel rail bracket and fuel
rail using the specified mounting torque.
1
2
LNW76CSH000801
5. Tighten the fuel leak off pipe (1) using the

mounting eyebolt using the specified torque.
LNW76CSH001201
Legend
1. Fuel Rail
3. Space Rubber
2. Tighten the fuel pipe using the mounting sleeve nut

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

connector.
FUEL SYSTEM (4JJ1)

6. Install the fuel hose (1).
6C-23

marking.
LNW76CSH000701
7. Tighten the engine oil level gage guide tube and

tighten the mounting bolt to the specified torque.
Tightening torque: 25Nm (2.5 kgm/18 lb ft)
8. Install the noise cover left side.
9. Install the dropping register connector.
LNW76ASH000501
11. Install the boost sensor connector.
25(2.5/18)
44(4.5/33)
25(2.5/18)
LNW76CMF000101
6C-24
FUEL SYSTEM (4JJ1)
Fuel Supply Pump

Components
2
4
11
5
10
8
7
LNW76CMF000201
Legend
1. Fuel Feed Pipe Assembly
2. Injection Pipe Sleeve Nut
3. Space Rubber A
4. Bracket
5. Space Rubber B
6. Fuel Supply Pump
The fuel system consists of many tiny holes and
spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injector.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injector during the
removal and installation procedure.
Removal
1. Partially drain the engine coolant. Refer to drain
procedure for engine cooling in this manual.
7.
8.
9.
10.
11.
Noise Cover
Timing Chain Cover Lower
Nut
Sprocket
Fuel Supply Pump Gear
FUEL SYSTEM (4JJ1)

3. Remove the fan guide.
6C-25
6. Remove the A/C compressor adjust pulley.

2
1
3
2
LNW76ASH000701
Legend
1. Fan Guide Bracket
2. Fan Guide Bracket
3. Bolt
1
LNW76CSH001101
Legend
1. Bolt
2. Nut
7. Disconnect the A/C compressor.
9. Remove the fuel rail assembly. Refer to removal
procedure for Fuel rail assembly in this manual.
Refer to removal procedure for Fuel rail assembly
in this manual.
11. Disconnect the connector of supply pump.
12. Remove the noise cover.
4. Remove the cooling Fan.
RTW56ASH025401
5. Remove the A/C compressor drive belt.
RTW56CSH001401
Legend
1. Noise Cover
6C-26
FUEL SYSTEM (4JJ1)
13. Remove the timing chain cover assembly. Upper &

lower.
1
1
RTW56ASH006901
LNW76CSH001001
Legend
1. Timing Chain Cover Upper
2. Timing Chain Cover Lower.
Legend
1. Align mark on intake camshaft and exhaust
camshaft to mark of bearing cap
15. Loosen the nut.
14. Align the timing marks at 3 locations as shown.
RTW56CSH001601
LNW76ASH001101
Legend
2. Mirror
3. TDC Mark
Legend
1. Nut
FUEL SYSTEM (4JJ1)

16. Remove the timing chain tennsioner.
6C-27
19. Timing chain in moved upwards.
2
1
LNW71BSH001401
Legend
1. Timing Chain Tennsioner.
2. Gasket
RTW56CSH003301
20. Paint the alignment mark. Between idle gear A and

supply pump gear.
17. Remove the timing chain tension lever pivot.

18. Remove the nut and sprocket.
2
1
RTW56CSH004101
Legend
1. Tension Lever Pivot
2. Sprocket
3. Nut
RTW56AMH000401
6C-28
FUEL SYSTEM (4JJ1)
21. Use a gear puller to remove the fuel supply pump

gear.
23. Remove the supply pump and O-ring.
LNW76CSH000901
RTW56CSH002901
22. Remove the supply pump and supply pump

bracket with spacer rubber.
NOTE:
Do not hold the high pressure pipe, during the
supply pump removal procedure.
Do not grasp the high pressure pipe, when moving
the supply pump from one location to another.
Legend
1. O-ring
2. Supply Pump
Installation
1. Install the O-ring to the fuel supply pump.
2. Install the fuel supply pump. Apply soapy water to
the O-rings before attaching.
NOTE:
Take care not to twist the O-ring.
2
1
3. Install the fuel supply pump bracket.

Temporarily tighten with the bolts and nuts (Gear
case side).
Temporarily tighten with the bolts (Cylinder body
side).
Fully tighten the bolts and nuts (Gear case side).
Fully tighten the bolts (Cylinder body side).
Tightening torque: 25 Nm (2.5 kgm /18 lb ft)
LNW76CSH001301
Legend
1. Supply pump
2. Space Rubber B
3. Supply Pump Bracket
4. Space Rubber A
FUEL SYSTEM (4JJ1)

3
6C-29
4
3
4
1
2
LNW71DSH000401
Legend
1. Fuel Supply Pump
2. Space Rubber B
3. Fuel Supply Pump Bracket
4. Space Rubber A
4. Confirm that the supply pump camshaft key is
turned to the right and is horizontal.
RTW56CSH005101
6. Install the timing chain to the each sprocket and

install the fuel supply pump sprocket to the pump
shaft.
a. Align the camshaft sprocket timing mark (1)
with the bright plate timing chain link (2).
b. Align the fuel supply pump sprocket timing
mark (3) with the yellow plate timing chain link
(4).
c. Install the fuel supply pump sprocket to the fuel
pump shaft by aligning the dowel pin that is
attached to the gear.
d. Hand-tighten the fuel supply pump shaft nut.
2
RTW56CSH004301
5. Install the fuel supply pump to the pump shaft.

a. Align the fuel pump gear timing mark (1) with
the idle gear A paint marks (2).
b. Ensure that the pump must be bit with
maingear(3)of the idle gear A. Depress the
pump gear when it is bitted with scissors gear
(4) of the idle gear A.
Legend
1. Timing Mark
2. Dark Plate
2. Timing Mark
2. Yellow Plate
RTW56CSH005001
6C-30
FUEL SYSTEM (4JJ1)
7. Install the timing chain tension lever pivot. Handtighten the pivot bolt.
Confirm that the tension lever moves smoothly.
8. Attach the hook of the timing chain tensioner.
Hold the latch(3) depressed. Insert the
plunger(2). Attach the hook (4) to the pin (1) to
hold the plunger in place.
1
RTW56ASH020401
11. Tighten the nut (1) to the specified torque.

