6a 4hk1 Engine Mechanical

Engine Mechanical (4HK1-TC) 6A-1
ENGINE
Engine Mechanical (4HK1-TC)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1-TC) . . . . . . . . . . 6A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-65
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 6A-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-66
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Torque Specifications . . . . . . . . . . . . . . . . . . . .6A-68
Main Data and Specifications. . . . . . . . . . . . . . 6A-13 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-68
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Valve Stem Seal and Valve Spring . . . . . . . . . . . 6A-69
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-70
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-71
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-21 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-74
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-22 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-74
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-74
Cylinder Head Cover (Except Europe) . . . . . . . . 6A-24 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6A-78
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-81
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-91
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-26 Torque Specifications . . . . . . . . . . . . . . . . . . . .6A-98
Cylinder Head Cover (For Europe) . . . . . . . . . . . 6A-27 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-98
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Piston and Connecting Rod . . . . . . . . . . . . . . .6A-100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-100
Tightening Torque Specifications . . . . . . . . . . . 6A-30 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .6A-101
Inlet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .6A-107
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-31 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-32 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-111
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-33 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112
Turbocharger and Exhaust Manifold . . . . . . . . . . 6A-34 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-34 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-37 Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-118
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-41 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-118
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 6A-43 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-119
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-43 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-119
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-119
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-45 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-47 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-122
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-54 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . .6A-123
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-54 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-123
Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . . 6A-55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-123
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-125
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55 Torque Specifications . . . . . . . . . . . . . . . . . . .6A-129
Dismount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-56 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-129
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-58 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . .6A-130
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-130
Torque Specifications . . . . . . . . . . . . . . . . . . . . 6A-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-130
Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-61 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-131
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-61 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-61 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6A-135
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-62 Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-135
6A-2 Engine Mechanical (4HK1-TC)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-135
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-136
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-136
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-141
Torque Specifications . . . . . . . . . . . . . . . . . . . 6A-144
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-144
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-146
Component. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-146
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-146
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-147
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-148
Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6A-150
Service Precautions . . . . . . . . . . . . . . . . . . . . 6A-150
Functional Check . . . . . . . . . . . . . . . . . . . . . . 6A-150
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-152
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . 6A-153
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-153
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-153
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-154
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . 6A-155
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-155
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-155
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-155
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-156
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-157
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-157
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-157
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-158
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-158
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-159
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-162
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-165
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-165
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-165
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 6A-166
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-166
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-167
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-168
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 6A-173
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-173
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6A-174
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-174
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-174
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-174
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-174
ISUZU DIESEL ENGINE (4HK1-TC)

Service Precautions Matters that require attention in specifically dealing
with this engine
Matters that require attention in terms of
maintenance Holes or clearances in the fuel system which serve as a
passage of fuel, including the inside of injector, are
To prevent damage to the engine and ensure reliability
finished extremely precisely. For this reason, they are
of its performance, pay attention to the following in
highly sensitive to foreign matter. If it gets inside, it can
maintaining the engine:
lead to breakdown on the road. Be sure to prevent it
• When lifting up or supporting the engine, do not from getting inside.
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
directly the ground. Use a wood 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 into it, 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.
• To protect and lubricate the rotational surface
during the initial operation, apply plenty of engine
oil to it.
• 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 to the same
location as they were removed.
• Parts, such as gaskets, oil seals and O-rings, have
to be replaced by brand-new ones every time the
engine is dismantled.
• As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust may be
clung to them. Then, apply the designated liquid
gasket to each place anew before assembly.
• Assemble it within 7 minutes after applying the
liquid gasket.
If 7minutes or longer passed, remove the liquid
gasket and apply it again.
• When assembling or installing parts, fasten them
with the prescribed tightening torque so that they
may be installed properly.
How To Read The Model
N6A6001E
Legend
1. Engine Model 2. Engine Selial Number
Explanation of Functions and Operations Cylinder Liner

