SERVICE INFORMATION 00-1

ENGINE 4J SERIES
SECTION 00
SERVICE INFORMATION
Contents
TROUBLE SHOOTING ......................................... 00-2
Hard Starting ..................................................... 00-2
Unstable Idling................................................... 00-5
Insufficient Power .............................................. 00-6
Excessive Fuel Consumption ............................ 00-7
Excessive Oil Consumption............................... 00-7
Overheating ....................................................... 00-7
White Exhaust Smoke ....................................... 00-8
Dark Exhaust Smoke......................................... 00-8
Oil Pressure Does Not Rise............................... 00-8
Abnormal Engine Noise..................................... 00-9
Engine Cooling Trouble ................................... 00-10
Engine Electrical Part Trouble ......................... 00-11
Turbocharger ................................................... 00-16
Lubrication Chart ............................................. 00-23
MAIN DATA AND SPECIFICATIONS ................. 00-24
Main Data and Specifications .......................... 00-24
Engine Cooling ................................................ 00-26
Starting System ............................................... 00-26
Charging system.............................................. 00-27
SERVICE STANDARD........................................ 00-28
Engine Mechanical .......................................... 00-28
SERVICING ........................................................ 00-32
Model Identification.......................................... 00-32
Air Cleaner....................................................... 00-32
Lubricating System .......................................... 00-33
Fuel System..................................................... 00-33
Cooling System ............................................... 00-36
Engine Control................................................. 00-39
Compression Pressure Measure-ment............ 00-43
Quick-On Start II System (4JB1 / 4JB1-TC / 4JH1-TC
only)................................................................. 00-44
Quick-ON Start III System (4JG2 only)............ 00-44
FIXING TORQUE................................................ 00-46
Cylinder Head Cover, Cylinder Head Rocker, Shaft
Braker .............................................................. 00-46
Crankshaft, Bearing Cap, Connecting Rod Bearing Cap,
Crankshaft Damper Pulley, Flywheel, Oil Pan........ 00-47
Timing Pulley Housing, Timing Pulley, Timing Gear,
Camshaft Oil Seal Retainer ............................. 00-48
Cooling System and Lubrication System......... 00-49
Intake Manifold, Exhaust Manifold, Exhaust Pipe ... 00-50
Engine Electricals ............................................ 00-52
Engine Fuel ..................................................... 00-53
Engine Mounting Bracket ................................ 00-55
SPECIAL TOOLS................................................ 00-56
00-2 SERVICE INFORMATION

TROUBLE SHOOTING
Hard Starting
1. Starter Inoperative

Checkpoint Possible cause Correction

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

2. Starter Motor Operates But Engine Does Not Turn Over

Checkpoint Possible cause Correction

Battery Loose battery cable terminal Clean and/or retighten the battery cable
terminal
Poor connections due to rusting Recharge or replace the battery
Battery discharged or weak Recharge or replace the battery
Fan belt loose or broken Adjust or replace the fan belt
Starter Defective pinion gear Replace the pinion gear
Defective magnetic switch Repair or replace the magnetic switch
Brush wear, Weak brush spring Replace the brush and/or the brush spring
Engine Piston, crank bearing seizure, or other Repair or replace the related parts
damage
 SERVICE INFORMATION 00-3
3. Engine Turns Over But Does Not Start

Checkpoint Possible cause Correction

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

4. Quick-On Start System

Preparation
1. Disconnect the thermoswitch connector.
2. Determine whether or not the glow plugs are receiving power.
a. Make sure that the starter switch is “OFF”.
b. Connect a voltmeter between one of the glow plugs and the cylinder wall.
c. Move the starter switch to the “ON” position.
The voltmeter needle will show the souse voltage (12V) if the glow plugs are receiving power.
If the voltmeter needle does not move, the glow plugs are not receiving power.
3. Perform the troubleshooting procedure.
00-4 SERVICE INFORMATION

Checkpoint Possible cause Correction

Glow Plugs are Receiving Power
Glow plug indicator Defective indicator light bulb Replace the indicator light bulb
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
Glow plug indicator Defective quick-on start timer Replace the quick-on start timer
light turns on the 0.3
seconds
Glow plug indicator Return the starter switch to the “ON” posi- Replace the quick-on start timer
light turns on for 3.5 tion from the “START” position after the
seconds engine starts if the glow plug relay remains
on less than 14 seconds, the quick-on start
timer is defective
Move the starter switch from the “OFF” Replace the quick-on start timer
position to the “ON” position if the glow
plug relay remains on less than 14 sec-
onds, the quick-on start timer is defective
Thermo switch Defective thermo switch Replace the thermo switch
Glow plug continuity No glow plug continuity Replace the glow plugs
Glow Plugs are not Receiving Power
Glow plug indicator Broken indicator light fuse Replace the fuse
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
Glow plug indicator Defective glow plug relay Replace the glow plug relay
light turns on for 3.5 The glow plug relay does not turn on after
seconds the starter switch is moved from the “OFF”
position to the “ON” position
Defective quick-on start timer Replace the quick-on start timer
Defective glow plug relay wiring harness Repair or replace the wiring harness
Defective fusible link or wiring harness Replace the fusible link or the wiring har-
The glow plug relay turns on when the ness
starter switch is moved from the “OFF”
position to the “ON” position

* When being normal temperature, the indicator lamp of 4JH1TC is not turn on.
 SERVICE INFORMATION 00-5
Unstable Idling

Checkpoint Possible cause Correction

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

*The adjustment of the position which is related to the injection pump is unnecessary for 4JH1TC by the adoption of
the electronic control injection pump.
00-6 SERVICE INFORMATION
Insufficient Power

Checkpoint Possible cause Correction

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

Checkpoint Possible cause Correction

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

Excessive Oil Consumption

Checkpoint Possible cause Correction

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

Overheating

Checkpoint Possible cause Correction

Cooling water Insufficient cooling water Replenish the cooling water
Fan clutch Oil leakage from the fan clutch Replace the fan clutch
Fan belt Fan belt loose or cracked causing slippage Replace the fan belt
Radiator Defective radiator cap or clogged radiator Replace the radiator cap or clean the radi-
core ator core
Water pump Defective water pump Repair or replace the water pump
Cylinder head and cyl- Defective sealing cap resulting in water Replace the sealing cap
inder body sealing cap leakage
Thermostat Defective thermostat Replace the thermostat
Cooling system Cooling system clogged by foreign mate- Clean the foreign material from the cooling
rial system
Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing
00-8 SERVICE INFORMATION
White Exhaust Smoke