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

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

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

Press the place of the arrow in the figure.
The hook is opened. The plunger pushes the
tension lever.
FUEL SYSTEM (4JJ1)

14. Check the mark (1) on the intake camshaft and
exhaust camshaft to the mark of camshaft bearing
cap.
6C-31
RTW76CSH001201
RTW56ASH006901

16. Apply liquid gasket (ThreeBond TB-1207C or
equivalent) to the timing chain cover upper (1).
Attach the cover within 5 minutes of applying
the liquid gasket.
18. Apply liquid gasket (ThreeBond TB-1207C or

equivalent) to the timing chain cover lower (1).
Attach the cover within 5 minutes of applying
the liquid gasket.
RTW56CSH002301
19. Install the timing chain cover lower (1). Tighten the
bolts (2) and nuts (3) to the specified torque.
RTW56CSH002101
17. Install the timing chain cover upper (1).

Tighten the bolt to the specified torque.
Apply Loctite #262 or equivalent to the bolt and
stud threads of cylinder head side (2).
6C-32
FUEL SYSTEM (4JJ1)

25. Install the A/C compressor adjust pulley.
1
3
LNW76CSH001401
20. Install the noise cover (1). Tighten the bolts to the
specified torque.
1
LNW76CSH001101
Legend
1. Bolt
2. Nut
Tighten the bolt and nut to the specified torque.
Bolt Tightening torque: 25 Nm (2.5 kgm/18 lb ft)
RTW56CSH001401
21. Install the connector of supply pump.

22. Install the fuel rail assembly.
Refer to the Install procedure for Fuel rail
assembly in this manual.
23. Install the A/C compressor bracket. Tighten the
bolts to the specified torque.
24. Install the A/C compressor.
Nut Tightening torque: 25 Nm (2.5 kgm/18 lb ft)

26. Install the A/C compressor drive belt.
Refer to the drive belt tension check procedure for
Heating and air conditioning in this manual.
28. Install the fan guide.
31. Start the engine and let idle.
IMPORTANT:
In order for the ECM to learn the characteristics of the
fuel supply pump, let the engine idle until warn-up. If
fuel system DTC's are stored in the meantime, clear
the DTC and warn-up the engine again.
FUEL SYSTEM (4JJ1)
6C-33
25(2.5/18)
25(2.5/18)
27(2.8/20)
25(2.5/18)
10(1.0/87lb in)
130(13.3/96)
10(1.0/87lb in)
10(1.0/87lb in)
25(2.5/18)
10(1.0/87lb in)
LNW76CLF000401
6C-34
FUEL SYSTEM (4JJ1)
Fuel Sedimenter Switch

Inspection
1. Check that there is continuity between the switch
connector terminals when the float in the fuel
sedimenter is above the water drain line.
2. Turn on the ignition switch, remove the fuel
sedimenter connector, and connect the terminals
of the connectors on the harness side. Confirm
that the sedimenter warning lamp lights up.
If abnormalities are detected during the check, replace
the CASE KIT (with switch) and carry out repairs in
case of defective connections between circuits or short
circuits.
2
1
3
Legend
1. Sensor
2. Connector on The Vehicle Side
3. Harness
4. Drain Plug
LNW76CSH000201
FUEL SYSTEM (4JJ1)
6C-35
Fuel Tank
Components
1
LNW21DLF000301
Legend
1. Fuel gauge unit connector
2. Breather hose
3. Fuel feed hose
Removal
1. Loosen the fuel filler cap.
2. Drain the fuel through the drain plug.
3. After draining the fuel tighten the drain plug to its
specified torque.
4. Remove the connector from the fuel gauge unit.
5. Remove the breather hose.
4. Fuel return hose

5. Band
6. Fuel tank
6. Remove the fuel feed hose.

7. Remove the fuel return hose.
Use a stopcock to prevent fuel from spilling,
point it upwards and tie it to the frame.
8. Remove the band for mounting the fuel tank and
remove the tip of the band on the frame side.
9. Pull the fuel tank to the outside.
6C-36
FUEL SYSTEM (4JJ1)
NOTE:
If the fuel tank can not be removed, remove the bracket
and lower the fuel tank downwards.
LNW21DMH000501
Mounting
1. Mount the fuel tank.
NOTE:
If you removed the bracket when removing the fuel
tank, attach the bracket to the frame and tighten it to its
specified torque.
Also, when placing the fuel tank on the bracket, make
sure the rubber that is attached to fuel tank contacts the
bracket.
2. Mount the band onto the fuel tank and tighten the
mounting nut to its tightening torque.
3. Mount the fuel return hose.
4. Mount the fuel feed hose.
Put the hose onto the pipe at least 25 mm
(0.9843 in).
5. Mount the breather hose.
Put fuel into the fuel tank and tighten the fuel
filler cap.
Connect the battery ground cable.
After starting the engine, check the hose
connections to make sure that there are not any
fuel leaks.
6. Connect the connector to the fuel gauge unit.
FUEL SYSTEM (4JJ1)
6C-37
Fuel Gauge Unit

Components
LNW21DMF000101
Legend
1. Fuel gauge unit connector
Removal
1. Remove the wiring connector from the fuel gauge
unit.
2. Remove the mounting screw and remove the fuel
gauge unit.
NOTE:
When removing and attaching the fuel gauge unit, take
caution with respect to interference with surrounding
objects; do not deform the arm.
Also, after removing the fuel gauge unit, place a seal so
that foreign materials do not get into the tank.
2. Fuel gauge unit
6C-38
FUEL SYSTEM (4JJ1)
Inspection
The fuel tank unit changes its internal resistance based
on the position of the float (height of liquid) and moves
the needle of the fuel meter.
1. While moving the float from E to F, inspect the

resistance value between connector terminals 1 J28 - 2 J-28.
2. Confirm that the low fuel light turns on when the
float is in the "E" position.
If there are any abnormalities found with the
inspection, replace with a part that works correctly.
LNW21DSH002301
J-28
1/2
Warning lamp lighting point

E
LNW76DMF000101
a
b
325.2mm / 12.80in (Fuel tank capacity 63L / 13.86Imp.gal)

379.7mm / 14.95in (Fuel tank capacity 75L / 16.5Imp.gal, 100L / 22Imp.gal)
FUEL SYSTEM (4JJ1)

c
d
6C-39

Float Position
Standard resistance volume

()
F (FULL stopper)
2.5
1/2
33.0
Warning lamp lighting

point
87.0
E (EMPTY stopper)
98.3
Mounting
Perform the removal process backwards for mounting.
1. Mount the fuel gauge unit.