Electronic Engine Control The cylinder liner is selected to match an internal
With the control unit, the range from injection to air diameter of a bore of the cylinder block and built, which
intake/exhaust, including fuel injection quantity, is imprinted on the left side of the cylinder.
injection timing, intake air restriction, EGR, and idling Piston
rpm, is controlled. The piston is aluminum-alloy and an autothermatic
Cylinder Block piston with a strut cast, while the combustion chamber
The cylinder block is cast-iron with the center distance is a round reentrant type.
of each bore being equal and is of the highly rigid, Cylinder Head
symmetrical structure with the crankshaft center being The cylinder head is cast-iron and there are 4 valves
the center. The bearing cap is of the ladder frame per cylinder. The angular tightening method of the
structure and tightened up under the plastic range cylinder head bolt further increases reliability and
rotation angle method. durability.
Crankshaft e. Rotate the crankshaft to make the No.1 cylinder
Tuftriding is given, while on the No. 1 balance weight meet the compression top dead center (TDC).
imprinted is the grade of each journal diameter.
Notice:
EGR System There are 2 timing marks on the crankshaft pulley.
Based upon data, including water temperature, engine Mark (1) is near the cylinder block and is used to bring
speeds or engine loads, it is controlled via Engine the 4HK1-TC engine to TDC.
Control Module (ECM) to purify exhaust by recycling Mark (2) is not applicable to this engine.
part of it. Be sure to use mark (1) when bringing the engine to
Its main components include an EGR valve, an EGR TDC.
cooler and various sensors.
Connecting Rod Cap Bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Common Rail-type Electronic Control Injection
System
The common 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 an
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.
Fuel Injector
The fuel injector is a 7-hole nozzle that adjusts fuel
N6A6002E
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the • Insert a 0.4 mm (0.016 in) thickness gauge into
fuel injector. a clearance between the rocker arm and the
ECM corrects the dispersion of fuel injection quantity bridge to check it and adjust it if needed.
between fuel injectors according to ID code data in
memory. At the replacement of fuel injectors, ID code
data should be stored in ECM. Valve clearance mm (in)
Fuel Filter with Sedimenter Intake valve 0.4 (0.016)
It is a fuel filter with sedimenter that gets rid of water by Exhaust valve 0.4 (0.016)
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that Caution:
notifies you that it is filled with water. Adjust while being cold.
Preheating System
The preheating system consists 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 make 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
a. Remove the cylinder head cover.
b. Remove the fuel injector harness assembly.
c. Loosen the terminal nuts alternately to remove.
d. Remove the leak-off pipe.
N6A6003E
2. Adjustment of valve clearance stem and the movement of the thickness
gauge has become tight.
Caution: b. Then, check if the end of the valve stem on
Adjust valve clearance carefully so that the bridge the opposite side is unstable or hits
contacts the end of the 2 valve stem. diagonally. If so, loosen the bridge adjusting
screw a little so that the end of the valves on
a. Completely loosen all of the bridge and rocker
both sides may touch properly.
arm adjusting nuts and adjusting screws (8 nuts
Valve bridge clearance: ± 0.1 mm (0.0039
and 8 screws).
in) or less
b. Place a 0.4 mm (0.016 in) thickness gauge
c. After making an adjustment so that the end
between the No. 1 cylinder rocker arm end and
of the valves on both sides may touch
the bridge cap.
properly, tighten up an adjusting screw nut
c. Tighten the rocker arm adjusting screw until the of the bridge with a minus driver so that the
thickness gauge is snug (not tight) between the bridge adjusting screw may not rotate.
rocker arm end and the bridge cap.
Tighten:
d. Tighten the rocker arm lock nut.
Adjusting screw nut to 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
e. Tighten the bridge adjusting screw until the
bridge contacts the valve head. Caution:
f. Tighten the bridge lock nut. If the adjusting screw of the bridge is poorly adjusted,
g. Check that the thickness gauge is still held the bridge would tilt and be pushed down and seized,
snugly between the rocker arm end and the which may damage the bridge guide, for example.
bridge cap. If it is too tight, slightly loosen the Thus, adjust it accurately.
bridge adjusting screw and lock nut to restore
snugness.
h. Remove the thickness gauge.
i. Repeat Steps b through h for the remaining
cylinders.
Tighten:
Bridge lock nut to 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
N6A6005E
Tighten:
Rocker arm adjustment screw nut to 22 N⋅m (2.2 kg⋅m/
16 lb⋅ft)
Bridge adjustment screw nut to 22 N⋅m (2.2 kg⋅m/16
lb⋅ft)
Adjustment table
N6A6004E
Cylinder No. 1 2 3 4
Legend
1. Rocker Arm Valve
IN EX IN EX IN EX IN EX
2. Bridge Cap arrangement
3. Bridge
No. 1 cylinder
Compression { { { {
a. With a thickness gauge kept inserted,
TDC
tighten an adjusting screw of the bridge
lightly and make sure that the tip of the No. 4 cylinder
adjusting screw touches the end of valve Compression × × × ×
TDC
• If the No. 1 cylinder is the compression • Install the cylinder head cover.
TDC, adjust a valve clearance with { mark Refer to “Cylinder Head Cover.”
given on the table and if the No. 4 cylinder is
the compression top dead center, that with × Compression pressure inspection
mark. • Warm up the engine.
• Remove a minus terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
built on the lower head cover (no fuel will be
injected).
Caution:
When the harness connector is removed, ECM judges
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory
of ECM.
(For how to clear memory of ECM, refer to Section 6E)
N6A6006E
N6A6008E
Legend
1. Fuel Injector Harness Connector
• Install the minus terminal of the battery.