Checkpoint Possible cause Correction

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

Dark Exhaust Smoke

Checkpoint Possible cause Correction

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

Oil Pressure Does Not Rise

Checkpoint Possible cause Correction

Engine oil Improper viscosity engine oil. Replace the engine oil
Insufficient engine oil Correct the engine oil volume
Oil pressure gauge or Defective oil pressure gauge or unit Repair or replace the oil pressure gauge or
unit unit
Oil pressure indicator Defective indicator light Replace the indicator light
light
Oil filter Clogged oil filter element Replace the oil filter element or the oil filter
cartridge
Relief valve and by- Relief valve sticking and/or weak by-pass Replace the relief valve and/or the by-pass
pass valve valve spring valve spring
Oil pump Clogged oil pump strainer Clean the oil pump strainer
Worn oil pump related parts Replace the oil pump related parts
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing
Camshaft Worn camshaft and camshaft bearing Replace the camshaft and the camshaft
bearing
Crankshaft and bear- Worn crankshaft and bearings Replace the crankshaft and/or the bear-
ings ings
 SERVICE INFORMATION 00-9
Abnormal Engine Noise
1. Engine Knocking
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

Checkpoint Possible cause Correction

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

2. Gas Leakage Noise

Checkpoint Possible cause Correction

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

3. Continuous Noise

Checkpoint Possible cause Correction

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

4. Slapping Noise

Checkpoint Possible cause Correction

Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Rocker arm Damaged rocker arm Replace the rocker arm
Flywheel Loose flywheel bolts Retighten the flywheel bolts
Crankshaft and thrust Worn or damaged crankshaft and/or thrust Replace the crankshaft and/or the thrust
bearings bearings bearings
Crankshaft and con- Worn or damaged crankshaft and/or con- Replace the crankshaft and/or the con-
necting rod bearings necting rod bearings necting rod bearings
Connecting rod bush- Worn or damaged connecting rod bushing Replace the connecting rod bushing and/
ing and piston pin and piston pin or the piston pin
Piston and cylinder Worn or damaged piston and cylinder Replace the piston and the cylinder liner.
liner liner.
00-10 SERVICE INFORMATION
Engine Cooling Trouble

Checkpoint Possible cause Correction

Engine overheating Low coolant level Replenish
Thermo unit faulty Replace
Faulty thermostat Replace
Faulty coolant unit Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of improper Replenish or change oil
engine oil Replenish
Damaged cylinder head gasket Replace
Clogged exhaust system Clean exhaust system or replace faulty
parts
Loose fan belt Adjust
Excessive fuel injected Adjust
Improper injection timing Adjust
Engine overcooling Faulty thermostat Replace
Too long engine warm- Faulty thermostat Replace
up time
Thermo unit faulty Replace
 SERVICE INFORMATION 00-11
Engine Electrical Part Trouble

N6A3628E
00-12 SERVICE INFORMATION

N6A3629E
SERVICE INFORMATION 00-13

N6A3630E
00-14 SERVICE INFORMATION

N6A0631E
SERVICE INFORMATION 00-15

N6A3632E
00-16 SERVICE INFORMATION
Turbocharger
Engine Has Less Than Normal Power

N6A3633E
SERVICE INFORMATION 00-17

N6A3634E
00-18 SERVICE INFORMATION
Blue or Black Smoke

N6A3635E
 SERVICE INFORMATION 00-19
Excessive Oil Consumption

N6A3636E
00-20 SERVICE INFORMATION
Excessive Turbocharger Noise

N6A3637E
SERVICE INFORMATION 00-21

N6A3638E
00-22 SERVICE INFORMATION
Excessive Rotating Part Wear

N6A3639E
 SERVICE INFORMATION 00-23
Lubrication Chart
4JB1, 4JB1-TC, 4JG2, 4JH1-TC, Oil Filter & Oil Cooler

N6A3001E

Operating Pressure
Oil filter relief valve (1): 559 — 618 kPa (5.7 — 6.3 kg/cm2/81 — 90 psi)
Oil cooler safety valve (2): 314 — 373 kPa (3.2 — 3.8 kg/cm2/46 — 54 psi)
Oil filter safety valve (3): 78 — 118 kPa (0.8 — 1.2 kg/cm2/11 — 19 psi)
Oil pressure switch (4): 29.4 — 49.0 kPa (0.3 — 0.5 kg/cm2/4.3 — 7.1 psi)
The 4J Series engine lubricating system is a full flow type.
Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter (re-
placeable type oil filters have on oil cooler). It is then delivered to the vital parts of the engine from the cylinder body
oil gallery.
00-24 SERVICE INFORMATION

MAIN DATA AND SPECIFICATIONS

Main Data and Specifications

Engine model
4JB1 / 4JB1-TC 4JG2 4JH1-TC
Engine type Four-cycle, overhead valve, water injection
Combustion chamber type Direct injection Swirl Direct injection
Cylinder liner type Dry type, chrome plate, stainless steel tube
Timing train system Gear drive Gear and Belt Drive Gear drive
No. of cylinders mm (in) 4 — 93 × 102 4 — 95.4 × 107 4 — 95.4 × 104.9
— Bore × stroke (3.66 × 4.02) (3.76 × 4.21) (3.76 × 4.16)
No. of piston rings Compression rings: 2 / Oil ring: 1
3 3
Total piston dis- cm (in ) 2,771 (169.0) 3,059 (186.6) 2,999 (183.3)
placement
Compression ratio (to 1) 18.2 (4JB1) 20.1 18.3
18.1 (4JB1-TC)
Compression kPa (kg/cm2/psi) 3,038 (31/441) 3,334 (34/483.8) 2,746 (28/398)
pressure
Engine weight N (kg/lb) Approximately Approximately Approximately
(Dry) 2,245 (229/505) 2,403 (245/540) 2,500 (255/562)
(4JB1)
2,511 (256/564)
(4JB1-TC)
Fuel injection order 1—3—4—2
Item
Fuel injection tim- deg BTDC 12 (′91/542A) TDC 0° (Belt ′91/ Not Adjustment
ing (4JB1) 542B)
BTDC 4 (4JB1-TC)
Specified fuel type SAE No. 2 diesel fuel
Idling speed rpm 750 — 790 700 — 740 675 — 725
Valve clearance Intake: mm (in) 0.40 (0.016)
(AT cold)
Exhaust: mm (in) 0.40 (0.016)
Valve clearance Intake: mm (in) 0.45 (0.018)
(AT hot)
Exhaust: mm (in) 0.45 (0.018)
Intake valves Open at (BTDC) 24.5
deg
Close at (BTDC) 55.5
deg
Exhaust valves Open at (BTDC) 54
deg
Close at (BTDC) 26
deg