2. Connect the wiring connector to the fuel gauge
unit.
55(5.6/41)
12(1.2/104lb in)
20(2.0/14)
LNW76DMF000201
MEMO
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ENGINE ELECTRICAL (4JJ1)
ENGINE
ENGINE ELECTRICAL
(4JJ1)
TABLE OF CONTENTS
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .6D-2
Servicing Cautions . . . . . . . . . . . . . . . . . . . . . . .6D-2
Important Generator Components and Function 6D-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .6D-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-4
Unit Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-6
Inspection and Repair . . . . . . . . . . . . . . . . . . . .6D-8
Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6D-8
Stator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-9
Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . .6D-10
Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . 6D-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-12
Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . .6D-12
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-14
Starting Circuit Diagram . . . . . . . . . . . . . . . . . .6D-14
Removal and Installation . . . . . . . . . . . . . . . . .6D-14
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .6D-15
Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6D-22
Magnetic Switch . . . . . . . . . . . . . . . . . . . . . . . .6D-24
Pre-Heating System . . . . . . . . . . . . . . . . . . . . . .6D-26
Inspection and Repair . . . . . . . . . . . . . . . . . . .6D-26
6D-1
6D-2
Charging System
Servicing Cautions
Battery polarity is important. If the battery cables
are reversed, the generator diodes will be
destroyed.
Do not remove the battery cables or the charging
circuit wiring when the engine is running.
Confirm that the terminal wires are connected to
the proper terminals by checking the terminal
numbers (the number on the terminal wire and the
terminal must be the same).
Disconnect the battery negative cable (-) before
inspecting the generator.
Do not open or close the battery relay switch when
the engine is running.
Disconnect the battery negative cable (-) when
using external equipment (Quick-Charge) to
charge the battery.
When steam cleaning or washing the engine, do

not allow steam or water to come in direct contact
with the battery and other electrical system
components.
Be sure to read the item on belt tension adjustment
before beginning the procedure.
Important
Function
Generator
Components
and
The generator uses a built-in solid-state IC voltage

regulator. The regulator and other important
components together with their connections are
The voltage regulator is installed to the rear cover
assembly of the generator together with the brush
holder and the rectifier. The generator requires no
additional voltage regulation.
9 diodes are connected to the stator coil to convert
AC to DC. The DC voltage is delivered to the
generator output terminal.
AC Generator
RTW76DMF000101
6D-3
Charging System
B
S
Rotor coil
Charge lamp
L
Charge
relay
IG-SW
Stator coil
Battery
Warnning
lamp
F
QOS
C/U
IC Regulator
P
SW
RTW56DMF000101
Troubleshooting
Symptoms
No charging
Inadequate charging
Excessive charging
Unstable charging current
Abnormal generator noise
No charging
Possible problem
Countermeasure
Dead battery
Replace
Open or shorted wiring
Repair
Open or shorted ammeter

Loose wiring connections
One or more generator coils open or shorted
Replace
Bad diode
Bad regulator
Loose regulator connections
Repair
Inadequate charging
Possible problem
Dead battery
Countermeasure
Replace
6D-4

Possible problem
Open or shorted wiring
Countermeasure
Repair
Loose wiring connections

Adjust belt tension
Stator coil intermittent short
Replace
Bad diode
Loose battery connections
Repair
Bad regulator
Replace
Loose regulator connections
Repair
Excessive charging
Possible problem
Bad regulator
Countermeasure
Replace
Unstable charging current

Possible problem
Countermeasure
Open wiring connection or broken wire
Repair
Adjust belt tension
Open or shorted stator coil
Replace
Loose terminal connections
Repair
Bad regulator
Replace
Loose regulator terminal connections
Repair
Abnormal operating noise

Possible problem
Countermeasure
Adjust belt tension
Bad bearing
Replace
Loose rotor core or stator core
Repair
Bad diode
Replace
Open or shorted stator coil
Replace
Diagnosis
On-vehicle Inspection
The charging system warning light tells the vehicle
operator of possible problems with the system.
When the ignition switch is moved to the ON position,
the light turns on. The light turns off immediately after
the engine is started. If the light turns on during engine
operation, there is a problem with the charging system.
Perform the checks described below.
1. Check the belt (broken or loose).
2. Check the harness connectors (loose or
disconnected).
3. With the engine off, turn the ignition switch to the

ON position. If the warning lamp does not light,
remove the harness connector from the generator.
Ground the connector L terminal. The lamp should
light. If it does not, the bulb is burned out. Replace
the bulb.
4. Start the engine. If the warning lamp remains on,
the generator must be repaired or replaced.
6D-5
Specifications
Battery power
Generator output
Rotational direction (Viewed from pulley)
Rated speed
Maximum speed
Volts
24
Amperes
45 / 50 / 80
Clockwise
rpm
5000
12000
6D-6
Unit Servicing
Components
5
4
10
2
9
7
LNW76DLF000101
Legend
1. Pulley Nut
2. Pulley
3. Front Cover Assembly
4. Rotor Assembly
5. Stator Assembly
Disassembly
1. Remove the through bolts.
2. Insert a flat-blade screwdriver between the front
cover and the stator. Pry the parts apart.
6.
7.
8.
9.
10.
Through Bolts
Rear Cover Assembly
Rectifier
Ball Bearing
Ball Bearing

3. Separate the front cover/rotor assembly from the
rear cover/stator assembly.
6D-7
8. Remove the bearing retainer and the bearing.
LNW71DSH000201
LNW76DSH000801
4. Place the front cover and rotor in a vise.

5. Remove the pulley nut and the pulley.
6. Remove the rotor from the front cover.
9. Remove the B-terminal nut and M5 nut.

10. Remove the rear cover from the stator.
LNW71DSH000301
LNW76DSH000201
7. Remove the screw from the front cover.
6D-8
11. Remove the stator assembly.
Limit
30.7 (1.209)
RTW46DSH000401
12. Remove the rectifier assembly from the stator

assembly.
LNW76DSH000501
3. Measure the electrical resistance between the slip

rings. If the resistance is greater than the specified
limit (open circuit), repair is required.
Rotor coil resistance at 20C (68F)
(45 A)
10.5
(50 A)
8.2
(80 A)
10.2
LNW76DSH000601

Repair or replace any parts found to be excessively
worn or damaged during the inspection procedure.
Rotor Assembly
1. Check for dirty or rough slip ring surfaces. Remove
dirt from the surfaces with a clean rag. Use No.
500 or No. 600 sandpaper to smooth the surfaces.
2. Measure the slip ring diameters. Replace the slip
ring if the diameter is less than the specified limit.
Slip ring diameter
Standard
mm (in)
31.7 (1.248)
LNW76DSH000301

4. Check for conductivity between the slip rings and
the rotor core. If there is continuity, the rotor
assembly must be replaced.
6D-9
2. Measure the resistance between the stator coil and

the stator core. If the resistance is less than the
specified value, the stator coil must be replaced.
Stator coil/core resistance: MIN 1 M
LNW76DSH000401
HCW31ESH004401
Stator Coil
1. Measure the stator coil resistance. If the resistance
is less than the specified value, the stator coil must
be replaced.
Stator coil resistance at 20C (68F)
45 A
0.19
50 A
0.19
80 A
0.07
LNW76DSH000701
Brushes
Measure the brush height. If the height is less than the
specified limit, the brushes must be replaced.
Brush height
mm (in)
Standard
25 (0.984)
Limit
6.5 (0.260)
6D-10