N6A6007E
• Turn on the starter to emit foreign matter within the
• Attach the harness assembly to the fuel cylinders.
injector.
Tighten the harness bracket with the
designated torque.
Tighten:
Harness bracket to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
• Attach the terminal nuts to the fuel injector.
Tighten:
Terminal nuts to 2 N⋅m (0.2 kg⋅m/17 lb⋅in)
Notice:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads to
damage to the terminal studs.
• Install an adapter and a gauge of a compression A list of defective phenomena
gauge of the special tool. • 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.
N6A6009E
Compression gauge set: 5-8840-2008-0

(Compression gauge: J-26999-12,
Gauge adapter: EN-46722)
• Turn on the starter to inspect compression
pressure.
Compression pressure MPa (kg/cm2 / psi) /

220 rpm
Standard 2.60 – 2.89 (26.5 – 29.5 /
377 – 419)
Limit 1.96 (20.0 / 284)
Differences among 294 kPa (3.0 kg/cm2 / 43
the cylinders psi)
• Measure each cylinder one by one.
Caution:
To keep engine speed at 220 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.

• Remove a minus terminal of the batteries.
• Install a harness connector for the fuel injector built
on the lower head cover.
• Install all the glow plugs.
Tighten:
Glow plugs to 20 N⋅m (2.0 kg⋅m/15 lb⋅ft)
• Install a minus terminal of the batteries.
Trouble Shooting
Engine does not turn over
Condition Possible Cause Correction

Starter motor does not rotate Dead or weak battery Charge or
Replace battery
Incomplete circuit Connect
Repair
Starter relay Replace starter relay
Starter motor brushes stuck, worn, Replace brushes
or broken
Starter motor internal damage Repair motor
Starter motor not meshed with Ring gear abrasion Replace ring gear
flywheel Pinion gear abrasion Replace pinion gear
Magnetic switch (starter motor) not Adjust
properly adjusted
Starter motor pinion meshed with Dead or weak battery Charge battery
ring gear but does not rotate Replace battery
Insufficient contact pressure Adjust pressure
between starter motor brushes and
commutator
Armature (starter motor) stuck Repair armature
Engine internal damage (Seizure) Repair engine
Engine turns over but does not start

Fuel is not delivered to fuel supply Air in fuel system Bleed air from fuel system
pump 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
Use of wrong fuel for prevailing Drain existing fuel and replace with
temperatures appropriate fuel
Clogged fuel filter Replace filter
Fuel is delivered to fuel supply Loose injection pipe connections Tighten connections
pump Loose or broken electrical Tighten and/or replace connectors
connectors
Bad rotational sensor Replace sensor
Engine control system malfunction System diagnosis
Insufficient or unstable fuel delivery Air in fuel system Bleed air from fuel system
volume Feed pump malfunction Repair pump
Loose or broken electrical Tighten and/or replace connectors
connectors
Clogged fuel filter Replace filter
Excessive black exhaust smoke

Bad injection timing Engine control system malfunction System diagnosis
Bad injection nozzle condition Carbon deposit at nozzle tip Clean nozzle tip
Sticking nozzle Replace fuel injector assembly
Insufficient compression pressure 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 due to Replace piston ring
damaged piston ring
Damaged gasket Replace gasket
Piston scoring Replace piston
Fuel condition Water in fuel Drain existing fuel and replace with
new fuel
Poor fuel quality Drain existing fuel and replace with
new fuel
Poor engine aspiration Clogged intake pipes Clean or replace pipes
Clogged air cleaner element Clean or replace element
Malfunction detected by engine Defective sensor Replace sensor
control system Engine control system malfunction System diagnosis
EGR valve and/or intake throttle Intake throttle valve sticking Repair or replace valve
valve malfunction EGR valve sticking Repair or replace valve
Exhaust brake valve sticking Repair or replace valve
Turbocharger malfunction Damaged turbocharger fan Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Oil leakage from oil seal Replace turbocharger
Defective booster sensor Replace sensor
Excessive white exhaust smoke

Bad injection timing Engine control system malfunction System diagnosis
Malfunction detected by engine Engine control system malfunction System diagnosis
control system Control unit malfunction Replace unit
Defective sensor Replace sensor
Insufficient compression pressure 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 due to Replace piston ring
damaged piston ring
Damaged gasket Replace gasket
Piston scoring Replace piston