′91/542A: Euro 1
Notice:
G.EXP: General Export Model ′91/543 B: Euro 2
EC: European Countries
Emission Gas Control Standard
 SERVICE INFORMATION 00-25

Engine model
4JB1 / 4JB1-TC 4JG2 4JH1-TC
Lubrication system
Lubrication method Pressurized circulation
Specified engine oil (API grade) CC (4JB1) CC CD
CD (4JB1-TC)
Oil pump type Gear
Oil filter type Disposable cartridge (Spin-on) Paper element
Oil capacity lit (US/UK gal) 6.6 — 7.1 (1.74 — 1.87/2.62 — 2.82) 6.0 — 8.0 (1.59 —
(Including oil filter) (For EC 6.2 — 8.2 (2.17 — 1.64/1.36 — 2.11/2.38 — 3.18)
1.80))
Oil cooler type Water cooled
Fuel system
Injection pump type Bosch distributor Bosch VP44
Governor type Mechanical (Partially variable speed) (For Electronically con-
EC Variable speed) trolled fuel injection
system
Item Injection nozzle type Hole Pinttle Hole
2
Injection nozzle kPa (kg/cm /psi) 18,142 (185/2,631) 14,710 (150/2,133) 1st: 19,500 (199/
opening pressure (4JB1) 2,830)
1st: 19,500 (199/ 2nd: 33,800 (345/
2,830) 4,906)
2nd: 26,500 (270/
3,840) (4JB1-TC)
Main fuel filter type Cartridge paper element and water separa- Cartridge paper ele-
tor ment with built in
water separator
Air cleaner type Dry paper element
Generator capac- V — A (W) 12 — 40 (480) and 12 — 50 12 — 60 (720)
ity 12 — 15 (600) 12 — 80 (960)
Starter motor out- V — kW 12 — 2.0 and 12 — 12 — 2.0 12 — 2.2
put 2.2 12 — 2.0 (For Tai-
wan)
Turbocharger IHI RHF4 (4JB1-TC) IHI RHF5
00-26 SERVICE INFORMATION
Engine Cooling

Cooling system Coolant forced circulation

Radiator (2 tube in row) Tube type Corrugated
Heat radiation capacity kcal/h 71400
Heat radiation area m2 (ft2) 11.78 (126.8)
2 (ft2)
Front area m 0.216 (2.325)
Dry weight N (kg/lb) 105 (10.7/23.6)
Radiator cap
Valve opening pres- kPa (kg/cm2/psi) 88.2 — 116. 7 (0.899 — 1.199/12.78 — 17.05)
sure
Coolant capacity lit (lmp.qt./US qt.) 3.1 (2.73/3.28) (For EC 5.8 (5.1/6.13))
Coolant pump
Pulley type Centrifugal impeller type
Pulley ratio 1.2
Thermostat type Wax pellet with jiggle valve.
Valve opening °C (°F) 82 (180)
Valve full open °C (°F) 95 (203)
Coolant total capacity lit (lmp.qt./US qt.) 10 (8.80/10.57) (For EC 7.3 (6.42/7.71))

Starting System

Manufacturer DENSO
Engine model 4JB1 / 4JB1-TC 4JG2 (G. EXP) 4JH1-TC
Rating
Voltage V 12
Output kW 2.0 2.2 2.2
Time Sec. 30
Number of tooth of pinion 9
Rotating direction (as viewed from pinion) Clockwise
Weight (approx.) kg 4.6 5.4 6.0
No-load characteristics
Voltage / current V/A 11.5/100 or less 11.5/120
Speed rpm 3700 or more 4000
Load characteristics
Voltage / current V/A 7.5/500 or less 7.5/500
Torque N⋅m (kg⋅m/lb⋅ft) 13.7 (1.4/10.1) 12.7 (1.3/9.4)
Speed rpm 1200 or more 1400 or more 1400
Locking characteristics
Voltage / current V/A 2.4/800 or less 2.0/850 or less 2.0/850
Torque N⋅m (kg⋅m/lb⋅ft) 18 (1.8/13 or more) 16 (1.6/12) or more 15.7 (1.6/12)
 SERVICE INFORMATION 00-27
Charging system

HITACHI HITACHI HITACHI

Manufacturer
LR150-449B LR160-502B LR180-512
Rated voltage V 12 12 12
Rated out put A 50 60 80
Rotating direction (As viewed from pul- Clockwise Clockwise Clockwise
ley)
Pulley effective diameter mm (in) 80 (3.15) 82 (3.23) 82 (3.23)
Weight (with pump) kg (lb) 6.0 (13.27) 5.8 (12.78) 6.3 (13.88)
4JB1-TC 4JH1-TC 4JH1-TC
4JB1/4JG2
00-28 SERVICE INFORMATION