Rectifier Assembly
Measure each of the diode resistances in both
directions (anode/cathode and cathode/anode). If any
of the diodes have the same resistance in both
directions, the rectifier must be replaced.
3
4
RTW46DSH001201
LNW76DMH000101
Tester Wire
E
U,V, and WN
NO conductivity
Conductivity
Negative side diode check
BAT
NO conductivity
Conductivity
U,V, and WN
Positive side diode check
6D-11
Rectifier Assembly
(45A / 50A)
E
P
6
SWITCH 2
B
3
5
LAMP 2 LAMP 1 SWITCH 3
4
1 VOLT METER
8
OUTPUT SIGNAL
7
PULSE
5~30V
GENERATOR
+
-
1kHz
2
DIRECT-CURRENT
STABILIZATION POWER SUPPLY
LNW76DSF000101
(80A)
E
P
7
SWITCH 2
2 SWITCH 1
1 VOLT METER
4
6
LAMP 2 LAMP 1 SWITCH 3
5
9
OUTPUT SIGNAL
8
PULSE
5~30V
GENERATOR
+
-
1kHz
3
DIRECT-CURRENT
STABILIZATION POWER SUPPLY
RTW46DSF000301
Test circuit
Refer to the judgment criteria shown in the Table
below.Carefully check Items 1 to 5.If all the items are
OK, the IC regulator is normal.
Circuit components
1
DC regulated power supply
0 - 30 volts variable with output of 1 ampere or more
Lamps (2)
Switches (3)
DC voltmeter
0 to 60 volts, 0.5 grade
Pulse generator (Oscillator)
24 volts, 1.8 watts
5 to 30 volt output at a frequency of 1KHz
6D-12
Judgment criteria
NO.
Switch
1
Switch
2
ON
OFF
Switch Voltmeter
3
reading
OFF
24V
ON
ON
OFF
Lamp condition
Lamp 1
Lamp 2
On
(dim)
ON
On or
flashing
ON
ON
OFF
32V
Off or
on (dim)
OFF
ON
OFF
24V
On or
flashing
ON
ON
ON
36V
On
Reassembly
Follow the disassembly steps in reverse order to
reassemble the generator. Pay close attention to the
items below.
Be very careful not to reverse battery polarity.
Reversed battery polarity will destroy the rectifier
diodes.
Do not ground the generator B-terminal. Heat and
fire damage to the harness will result.
If using a fast charge procedure, be sure to
disconnect the battery positive cable. If you do not,
the rectifier diodes will be exposed to high positive
voltage that will destroy them.
Be very careful to reassemble the parts to their
original positions. Particular care must be taken
with insulated parts.
Carefully clean all insulated parts so that they are
completely free of oil and/or grease.
Be sure that B-terminal twist-type stoppers (round
terminal) are securely inserted before tightening
the nuts.
Final Assembly
1. Pulley and rotor assembly.
Install the pulley and rotor assembly
a. Carefully clamp the rotor assembly in a vise.
Remarks
Initial excitation check
Full excitation check
OFF
ON
Lamp 1 off or dimly lit when the voltmeter shows

less than 24 volts or 32 volts
Stator and brush separation check
Excess voltage check
b. Tighten the pulley nut.
RTW46DSH002101

c. The rear ball bearing is pressed into the wheel
eccentric groove.The bearing ring projects from
the groove.During installation, rotate the
bearing to the point of minimum bearing ring
projection.
6D-13
Insert the pin from the outside of the rear cover.

Press the brushes into the holder. Complete the
assembly procedure.
Pin
Ring
Projection part
(0.65mm blow)
eccentric groove
RTW46DSH005301
RTW46DSH004901
3. Use a bench press to install the rear cover

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

Use a pair of long-nose pliers to connect the
stator coil leads and the rectifier leads.
Finish the work as quickly as possible to
prevent the rectifier from heat transferred by the
soldering.
RTW56DSH000201
4. Through bolts.
place a guide bar through the holes in the front
cover and rear cover flange for proper
alignment.Install the through bolts.
RTW46DSH000401
Tightening torque:4Nm(0.4 kgm / 35 lb in)
6D-14
Starter Motor
Starting Circuit Diagram
3. Install the E/G oil level gage.

4. Install the A/T oil level gage.
5. Reconnect the battery cable at the starter motor
and the ground cable at the cylinder body.
6. Reconnect the battery cable and the ground cable
at the battery terminals.
Type : S13-555A
Starter switch
Battery
RTW46DSH005501

before you begin.
Important Operations - RemovalStarter Motor
1. Disconnect the battery cable and the ground cable
at the battery terminals.
2. Remove the A/T oil level gage.
3. Remove the E/G oil level gage.
4. Disconnect the magnetic switch cable at the
terminal bolts.
5. Disconnect the battery cable at the starter motor
and the ground cable at the cylinder body.
6. Remove the starter motor from the engine.
Important Operations - Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention
to the important points during the installation
procedure.
Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified
torque.
Motor Bolt Torque:
Nm (kgm / lb ft)
85 (8.7 / 63)
6D-15
Components
24 V 4.0 kW
6
5
4
3
2
1
19
20
21
22
23
24
25
26
18
17
10
11
12
13
14
15
16
Legend
1. Plunger
2. Dust Cover
3. Magnetic Switch
4. Terminal Cover
5. Gear Case
6. T0rsion Spring
7. Dust Cover
8. Shift Lever
9. Through Bolt
10. Rear Cover
11. Brush Holder
12. O Ring
13. Yoke
LNW76DLF000201
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Ball Bearing
Armature
Ball Bearing
Bearing Retainer
Pinion Shaft
Ball Bearing
Clutch
Ball Bearing
Return Spring
Stopper
Clip
Ball Bearing
Bearing Holder
6D-16
24 V 4.5 kW
5
4
3
2
1
27
28
29
30
31
32
33
34
26
21
19
22
23
24
25
20
10
13
12
11
14
15
17
16
18
LNW76DLF000301
Legend
1. Plunger
2. Dust Cover
3. Magnetic Switch
4. Terminal Cover
5. Torsion Spring
6. Shift Lever
7. Dust Cover
8. Gear Case
9. Through Bolt
10. Rear Cover
11. Drain Pipe
12. Brush Holder
13. O Ring
14. Yoke
15. O Ring
16. Ball Bearing
17. Armature
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Ball Bearing
Bearing Retainer
Clip
Pinion Stopper
Pinion
Cushion Spring
Sleeve Cover
Stopper Washer
Pinion Shaft
Ball Bearing
Clutch
Ball Bearing
Return Spring
Stopper
Clip
Ball Bearing
Bearing Holder

Important Operations
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
6D-17
Remove the torsion spring from the magnetic

switch.
RTW46DSH002801
RTW46DSH002601
2. Magnetic Switch Assembly

Remove the magnetic switch bolts, then remove
the switch from the shift lever.
3. Through Bolt
4. Screw
5. Rear Cover
Remove the through bolts, then remove the rear
cover.
RTW46DSH002701
RTW46DSH002901
6D-18
6. Motor Assembly
Remove the four brushes from the brush holders.
9. Armature
Remove the brush holder and pull out the armature
assembly free from the yoke.
Brush
RTW46DSH003001
RTW46DSH003201
Remove the yoke along with the armature and the

brush holder from the gear case.
Remove the brushes and commutator carefully so
as not to allow them in contact with the adjacent
parts.
10.
11.
12.
13.
14.
15.
Bearing Retainer
Pinion Assembly
Dust Cover
Shift Lever (4.0kW only)
Shift Lever and Lever pin (4.5kW only)
Gear Case
a. Remove the bearing retainer.
b. Remove the pinion from the gear case.
RTW46DSH003101
7. Brush Holder
8. Yoke
LNW76DSH000901

c. Use a screwdriver to remove the stopper clip.
Then disassemble the pinion assembly.
6D-19
2. Check the commutator mica segments

excessive wear.
3. Measure the mica segment depth.
Mica Segment Depth
for
mm (in)
Standard
0.5 0.8 (0.020 0.030)
Limit
0.2 (0.008)
If the mica segment depth is less than the standard

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

replacement if excessive wear or damage is discovered
during inspection.
Armature
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
RTW56DSH000701
Commutator Run-Out
mm (in)
Standard
0.05 (0.002)
Limit
0.20 (0.079)
Legend
1. Insulator
2. 0.5 to 0.8 mm (0.020 to 0.030 in)
3. Commutator Segments
4. Correct
5. Incorrect
4. Measure the commutator outside diameter.
Commutator Outside Diameter
RTW46DSH003501
mm (in)
Standard
36.5 (1.44)
Limit
35.5 (1.40)
6D-20
If the measured outside diameter is less than the

specified limit, the commutator must be replaced.
b. Repair Step 1 at different segments of the

armature core.
There should be continuity between all
segments of the commutator.
If there is not, the armature must be replaced.
HCW51ESH000901
5. Use a circuit tester to check the armature

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

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

continuity.
a. Hold one circuit tester probe against the "M"
terminal lead wire.

b. Hold the other circuit tester probe against the
field winding brush.
There should be continuity.If there is no
continuity, the yoke must be replaced.
6D-21
2. Use a circuit tester to check the brush holder

insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.
RTW46DSH003901
RTW46DSH004101
Brush and Brush Holder

1. Use a vernier caliper to measure the brush length
(four brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Inspect the brushes for excessive wear.

If the negative brushes have excessive wear, the entire
brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.
Overrunning Clutch
Brush Length
mm (in)
Standard
15.5 (0.61)
Limit
12 (0.47)
1. Inspect the overrunning clutch gear teeth for

excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
RTW46DSH004001
LNW61DSH002701
6D-22
Bearing
b. Install the dust cover.
Inspect the bearings for excessive wear

damage.Replace the bearings if necessary.
and
Dust Cover Bolt Torque:
Nm (kgm/lb in)
10.6 (1.08 / 78)
RTW46DSH004401
Reassembly
RTW46DSH005701
Important Operations
1. Magnetic Switch Assembly
a. Attach the torsion spring to the hole in the
magnetic switch as illustrated.
b. Insert the shift lever into the plunger hole of the
magnetic switch.
4. Pinion Assembly
Apply a coat of grease to the reduction gear and
install the pinion assembly to the armature shaft.
LNW61DSH002801
RTW46DSH005601
2. Gear Case
3. Dust Cover
a. Install the magnetic switch assembly in the gear
case.
5. Brush Holders
a. Install the brushes into the brush holder with
raising the spring end of the brush spring.
Take care not to damage the commutator face.
6D-23
b. Install the brush holder with aligning the

peripheries of the yoke and the brush holder.
RTW46DSH002601
RTW46DSH004501
6. Through Bolt
Install the through bolts in the rear cover and
tighten them to the specified torque.
Through Bolt Torque:
Inspection After Assembly

Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft
end and pinion stopper clearance.
Nm (kgm/lb in)
Pinion Shaft Thrust Play:
8.1 (0.83 / 69.7)
mm (in)
0.3 - 1.0 (0.012 - 0.039)
0.3-1.0mm
LNW61DSH002901
7. Lead Wire
Connect the lead wire in the magnetic switch and
tighten the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque:
8.6 (0.88 / 74.9)
Nm (kgm/lb in)
LNW76DSH001001
6D-24
Magnetic Switch
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the "M"
terminal.
To prevent coil burning, complete each test as quickly
as possible (within three to five seconds).
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the
solenoid switch body and the M terminal. When
current is applied to the S terminal from the battery
positive terminal, the pinion should flutter.
3. Return Test
Disconnect the battery positive lead at the S
terminal.
The pinion should return to its home position.
S
RTW46DSH004701
RTW46DSH004601
2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion
should continue to flutter.
RTW46DSH005901
6D-25
8.6 (0.88 / 6.4)
8.1 (0.83 / 6.0)
LNW76DLF000401
6D-26
Pre-Heating System
replacement if excessive wear of damage is discovered
during inspection.
Visual Check
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
Glow Relay
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range,
the glow relay must be replaced.
LNW21KSH001401
Glow Relay Resistance:

94 - 114
1
3
4
4
2
1
3
LNW61DSH003001
Glow Plug
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference):
Approximately 0.9
EXHAUST SYSTEM (4JJ1)
ENGINE
EXHAUST SYSTEM
(4JJ1)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6F-2
Explanations on functions and operation . . . . . . 6F-2
Functional check . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
List of abnormal phenomena . . . . . . . . . . . . . . . 6F-3
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6F-3
Exhaust Silencer and Exhaust Pipe . . . . . . . . . . . 6F-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-4
DPD Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6F-5
DPD Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6F-6
DPD Reassembly. . . . . . . . . . . . . . . . . . . . . . . . 6F-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-8
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6F-10
Exhaust Brake System . . . . . . . . . . . . . . . . . . . . 6F-11
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-11
Explanations on functions and operation . . . . . 6F-11
Functional check . . . . . . . . . . . . . . . . . . . . . . . 6F-11
Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-13
Exhaust Throttle . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-17
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-19
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6F-19
Explanations on functions and operation . . . . . 6F-19
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . 6F-20
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-21
6F-1
6F-2
Exhaust System
Service Precautions
Offset in position of the exhaust system during

assembly may sometimes cause vibrations or rattling
noise. Therefore, temporarily tighten the bolt until all
the parts have been positioned, and sequentially
tighten from the engine side to the rear pipe side.
The exhaust brake assembly operates the auxiliary

brakes by adjusting the exhaust pressure. The silencer
has a built-in catalytic converter and the catalyst is a
ceramic monolith (honeycomb). This reduces the CO
and HC in the exhaust gas. The rear exhaust pipe has
a built-in post silencer. This improves the silencing
effect.
The main parts consist of the front exhaust pipe, center
exhaust pipe, exhaust brake unit, silencer with built-in
catalyst, and rear exhaust pipe.
3
2
7
1
9
5
LNW76FLF000201
Legend
1. Front Exhaust Pipe A
2. Exhaust Brake Assembly
3. Front Exhaust Pipe B
4. DPD(Diesel Particulate
Specification)
Defuser,
EURO
5.
6.
7.
8.
9.
Exhaust Silencer(EURO 3 Specification)