SERVICE STANDARD
Engine Mechanical

mm (in)
Service standard Service limit
Parts Item 4JB1 / 4JB1 / Remarks
4JH1-TC 4JG2 4JH1-TC 4JG2
4JB1-TC 4JB1-TC
Cylinder Cylinder head deck, Cannot
Head and exhaust mani- be
0.05 (0.002) or less 0.2 (0.0079)
fold mating surface Regroun
for flatness d
Cylinder head height 92.0 (3.622) 91.55 (3.6043)
Cylinder Head Lower
0.05 (0.002) or less 0.20 (0.008)
Face Warpage.
Manifold Warpage. 0.05 (0.002) or less 0.20 (0.008)
Hot plug sinking — 0.02 (0.0008)
Hot plug exert pres- 4,500 — 5,500 kg (9922.5 —
—
sure 12127.5 lbs)
Valve Free height 48.0 (1.891) 47.10 (1.856)
Spring
Squareness — 1.7 (0.067)
Spring ten- N (kg/ At
sion lb) installed
296 (30.2/66.4) 257.9 (26.3/57.9) height
38.9
(1.531)
Valve Diameter IN 7.946 — 7.961 (0.3128 —
7.880 (0.3102)
and Valve Stem 0.3134)
Valve
EX 7.921 — 7.936 (0.3118 —
Guide 7.850 (0.3090)
0.3124)
Valve and IN 0.039 — 0.069 (0.0015 —
0.200 (0.0079)
valve guide 0.0027)
clearance
EX 0.064 — 0.096 (0.0025 —
0.250 (0.0098)
0.0038)
Valve guide upper
end height (Mea-
13.0 (0.512) —
sured from the Cylin-
der head upper face)
Valve guide margin 1.1 (0.0433) 1.6 (0.0630)
Valve thick- IN 1.79 1.5
1.41 (0.0556) 1.1 (0.0433)
ness (0.0705) (0.06)
EX 1.83 1.5
1.39 (0.0547) 1.1 (0.0433)
(0.0720) (0.06)
Valve seat contact
45°
surface angle
Valve seat IN 1.7 (0.0669) 2.2 (0.0866)
contact width EX 2.0 (0.0787) 2.5 (0.0984)
Push rod Curvature — 0.4 (0.0157) or less
 SERVICE INFORMATION 00-29

mm (in)
Service standard Service limit
Parts Item 4JB1 / 4JB1 / Remarks
4JH1-TC 4JG2 4JH1-TC 4JG2
4JB1-TC 4JB1-TC
Cam- End play 0.08 (0.0031) 0.2 (0.0079)
shaft
Cam lobe height 42.02 (1.6543) 41.65 (1.6397)
Journal diameter 49.945 — 49.975(1.9663 —
49.60 (1.9527)
1.9675)
Runout 0.02 (0.0008) or less 0.10 (0.0039)
Camshaft bearing 50.000 — 50.030 (1.9685 —
50.08(1.9716)
inside diameter 1.9697)
Camshaft oil clear- 0.025 — 0.085 (0.0098 —
0.12 (0.0047)
ance 0.00334)
Tappet Outside diameter 12.97 — 12.99 (0.5106 —
12.95 (0.5098)
0.5114)
Oil clearance
(Between tappet and 0.03 (0.0118) 0.10 (0.0039)
cylinder body)
Rocker Rocker shaft outside 18.98 — 19.00 (0.7472 —
18.90 (0.7440)
arm diameter 0.7480)
Assem- Rocker arm inside 19.036 — 19.060 (0.7494 —
bly 19.10 (0.7520)
diameter 0.7504)
Oil clearance
0.06 — 0.08 (0.00235 —
(Between rocker arm 0.10 (0.004)
0.00315)
and rocker shaft)
Rocker shaft runout — 0.2 (0.0079) or less
Oil pump Oil clearance Body 0.15
0.14 (0.0055) 0.20 (0.0079)
and gear (0.0059)
Body cover and gear 0.06 (0.0024) 0.15 (0.0059)
Crank- Thrust clearance 0.10 (0.0039) 0.30 (0.018)
shaft
Main bearing clear- 0.037— 0.031 — 0.035 —
ance (Between main 0.068 0.063 0.080
bearing and Crank- (0.0015 (0.0012 (0.0014 0.11 (0.0043)
shaft) — — —
0.0027) 0.0025) 0.0032)
Crankshaft runout 0.05 (0.00197) or less 0.08 (0.0031)
Main journal diameter 69.917 — 69.932 (2.7526 —
69.91 (2.7524)
2.7532)
Crankshaft pin diam- 52.915 — 52.930 (2.0833 —
52.90 (2.0827)
eter 2.0839)
Crankshaft Journal
and Crank Pin 0.05 (0.002) or less 0.08 (0.003)
uneven wear
Crank Pin and Bear- 0.029 — 0.066 (0.0011 —
0.100 (0.0039)
ing Clearance. 0.0026)
00-30 SERVICE INFORMATION

mm (in)
Service standard Service limit
Parts Item 4JB1 / 4JB1 / Remarks
4JH1-TC 4JG2 4JH1-TC 4JG2
4JB1-TC 4JB1-TC
Piston, Piston diameter 95.355 95.365 92.985
Piston — — —
pin, Pis- 95.394 95.404 93.024
—
ton ring (3.7541 (3.7545 (3.6600
and Con- — — —
necting 3.7557) 3.9039) 3.6623)
rod
Piston Clearance 0.025 —
(Between piston and 0.045
0.047 — 0.065
Cylinder liner) (0.0010 —
(0.0019 — 0.0026)
—
0.0018)
Piston ring 1st 0.30 — 0.20 — 0.20 —
gap 0.50 0.35 0.40
(0.0118 (0.0079 (0.0079 1.5 (0.0591)
— — —
0.0197) 0.0138) 0.0157)
2nd 0.30 — 0.37 — 0.20 —
0.50 0.52 0.40
(0.0118 (0.0146 (0.0079 1.5 (0.0591)
— — —
0.0197) 0.0205) 0.00157)
Oil 0.25 — 0.20 — 0.10 —
0.45 0.40 0.30
(0.0098 (0.0079 (0.0039 1.5 (0.0591)
— — —
0.0177) 0.00157) 0.0118)
Piston ring 1st 0.090 —
clearance 0.125
0.09 — 0.13 (0.0035
(0.0035
— 0.0051)
—
0.0049)
2nd 0.050 —
0.075
0.05 — 0.09 (0.002
(0.0020 0.15 (0.0059)
— 0.0035)
—
0.0030)
Oil 0.03 — 0.07 (0.0012 — 0.0028) 0.15 (0.0059)
Piston pin diameter 30.995 33.995 30.995
— — —
31.000 34.000 31.000 30.970
33.970 (1.3374)
(1.2202 (1.3384 (1.2202 (1.2190)
— — —
1.2204) 1.3386) 1.2204)
Fitting interference
0.008 — 0.020 (0.0003 —
(Between connecting 0.05 (0.0020)
0.0008)
rod and piston pin)
Fitting interference
0.002 — 0.015 (0.0001 —
(Between piston and 0.04 (0.0016)
0.0006)
piston pin)
 SERVICE INFORMATION 00-31

mm (in)
Service standard Service limit
Parts Item 4JB1 / 4JB1 / Remarks
4JH1-TC 4JG2 4JH1-TC 4JG2
4JB1-TC 4JB1-TC
Piston, Connecting Bend Per 100
0.08 (0.0031) or less 0.20 (0.0079)
Piston rod align- (3.94)
pin, Pis- ment
Twist Per 100
ton ring 0.05 (0.0020) or less 0.15 (0.0059)
(3.94)
and Con-
necting Piston pin and Con-
0.008 — 0.020 (0.0003 —
rod necting Rod Bushing 0.050 (0.0020)
0.0008)
Clearance
Connecting rod thrust
0.230 (0.0091) 0.35 (0.0138)
clearance
Oil clearance 0.029 —
(Between crank pin 0.066
0.029 — 0.083
and Connecting rod) (0.0011 0.100 (0.0039)
(0.0014 — 0.0033)
—
0.0026)
Cylinder Warpage (Upper sur-
Block face of the cylinder — 0.20 (0.0079)
block)
Cylinder bore diame- 95.011
ter —
97.000 — 97.040 95.040
(3.8189 — 3.8205) (3.7406
—
3.7417)
Cylinder liner projec-
0.0 — 0.1 (0.00 — 0.0039)
tion
Cylinder liner inside 93.020
diameter —
95.420 — 95.460 93.060
(3.7567 — 3.7583) (3.6622
—
3.6638)
Cylinder liner outside 95.011
diameter —
97.011 — 97.050 95.050
(3.8193 — 3.8209) (3.7405
—
3.7421)
00-32 SERVICE INFORMATION

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

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

N6A0009E

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

Carbon and Dust Fouled Element

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

Dust Fouled Element

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

Compressed air pressure kPa (kg/cm2/psi)

392 — 490 (4 — 5/57 — 71)

N6A0010E

3. Remove the element from the solution and rinse it

well with running water.
Water pressure must not exceed 274 kPa (2.8 kg/
cm2/40 psi)
 SERVICE INFORMATION 00-33
5. Use the filter wrench to turn in the filter an addition-
al 1 and 1/4 turns.
Filter Wrench:
5-8840-0200-0 (89mm/3.5in)
5-8840 0202-0 (106mm/4.2in)
5-8840-2209-0 (100.6mm/4.0in)

N6A0011E

4. Dry the element in a well ventilated area.

An electric fan will hasten drying.

N6A3007E

6. Check the engine oil level and replenish to the

specified level if required.

Replenishment Engine Oil lit (Imp qt/US qt)

0.7 (0.62/0.74)

N6A0012E

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

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

Replacement Procedure
7. Start the engine and check for oil leakage from the
1. Loosen the used oil filter by turning it counterclock- main oil filter.
wise with the filter wrench.
2. Clean the oil filter fitting face. Fuel System
This will allow the new oil filter to seat properly.
Fuel Filter Replacement Procedure
3. Apply a light coat of engine oil to the O-ring.
1. Loosen the used fuel filter by turning it counter-
4. Turn in the new oil filter until the filter O-ring is fitted
clockwise with the filter wrench.
against the sealing face.
Filter Wrench: 5-8840-0253-0 (J-22700)
00-34 SERVICE INFORMATION

N6A3009E N6A3011E

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

N6A3010E

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

contact. N6A3012E

6. Operate the priming pump until fuel begins to flow

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

Fuel Filter Water Draining Procedure

The indicator light will come on when the water level in
the water separator exceeds the specified level.
Drain the water and foreign material from the water sep-
arator with the following procedure.
 SERVICE INFORMATION 00-35
Air Bleeding
1. Loosen the bleeding plug on the injection pump
overflow valve.
2. Operate the priming pump until fuel mixed with
foam flows from the bleeding plug.
3. Tighten the bleeding plug.
4. Operate the priming pump several times and check
for fuel leakage.

N6A3013E

1. Find a safe place to park the vehicle.

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

Injection Pump Air Bleeding (4JH1-TC only)

Injection pump air bleeding is required to start the en-
gine when —
• The fuel supply has been exhausted (running out
of gas).
• The fuel filter has been replaced.
• The injection pump has been replaced.
Caution:
If the injection pump has been replaced, the air bleeding
procedure will require more time and effort (this is be-
cause there is no fuel in the pump).
1. Loosen the air bleed nut on the priming pump
plunger (at the top of the fuel filter).
2. Move the priming pump plunger up-and-down until
strong resistance is felt (about 15 cycles).
N6A3012E
3. Stop pumping and tighten the air bleed nut.
4. After draining, securely tighten the drain plug by 4. Wait for 1 minute.
turning it clockwise and operate the priming pump 5. Loosen the air bleed nut on the priming pump
manually up and down several times. plunger again.
5. After starting the engine, check to see that there is 6. Move the priming pump plunger up-and-down until
no fuel leak from the drain plug. Also check to see strong resistance if felt (about 10 cycles).
that the fuel filter water indicator light has turned 7. Stop pumping and tighten the air bleed nut.
off. 8. Wait for 1 minute.
If water separator requires frequent draining, have
9. Loosen the air bleed nut on the priming pump
the fuel tank drained for removal of water at your
plunger again.
Isuzu Dealer.
10. Move the priming pump plunger up-and-down until
strong resistance is felt (about 5 cycles).
11. Stop pumping and tighten the air bleed nut.
00-36 SERVICE INFORMATION
12. Press the accelerator and clutch pedals all the way 2. Open radiator cap and drain the cooling system by
to the floor and hold them down. Turn the ignition loosening the drain valve on the radiator and on the
switch to the ON position. Wait until the glow indi- cylinder body.
cator lamp turns on and off.
Caution:
If the engine is cold, the glow indicator light will stay on
for 4 — 7 seconds before turning off.
However, if the engine is hot, the lamp will not turn on.
13. Turn the ignition switch to the START position and
crank the engine until it starts (do not crank the en-
gine for more than 10 seconds).
If the engine does not start, repeat Steps 9 — 13.
14. Allow the engine to idle for 5 minutes.