Exhaust Throttle Assembly
Exhaust Silencer
Center Exhaust Pipe
Rear Exhaust Pipe

Functional check
During check or repairs of the exhaust system,
confirm that the clearance between the body and
the floor is adequate.
Adequate care should be taken to prevent damage
due to heating or vibrations in the body panel as it
may lead to exhaust gas entering the cabin.
Check for loose or damaged connectors and
leakage of exhaust gas.
Check for degradation, cracks or damage to the
clamp or rubber.
If the pipe or silencer is damaged or has a dent
then repair or replace it.
6F-3
Check for dents, damage holes or cracks due to

corrosion, and abnormal noise during operation.
If CO or HC value in the exhaust gas increases
when measuring the exhaust gas (vehicle
inspection, etc.), replace the silencer (built-in
catalyst).
List of abnormal phenomena

Vibration or rattling noise from the exhaust system.
Clogging of the exhaust system.
Exhaust leakage or noise.
Trouble Shooting
Vibration or rattling noise from the exhaust system
Condition
Possible Cause
Correction
Vibration or rattling noise from the Loose or misaligned components Match the joints and then re-tighten.
exhaust system
Or,check for damage in the hanger,
mounting brackets and clamps.
Clogging of the exhaust system
Condition
Clogging of the exhaust system
Possible Cause
Correction
The exhaust brake is in the ON Refer to the Engine Control Systems

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

Condition
Exhaust leakage or noise
Possible Cause
Correction
Defect or misalignment in mounting
Match the joints and then re-tighten.
Damage or burn-out of exhaust Replace the damaged parts.

piping or silencer
Defective components in the Replace the defective parts.
exhaust system (clamps, pipes,
silencer)
Internal damage to silencer
Replace the silencer
6F-4
Exhaust Silencer and Exhaust Pipe

Removal
1. Remove the rear exhaust pipe.
Remove the clamp and rear exhaust pipe.
LNW76FSH000501
2.
3.
4.
5.
6.
Remove the center exhaust pipe.

Remove the exhaust silencer.
Remove the exhaust throttle air pipe.
Remove the exhaust throttle assembly.
Remove
the
exhaust
silencer(EURO
3
Specification).
7. Remove the DPD assembly (EURO 4
Specification).
Remove the 2 connectors on the DPD exhaust
temperature sensor.
Remove the clip that secures the connectors on
the DPD exhaust temperature sensor.
Remove the 2 DPD differential pressure hoses.
Remove the DPD assembly from the front pipe.
LNW76FSH000101
Legend
1. Differential Pressure Pipe (F)
2. Exhaust Temperature Sensor (R)
3. Differential Pressure Sensor
4. Differential Pressure Hose (F)
5. Differential Pressure Hose (R)
6. Differential Pressure Pipe (R)
7. Exhaust Temperature Sensor (F)
NOTE:
In the event that the differential pressure sensor
assembly must be removed, pay attention to the
following points.
Do not loosen the 4 screws used to tighten the
differential pressure sensor. If these screws have
been loosened, replace the differential pressure
sensor assembly.
If the differential sensor assembly is dropped, it
cannot be reused.
6F-5
1
2
2
3
LNW76FSH000201
Legend
1. Sensor Assembly
2. Tightening Screw
8. Remove the front exhaust pipe (B).
9. Remove the exhaust brake.
Remove the air hose and the exhaust brake
assembly.
10. Remove the front pipe (A).
Remove the clamp and front pipe.
DPD Disassembly
1. Loosen the clip (1) from the hose connecting to the
differential pressure pipe and remove the hose.
2. Loosen the sleeve nuts (2) and (4) that secure the
differential pressure pipe.
3. Remove the clip (3) that secure the differential
pressure pipe.
4. Remove the differential pressure pipe.
LNW76FSH000301
Legend
1. Hose Clip
2. Sleeve Nut (Rr)
3. Clip
4. Sleeve Nut (Ft)
5. Disassemble the DPD assembly.
Loosen the nuts used for mounting the
oxidation catalyst section, and detach the
oxidation catalyst section.
Loosen the nuts used for mounting the filter and
detach the filter and rear case.
NOTE:
Do not submit the DPD assembly to high impact or drop
the assembly.
6F-6
3
1
2
LNW41GSH000201
Legend
1. Oxidation Catalyst Section
2. Gasket
3. Filter Section
4. Gasket
5. Rear Case
DPD Inspection
1. Perform an external appearance inspection on
exhaust pipe related components.
Damage to a body panel caused by heating or
vibration can lead to exhaust gas intruding into
the cabin.
Inspect the connections for looseness,
damage, and exhaust gas leaks.
Inspect the clamps and rubber for deterioration,
cracks, and damage.
Inspect the pipe and silencer for dents and
corrosion induced cracks, and if damaged,
repair or replace the damaged part(s).
2. Perform an DPD related inspection.
Visually inspect the filter for erosion, damage,
or blocking.
Light shines through the filter from the opposite
side. If light is transmitted and is visible, replace
the filter section.
NOTE:
Before DPD disassemble, be sure to use a scan tool to
check the DPD differential pressure, status, and
inspection and servicing details. Refer to the "Engine
control" section for details.
LNW41GSH000601
Legend
1. Filter
2. Filter Case
3. If the differential pressure sensor assembly has
been replaced, carry out the following steps (on
the vehicle).
Without turning the engine on, turn the key from
"OFF" to "ON".
The DPD lamp is turned on, and then after 30
seconds turned off.
After confirming that the DPD lamp has gone
off, turn the key to the "OFF" position and leave
for 15 seconds.
4. Check the oxidation catalyst.
Visually inspect the catalyst for erosion,
damage, or plugging.
DPD Reassembly
1. Insert gaskets in the filter section and the rear case
and tighten temporarily with bolts and nuts.
2. Insert gaskets in the filter section and oxidation
catalyst and tighten temporarily with bolts and
nuts.
NOTE:
Check the mounting location of the filter section and
rear case, and the filter section and oxidation catalyst,
and tighten each pipe bracket in 2 places by tightening
the bolts alternatively.
3. Tighten the bolts and nuts to the specified torque.
Tighten all of the bolts and nuts twice.
Torque : 25 Nm (2.5 kgm / 18 lbft)