Cooling System
Coolant Level
Check the coolant level and replenish the radiator re-
serve tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough N6A3015E
coolant to bring the level up to the “MAX” line.
Notice:
For best result it is suggested that the engine cooling
system be flushed at least once a year. It is advisable to
flush the interior of the cooling system including the ra-
diator before using anti-freeze (ethylene-glycol based).
Replace damaged rubber hoses as the engine anti-
freeze coolant is liable to leak out even minor cracks.
Isuzu recommends to use Isuzu genuine anti-freeze
(ethylene-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.

Caution:
A failure to correctly fill the engine cooling system in
changing or topping up coolant may sometimes cause
the coolant to overflow from the filler neck even before
the engine and radiator are completely full. If the engine
runs under this condition, shortage of coolant may pos-
sibly result in engine overheating. To avoid such trouble,
N6A3390E
the following precautions should be taken in filling the
system.
Legend 3. To refill engine coolant, pour coolant up to filler
1. Reserve tank neck using a filling hose which is smaller in outside
diameter of the filler neck.
Engine Coolant Change Procedure Otherwise air between the filler neck and the filling
hose will block entry, preventing the system from
1. To change engine coolant, make sure that the en-
completely filling up.
gine is cool.
4. Keep a filling rate of 9 liter/min. or less. Filling over
WARNING:
Warning: this maximum rate may force air inside the engine
WHEN THE COOLANT IS HEATED TO A HIGH TEM- and radiator. And also, the coolant overflow will in-
PERATURE, BE SURE NOT TO LOOSEN OR RE- crease, making it difficult to determine, whether or
MOVE THE RADIATOR CAP. OTHERWISE YOU not the system is completely full.
MIGHT GET SCALDED BY HOT VAPOR OR BOILING 5. After filling the system to the full, pull out the filling
WATER. TO OPEN THE RADIATOR CAP, PUT A hose and check to see if air trapped in the system
PIECE OF THICK CLOTH ON THE CAP AND LOOS- is dislodged and the coolant level goes down.
EN THE CAP SLOWLY TO REDUCE THE PRESSURE Should the coolant level go down, repeat topping-
WHEN THE COOLANT HAS BECOME COOLER. up until there is no more drop in the coolant level.
 SERVICE INFORMATION 00-37
6. After directly filling the radiator, fill the reservoir to Radiator Cap Inspection
the maximum level. The radiator filler cap is designed to maintain coolant
7. Install and tighten radiator cap and start the en- pressure in the cooling system at 1.05 kg/cm2 (15 psi /
gine. After idling for 2 to 3 minutes, stop the engine 103 kPa). Check the radiator filler cap with a radiator fill-
and reopen radiator cap. If the water level is lower, er cap tester. The radiator filler cap must be replaced if
replenish. it fails to hold the specified pressure during the test pro-
WARNING: cedure.
Warning:
WHEN THE COOLANT IS HEATED TO A HIGH TEM- Radiator Filler Cap Pressure
PERATURE, BE SURE NOT TO LOOSEN OR RE- Pressure Valve kPa (kg/cm2/psi)
MOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING 88 — 118 (0.9 — 1.2/12.8 — 17.1)
WATER. TO OPEN THE RADIATOR CAP, PUT A
PIECE OF THICK CLOTH ON THE CAP AND LOOS-
Negative Valve (Reference) kPa (kg/cm2/psi)
EN THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER. 1.0 — 13.9 (0.01 — 0.04/0.14 — 0.57)
8. After tightening radiator cap, warm up the engine at
about 2,000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
circulate also into heater water system.
9. Check to see the thermostat has opened through
the needle position of water thermometer, conduct
a 5 minutes idling again and stop the engine.
10. When the engine has been cooled, check filler
neck for water level and replenish if required.
Should extreme shortage of coolant is found,
Check the coolant system and reservoir tank hose
for leakage.
11. Fill the coolant into the reservoir tank up to “MAX”
line.

Cooling System Inspection

Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for leak-
age. N6A3017E

The testing pressure must not exceed the specified

Thermostat Operating Test
pressure.
1. Completely submerge the thermostat in water.
Testing Pressure kPa (Kg/cm2/psi) 2. Heat the water.
147 (1.5/21) Stir the water constantly by suitable wood bar (1) to
avoid direct heat being applied use wood plate (2)
to the thermostat.
3. Check the thermostat initial opening temperature.

Thermostat Initial Opening °C (°F)

Temperature
82 (180)

4. Check the thermostat full opening temperature.

Thermostat Full Opening °C (°F)

Temperature
95 (203)

Valve Lift at Fully Open mm (in)

Position
10 (0.39)
N6A3016E
00-38 SERVICE INFORMATION
3. Cooling fan pulley (3)

N6A3018E

N6A3020E
Drive Belt Adjustment
Depress the drive belt mid portion with a 98 N (10 kg / Compressor Pulley Drive Belt
22 lb) force. Move the idler pulley as required to adjust the compres-
sor drive belt tension.
Drive Belt Deflection mm (in)
If the vehicle is equipped with power steering, move the
8 — 12 (0.32 — 0.47) oil pump as required.
Depress the drive belt mid portion with a 98 N (10 kg /
Check the drive belt for cracking and other damage. 22 lb) force.
1. Crankshaft damper pulley (1)
2. Generator pulley (2) Belt Deflection mm (in)
3. Cooling fan pulley (3) 8 — 12 (0.32 — 0.47)
4. Oil pump pulley or idler pulley (4)
1. Crankshaft damper pulley (1)
5. Compressor pulley or idle pulley (5)
2. Oil pump pulley or idler pulley (2)

N6A3019E
N6A3021E

Cooling Fan Pulley Drive Belt

Power Steering Oil Pump Pulley Drive Belt
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid portion with a 98 N (10 kg / Move the oil pump as required to adjust the oil pump
22 lb) force. drive belt tension.
On air conditioner equipped models, both drive belts
1. Crankshaft damper pulley (1)
pulley must always be replaced as a set.
2. Generator pulley (2)
 SERVICE INFORMATION 00-39
Depress the drive belt mid portion with a 98 N (10 kg / 4. Check that the idling control cable is tight (free of
22 lb) force. slack).
If required, remove the slack from the cable.
Belt Deflection mm (in)
8 — 12 (0.32 — 0.47)

1. Crankshaft damper pulley (1)

2. Oil pump pulley (2)
3. Compressor pulley or idler pulley (3)

N6A3779E

Accelerator Control Cable Adjustment

(4JB1/4JB1-TC/4JG2 Only)
1. Loosen the accelerator cable clamp bolt.
2. Check that the idling control knob on the instru-
N6A3022E ment panel is in the engine idling position.
3. Hold the accelerator lever in the fully closed posi-
Engine Control tion and stretch the control cable in the direction in-
dicated by the arrow to remove any slack.
Idling Speed Inspection
1. Set the vehicle parking brake and choke the drive Accelerator Pedal Adjustment
wheels. LHD
2. Place the transmission in neutral. 1. Loosen the lock nut.
3. Start the engine and allow it to warm up. 2. Adjust bolt height from floor.
4. Disconnect the engine control cable from the con-
trol lever. Adjust Bolt Height (A) mm (in)
5. Set a tachometer to the engine. 18 — 28 (0.71 — 1.1)
6. Check the engine idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.

Engine Idling Speed rpm

4JB1 / 4JB1-TC 750 — 790
4JG2 700 — 740
4JH1-TC 675 — 725

Idling Speed Adjustment

(4JB1/4JB1-TC/4JG2 only)
1. Loosen the idling set bolt lock nut on the injection
pump idling set bolt.
2. Adjust the idling speed to the specified range by
turning the idling set bolt.
3. Lock the idling set bolt with the idling set bolt lock
nut. N6A3024E
00-40 SERVICE INFORMATION
3. Check to see if the accelerator pedal play is in the
range of 5 to 10mm above the pedal pad.
4. Press down on the accelerator pedal fully and
check to see if the engine rotates at its maximum
speed with each of the linkage in the smooth oper-
ation.
5. In the operating range of accelerator pedal and the
injection pump lever returns to their respective
original positions without fail.
RHD
1. Hold the accelerator pedal pad securely by hand,
and give it a full stroke.
2. Adjust the stopper bolt so that the clearance be-
tween the pad stopper bolt and the rear side of the
pad becomes the specified length.

mm (in)
N6A3026E
0 — 2 (0 — 0.079)
2. Check the rocker arm shaft bracket nuts for loose-
ness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.

Tighten:
• Rocker arm shaft bracket nut to 54 N⋅m (5.5 kg⋅m / 40
lb⋅ft)

N6A3025E

3. Check to see if the accelerator pedal play is in the

range of 5 to 10mm above the pedal pad.
4. Press down on the accelerator pedal fully and
check to see if the engine rotates at its maximum
speed with each of the linkage in the smooth oper-
ation.
N6A3027E
5. In the operating range of accelerator pedal and the
injection pump lever returns to their respective 3. Check for play in the No. 1 intake and exhaust
original positions without fail. valve push rods.
If the No. 1 cylinder intake and exhaust valve push
Valve Clearance Adjustment rods have play, the No. 1 piston is at TDC on the
1. Bring the piston in either the No. 1 cylinder or the compression stroke.
No. 4 cylinder to TDC on the compression stroke If the No. 1 cylinder intake and exhaust valve push
by turning the crankshaft until the crankshaft rods are depressed, the No. 4 piston is at TDC on
damper pulley TDC line is aligned with the timing the compression stroke.
pointer.
 SERVICE INFORMATION 00-41
• No.4 Cylinder T.D.C. (Compression stroke)

N6A3028E

N6A3030E
Adjust the No. 1 or the No. 4 cylinder valve clear-
ance while their respective cylinders are at TDC on Injection Timing Adjustment
the compression stroke.
(4JB1/4JB1-TC/4JG2 Only)
Valve Clearance (At Cold) mm (in) 1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing
0.4 (0.016)
gear case notched line.
4. Loosen each valve clearance adjusting screw as
shown in the illustration.
• No.1 Cylinder T.D.C. (Compression stroke)

N6A3031E

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

the compression stroke by turning the crankshaft
N6A3029E until the crankshaft pulley TDC line is aligned with
the timing mark (2).
5. Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.
6. Turn the valve clearance adjusting screw until a
slight drag can be felt on the feeler gauge.
7. Tighten the lock nut securely.
8. Rotate the crankshaft 360°.
9. Realign the crankshaft damper pulley TDC
notched line with the timing pointer.
10. Adjust the clearance for the remaining valves as
shown in the illustration.
00-42 SERVICE INFORMATION
9. Move the crankshaft pulley slightly in both direc-
tions to check that the gauge indication is stable.

N6A3032E

Notice: N6A3034E
Check for play in the No. 1 intake and exhaust valve
push rods. 10. Turn the crankshaft clockwise and read the gauge
If the No. 1 cylinder intake and exhaust valve push rods indication when the crankshaft pulley timing mark
have play, the No. 1 piston is at TDC on the compres- is aligned with the pointer.
sion stroke. 4JB1 BTDC 14°
3. Disconnect the injection pipe from the injection
pump. 4JB1-TC BTDC 4°
4. Remove one bolt from the distributor head. 4JG2 ATDC 2°
5. Insert a screwdriver into a hole in the fast idle lever
and turn the lever to release the W-C.S.D. function.
Standard Reading mm (in)
(If so equipped)
6. Install the static timing gauge (3). 0.5 (0.02)
The probe of the gauge should be depressed in-
ward approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827)

N6A3035E

If the injection timing is outside the specified range,

N6A3033E continue with the following steps.
11. Loosen the injection pump fixing nuts and bracket
7. Rotate the crankshaft to bring the piston in the No. bolts.
1 cylinder to a point 30 — 40° BTDC.
12. Adjust the injection pump setting angle.
8. Set the timing gauge needle to zero.
 SERVICE INFORMATION 00-43

When large than When smaller than

standard value standard value
Gear drive A B

A: Move the injection pump toward the engine.

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

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

N6A3037E

4. Turn the engine over with the starter motor and

take the compression gauge reading.