NOTE:
After tightening all of the bolts and all of the nuts,
tighten them all to the same torque (tightening twice)
6F-7
7. Insert the hose for the differential pressure pipe

until it reaches the spool and secure with a clip.
1
5
3
2
2
3
LNW76FSH000301
LNW41GSH000201
Legend
1. Oxidation Catalyst Section
2. Gasket
3. Filter Section
4. Gasket
5. Rear Case
4. Insert the protruded section of the differential
pressure pipe (only Ft side) into DPF and tighten
the sleeve nut (4) by hand. Then, tighten the
sleeve nut (Rr) (2) by hand.
NOTE:
Clean the old anti-seize compound from the sleeve nut
and apply new anti-seize compound.
5. Fix the pipe in place using a clip (3).
Torque: 10 Nm (1.0 kgm / 87 lbin)
6. Fully tighten the sleeve nuts.
Torque (Ft): 45 Nm (4.6 kgm / 33 lbft)
Torque (Rr): 35 Nm (3.6 kgm / 26 lbft)
Legend
1. Hose Clip
2. Sleeve Nut (Rr)
3. Clip
4. Sleeve Nut (Ft)
NOTE:
If the procedures described above are not followed, the
sleeve nut may become loose.
Air-tightness check
Once the engine is warmed up, run at maximum
non-load RPM.
To ensure there are no gas leakages, with the
engine revved up, spray soapy water on the
pressure hose (1) and sleeve nuts (2) (4)
connecting parts.
6F-8

Attach the hose clips (4 locations) securely to
prevent gas leakage.
1
2
3
NOTE:
Do not confuse the front/rear directions.
Do not use hoses that are cracked.
Do not overtighten or remove the differential sensor
assembly's tightening screws.
If there is a gas leak in the coupling section, a
sensor malfunction may occur.
Ensure to check for gas leakage after starting the
engine.
LNW76FSH000301
Legend
1. Hose clip
2. Sleeve Nut (Rr)
3. Clip
4. Sleeve Nut (Ft)
Installation
NOTE:
A possible cause of vibration or looseness is the
misspositioning of the exhaust system during
assembly. Therefore, do not fully tighten the bolts
until all the components are positioned, and when
positioned, tighten the bolts starting at the engine
and working outwards.
Do not re-use gaskets or nuts that were removed.
1. Install the front exhaust pipe A.
NOTE:
Tighten the front exhaust pipe so that it is balanced,
and make sure there are not any gas leaks.
2. Install the exhaust brake and front exhaust pipe B.
Install the air hose.
3. Install the DPD assembly to the front pipe (EURO
4 Specification).
4. Install the DPD differential pressure hose to the
differential pressure pipe (EURO 4 Specification).
Insert the front side of the differential pressure
hose into the port of the differential pressure
sensor that is marked "F" (white).
6
5
3
4
LNW41GSH000901
Legend
2. Clip
3. Differential Pressure Hose
4. Properly Fitted Hoses
5. Reversely Fitted Hoses
6. Differential Pressure Hose
7. Clip
6F-9
6. Fix the DPD temperature sensor harness with clips

(EURO 4 Specification).
7. Install the exhaust silencer to the front pipe (EURO
3 Specification).
1
8. Install the exhaust throttle assembly and extension

pipe.

9. Install the exhaust throttle air hose.
10. Install the center exhaust pipe.
11. Install the rear exhaust pipe.
Tighten the clamp.
5
4

LNW41GSH000801
Legend
1. Nut
2. F; Front Mark
3. Rear Side Differential Pressure Hose Spigot
4. Front Side Differential Pressure Hose Spigot
5. Bracket
5. Connect the DPD temperature sensor connectors
(EURO 4 Specification).
NOTE:
Do not confuse the front/rear directions.
3
LNW76FSH000501
LNW76FSH000101
Legend
1. Differential pressure pipe (F)
2. Exhaust temperature sensor 1 (filter inlet)
3. Differential pressure sensor
4. Differential pressure hose (F)
5. Differential pressure hose (R)
6. Differential pressure pipe (R)
7. Exhaust temperature sensor 2 (catalyst inlet)
6F-10
22(2.2/16)
27(2.8/20)
27(2.8/20)
67(6.8/49)
50(5.1/37)
50(5.1/37)
LNW76FLF000401
6F-11
Exhaust Brake System

Service Precautions
During assembly and mounting, mount the parts
appropriately at the specified tightening torque value.
LNW21GMF001401
Functional check
Operational check
Confirm the sound of the valve touching the
stopper when the exhaust brake is operated in the
idling condition.
6F-12
Exhaust Brake
Components
2
10
3
4
5
6
Legend
1. Power Chamber, Insulator, Gasket and Bearing
2. Lock Nuts and Clevis Joint
3. Split Pin and washer
4. Exhaust Brake Valve
Removal
1.
2.
3.
4.
Remove the vacuum and clips.

Remove the nut.
Remove the exhaust pipe.
Remove the exhaust brake assembly.
Disassembly
1.
2.
3.
4.
Remove the split pin.

Remove the lock nuts.
Remove the clevis joint.
Remove the power chamber.
Reassembly
1. Mount the power chamber.
5. Front Exhaust Pipe B

6. Exhaust Brake Assembly
7. Front Exhaust Pipe A
LNW76FMF000101

Tightening torque : 14 Nm (1.4kgm / 122lbin)
6F-13
Unit check
Negative pressure in the power chamber caused
by the vacuum pump.
When a pressure of 53.3 to 93.3 kPa (400 to 700
mmHg) is applied, the exhaust brake valve should
open or close smoothly.
LNW21GSH001601
2. Mount the lock nuts.

3. After mounting the clevis joint, tighten the lock nuts
Tightening torque : 13Nm (1.3kgm / 113lbin)
LNW21GSH001401
Installation
1. Mount the exhaust brake assembly.
Tightening torque : 17Nm (1.7 kgm / 12 lbft)
LNW21GSH002201
4. Mount the split pin.
Inspection
Check for damage or degradation in the parts
mentioned below.
Exhaust brake valve
Exhaust brake shaft
Butterfly valve
Bush
Power chamber
LNW46FSH000101
6F-14
2. Mount the exhaust pipe.
3. Mount the nuts.

Tightening torque : 67 Nm (6.8kgm / 49lbft)
4. Mount the vacuum hose and the clips.
LNW76FSH000401
M6
41 (4.2/30)
27 (2.8/20)
67 (6.8/49)
LNW76FMF000201
6F-15
Exhaust Throttle
Components
2
12
3
4
5
6
8
11
7
10
LNW76GMF000101
Legend
1. Power Chamber
2. Gasket
3. Insulator
4. Bearing
5. Lock Nuts and Clevis Joint
6. Pin and Split Pin
Removal
1.
2.
3.
4.
5.
Remove the vacuum hose and clip.