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

Standard Limit
4JB1 3,038 (31/441) 2,157 (22/313)
4JG2 3,334 (34/484) 2,452 (25/356)

N6A3036E

Legend
A. To advance
B. To retard

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

Compression Pressure Measure-ment

1. Start the engine and allow it to idle until the coolant N6A3038E
temperature reaches 70 — 80°C (158 — 176°F).
2. Remove the following parts. 5. Repeat the procedure (Steps 3 and 4) for the re-
• Glow plugs maining cylinders.
If the measured value is less than the specified lim-
• Fuel cut solenoid connector it, refer to “Troubleshooting” in this Manual.
• QOS (Quick-On Start System) fusible link wire at
the connector.
3. Set the adapter and compression gauge to the No.
1 cylinder glow plug hole.
Compression Gauge
(with Adapter): 5-8840-2008-0 (J-29762)
Adapter: 5-8531-7001-0
00-44 SERVICE INFORMATION
Quick-On Start II System (4JB1 / 4JB1-TC / Quick-ON Start III System (4JG2 only)
4JH1-TC only)
Quick-On Start System Inspection Procedure
Quick-On Start System Inspection Procedure 1. Disconnect the thermo-sensor connection on the
1. Disconnect the thermo-sensor connection on the thermostat outlet pipe.
thermostat outlet pipe.

N6A3039E

N6A3039E
2. Turn the starter switch to the “ON” position.
2. Turn the starter switch to the “ON” position. If the Quick-On Start III System is operating prop-
If the Quick-On Start II System is operating proper- erly, the glow relay will make a clicking sound with-
ly, the glow relay will make a clicking sound within in seven seconds after the starter switch is turned
15 seconds after the starter switch is turned on. on.
3. Measure the glow plug terminal voltage with a cir- 3. Measure the glow plug terminal voltage with a cir-
cuit tester immediately after turning the starter cuit tester immediately after turning the starter
switch to the “ON” position. switch to the “ON” position.

Glow Plug Terminal Voltage V Glow Plug Terminal Voltage V

Approx. 11 8—9

Notice:
Electrical power to the quick-on start system will be cut
after the starter has remained in the “ON” position for
twenty seconds.
Turn the starter switch to the “OFF” position and back to
the “ON” position.
This will reset the Quick-On Start III System.

N6A3040E
 SERVICE INFORMATION 00-45

N6A3725E
00-46 SERVICE INFORMATION

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

N6A3042E
 SERVICE INFORMATION 00-47
Crankshaft, Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley, Fly-
wheel, Oil Pan

N6A3043E

Legend
A. Apply engine oil
00-48 SERVICE INFORMATION
Timing Pulley Housing, Timing Pulley, Timing Gear, Camshaft Oil Seal Retainer

N6A3044E
 SERVICE INFORMATION 00-49
Cooling System and Lubrication System

N6A3045E
00-50 SERVICE INFORMATION
Intake Manifold, Exhaust Manifold, Exhaust Pipe

N6A3046E
SERVICE INFORMATION 00-51

N6A3047E
00-52 SERVICE INFORMATION
Engine Electricals

N6A3048E
 SERVICE INFORMATION 00-53
Engine Fuel
Except 4JH1-TC

N6A3049E
00-54 SERVICE INFORMATION
4JH1-TC

N6A3050E
 SERVICE INFORMATION 00-55
Engine Mounting Bracket

N6A3051E
00-56 SERVICE INFORMATION

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

5-8840-2035-0 / Crank 5-8840-9018-0 / Piston

Timing Pulley (4JG2 Belt Ring Compressor
Drive only)

5884090180
5884020350

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

Wrench (89.0 mm/3.5 in) Meter

5884020930
5884002000

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

Wrench (106.0 mm/4.2 Guide Replacer
in)

9852312120
5884002020

5-8840-0086-0 / Cam-
5-8840-2209-0 / Oil Filter shaft Timing Pulley
Wrench (100.6 mm/4.0 Remover (4JG2 Belt
in) Drive only)

5884000860
5884022090

9-8523-1423-0 (J-29760) 5-8840-0199-0 / Rubber

/ Valve Spring Compres- Hardness Tester
sor

5884001990
9852314230

5-8840-2675-0 / Com-
5-8840-2033-0 / Oil Seal
pression gauge
Installer

5884026750
5884020330
 SERVICE INFORMATION 00-57

Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks

5-8531-7001-0 / Gauge 5-8840-2038-0 / Cam-

Adapter shaft Bearing Replacer

5853170010 5884020380

5-8840-2036-0 / Front Oil

5-8531-7002-0 / Gauge
Seal Installer (4JB1,
Adapter
4JG2, Gear Drive only)

5853170020 5884020360

Base 5-86739-149-0 /
5-8840-0145-0 / Measur-
Lever 5-86739-150-0 /
ing Device
Scissor gear setting tool

5884001450 5867391490

x-xxxx-xxxx-x / Crank-
5-8840-0259-0 / Nozzle
shaft Timing Pulley
Holder Wrench (4JG2
Installer (4JG2 Belt Drive
only)
only)

-1 5884002590

5-8840-0253-0 / (J-
5-8840-0266-0 / Angle
22700) Fuel Filter
Gauge
Wrench

5884002660 5884002530

5-8840-2362-0 / Front Oil

5-8840-9016-0 / Injec-
Seal Remover (4JG2,
tion Nozzle Tester
Belt Drive only)

5884090160 5884023620

5-8840-2034-0 / Nozzle 5-8840-2361-0 / Front Oil

Holder Remover (4JB1 Seal Installer (4JG2, Belt
only) Drive only)

5884020340 5884023610
00-58 SERVICE INFORMATION

Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks

5-8840-2360-0 / Rear Oil 5-8840-0019-0 / Sliding

Seal Remover Hammer

5884023600 5884000190

5-8840-2359-0 / Rear Oil 5-8522-0024-0 / Pilot

Seal Installer Bearing Installer

5884023590 5852200240

5-8840-2040-0 / Cylin-
der Liner Installer (4JB1
only)

5884020400

5-8840-2313-0 / Cylin-
der Liner Installer (4JG2
only)

5884023130

5-8840-2039-0 / Cylin-
der Liner Remover (4JB1
only)

5884020390

5-8840-2304-0 / Cylin-
der Liner Remover Ankle
(4JG2 only)

5884023040

5-8840-2000-0 / Pilot
Bearing Remover

5884020000