Remove the nut.
Remove the rear exhaust pipe.
Remove the center exhaust pipe.
Remove the exhaust silencer.
7.
8.
9.
10.
11.
12.
Cover
Extension Silencer
Exhaust Center Pipe
DPD (Diesel Particulate Defuser)
Exhaust Throttle Body
Exhaust Throttle Asembly
6F-16

Unit inspection
Apply vacuum pressure to the power chamber
using a vacuum pump.
The exhaust throttle valve should open and close
smoothly when pressure of 75 - 93.3kPa {560 700mmHg} is applied.
LNW76FSH000601
6. Remove the exhaust throttle assembly.
Disassembly
1.
2.
3.
4.
Remove the split pin.

Remove the lock nut.
Remove the clevis joint.
Remove the power chamber.
LNW21GSH001401
NOTE:
Do not change the exhaust throttle's adjustment as it
may have an affect on DPD performance.
Inspection
Inspect the following parts
deterioration, etc.
Exhaust throttle valve
Exhaust throttle shaft
Butterfly valve
Power chamber
for
damage
and
Reassembly
1. Install the power chamber.
Tightening torque 14 Nm (1.4 kgm / 122 lbin)
LNW41GSH001101
2. Install the lock nut.

3. After mounting the clevis joint, tighten the lock nut
to specified tightening torque.

NOTE:
Do not adjust or remove the adjusting bolt.
Do not remove the lever.
6F-17
4. Install the rear exhaust pipe.
LNW76FSH000601

LNW41GSH001201
Legend
1. Lever
2. Adjusting bolt
4. Install the split pin.
Installation
1. Install the exhaust throttle assembly.
Tightening torque 20Nm (2.0kgm / 14 lbin)
LNW21GSH002301
2. Install the exhaust silencer.

3. Install the exhaust center pipe.
5. Install the vacuum hose and clip.
6F-18
13 (1.3/113lb in)
14 (1.4/122lb in)
27 (2.8/20)
50 (5.1/37)
LNW76GLF000101
6F-19
EGR System
Service Precautions
Perform EGR related assembly according to the usual

procedure of temporarily fitting and then permanently
tightening the parts so that unnecessary stresses are
not applied on the parts.
Re-circulate a part of the exhaust gas of the EGR

system in the intake manifold.Reduce the combustion
temperature and inhibit NOx generation since inert
gases may be mixed up in the intake sir.
An electronic control system is used in this EGR to
balance the requirements of operability and low
emissions.A DC motor is operated using the control
current of the Engine Control Module (ECM) to control
the EGR.
Refer to the chapter on Engine Control System for
details on fault diagnosis of the EGR system.
2
LNW46FMF000501
Legend
1. EGR cooler
2. Engine Control Module (ECM)
3. EGR Valve DC Motor
6F-20
EGR Valve and EGR Cooler

Components
1
2
5
6
LNW71FLF000101
Legend
1. EGR Valve
2. EGR Valve Gasket
3. EGR Cooler
Removal
Refer to Turbocharger in ENGINE MECHANICAL
section.
4. Heat Protector
5. EGR Cooler Gasket
6. EGR Cooler Gasket
6F-21
b. Tighten the bolt and nuts by final tightening

order.
3. Remove the heat protector.
Final tightening order : 345126

Tightening torque :
Bolt, Nut 1 to 5
27 Nm (2.8 kgm / 20 lbft)
Bolt 6
52 Nm (5.3 kgm / 38 lbft)
6
4
1
2
LNW71FSH000101

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

4. Install the heat protector
Tightening torque : 25 Nm (2.5 kgm / 18 lbft)
5. Install the turbocharger.
Refer to Turbocharger in ENGINE MECHANICAL
section.
LNW71FSH000301
Installation
1. Install the EGR valve.
Tightening torque : 27 Nm (2.8kgm / 20lbft)
2. Install the EGR Cooler.
a. Install the gaskets and the EGR cooler.
Temporarily tighten the bolts and the nuts.
Temporary tightening order : 123456
6F-22
52 (5.3/38)
27 (2.8/20)
27 (2.8/20)
25 (2.5/18)
27 (2.8/20)
LNW76FLF000101
ACCELERATOR CONTROL SYSYEM (4JJ1)
ENGINE
ACCELERATOR CONTROL SYSYEM
(4JJ1)
TABLE OF CONTENTS
Accelerator Pedal Assembly . . . . . . . . . . . . . . . . .6H-2
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6H-2
6H-1
6H-2
ACCELERATOR CONTROL SYSYEM (4JJ1)
Accelerator Pedal Assembly

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

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

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

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED

SERVICE MARKETING DEPARTMENT
Tokyo, Japan
First edition August. 2006
No. LG4JJ-WE-0761

Engine 4JJ1

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WORKSHOP MANUAL

Isuzu Motors Limited

ENGINE MECHANICAL (4JJ1)

ENGINE MECHANICAL (4JJ1)

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104

ENGINE MECHANICAL (4JJ1)

ISUZU DIESEL ENGINE (4JJ1)

Matters that require attention in specifically dealing

To prevent damage to the engine and ensure reliability

Holes or clearances in the fuel system, which serve as

ENGINE MECHANICAL (4JJ1)

How to read the model

Electronic engine control

ENGINE MECHANICAL (4JJ1)

Fuel filter with sedimenter

ENGINE MECHANICAL (4JJ1)

Loosen each adjusting screw of the rocker arm

Insert a 0.15 mm (0.006 in) thickness gauge

If the No.1 cylinder is the compression TDC,

ENGINE MECHANICAL (4JJ1)

Turn on the starter to inspect compression

Compression pressure inspection

Engine does not turn over.

Compression gauge: 5-8840-2675-0

Starter motor does not rotate

Dead or weak battery

Starter motor brushes stuck, worn,

Starter motor internal damage

Ring gear abrasion

Replace ring gear

Magnetic switch (starter motor) not

Starter motor not meshed with

ENGINE MECHANICAL (4JJ1)

Starter motor pinion meshed with

Dead or weak battery

Armature (starter motor) stuck

Engine internal damage (Seizure)

Engine turns over but does not start

Fuel is delivered to fuel supply

Insufficient or unstable fuel delivery

Air in fuel system

Bleed air from fuel system

Air entering fuel pipe

Replace pipe and bleed air from

Empty fuel tank

Clogged strainer (fuel suction)

Clean or replace strainer

Clogged fuel pipe

Clean or replace pipe

Feed pump malfunction

Use of wrong fuel for prevailing

Drain existing fuel and replace with

Clogged fuel filter

Loose injection pipe connections

Tighten and/or replace connectors