Fuel condition Water in fuel Drain existing fuel and replace with
new fuel
Excessive oil consumption Worn or damaged piston ring(s) Replace ring(s)
Defective valve stem oil seal Replace oil seal
Defective turbocharger oil seal Replace turbocharger
Clogged turbocharger oil return Repair pipe
pipe
Engine knocking

Bad timing Engine control system malfunction System diagnosis
Malfunction detected by engine Defective sensor Replace sensor
control system Control unit malfunction Replace unit
Fuel condition Poor quality fuel Drain existing fuel and replace with
new fuel
Poor engine aspiration Clogged intake pipes Clean or replace pipes
Engine break-down Foreign material in cylinders Engine overhaul
Scored pistons and/or bearings Replace pistons and/or bearings
Abnormal engine rotation

Engine speed cannot be increased Engine control system malfunction System diagnosis
Defective control unit Replace unit
Engine speed unstable Defective control unit Replace unit
Clogged fuel filter element Replace element
Defective fuel injector nozzle(s) Replace fuel injector assembly
Water in fuel Drain existing fuel and replace with
new fuel
Air in fuel system Bleed air from fuel system
Exhaust brake valve sticking Repair or replace valve
Turbocharger malfunction Damaged turbocharger fan Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Defective booster sensor Replace sensor
Abnormal battery charging

No charging Open or shorted wiring and/or Repair or replace wiring and/or
connectors connectors
Defective generator Repair or replace generator
Defective battery Replace battery

Insufficient charging Open or shorted wiring and/or Repair or replace wiring and/or
connectors connectors
Loose generator drive belt Adjust belt tension or replace belt
Excessive charging Shorted wiring Repair or replace wiring
Turbocharger Troubleshooting

Engine has less than normal power Air leakage from intake pipe rubber Repair
hose
Air leakage from inlet cover Repair
Clogged intercooler cooling section Clean
Clogged air cleaner element Clean or replace
Exhaust brake valve stuck Repair or replace
Turbine and housing contact Replace
(Interference)
Excessive carbon deposit near Clean or repair
turbine exhaust port that interferes
with turbine
Rough turbine shaft rotation Repair or replace
Damaged turbine fan Repair or replace
Blue exhaust smoke Oil leakage from turbocharger oil Repair or replace
seal
Clogged turbocharger oil return Repair
pipe
Clogged center housing oil Repair or replace
passages
Engine oil deterioration Change engine oil
Noisy turbocharger operation Gas leakage from intake or exhaust Repair
system
Turbine and housing contact Repair or replace
(Interference)
Damaged turbine fan Replace
Turbine shaft bearing abrasion or Repair or replace
scoring
Excessive rotating part wear Engine oil deterioration Change engine oil
Clogged turbocharger oil feed pipe Repair
Low engine oil pressure Repair
Main Data and Specifications
Item Engine model 4HK1-TCS Engine model 4HK1-TCN

Type Diesel/4-cycle/water cooling Diesel/4-cycle/water cooling
type in-line OHC type in-line OHC
Combustion chamber type Direct injection type Direct injection type
Cylinder liner type Dry type Dry type
Number of cylinders -cylinder mm (in) 4-115 (4.53) × 125 (4.92) 4-115 (4.53) × 125 (4.92)
bore × strokes
Displacement cc (cu.in) 5193(317) 5193(317)
Compression ratio 17.5 17.5
Compression pressure MPa (kg/cm2/ 2.60 – 2.89 (26.5 – 29.5/377 – 2.60 – 2.89 (26.5 – 29.5/377 –
psi)/rpm 419)/220 419)/220
Idling speed rpm 650 650
Valve clearance Intake 0.4 (0.016) (cold) 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold) 0.4 (0.016) (cold)
Ignition type Compressed ignition Compressed ignition
Injection order 1-3-4-2 1-3-4-2
Lubricating system
Lubricating type Pressure type Pressure type
Oil pump type Gear type Gear type
Volume of lubricating oil Liters (US/Imp 13.0 (3.43/2.86) 13.0 (3.43/2.86)
gal.)
Oil filter type Full flow filter (cartridge type) Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling Built-in-type, water cooling
Cooling system
Cooling type Water cooling type Water cooling type
Radiator type Corrugated fin(pressure type) Corrugated fin(pressure type)
Water pump type Centrifugal, belt type Centrifugal, belt type
Thermostat type 2 wax-type units 2 wax-type units
Thermostat valve-opening °C (°F) 82 (180), 85 (185) 82 (180), 85 (185)
temperature
Volume of coolant Liters (US/Imp 17.6 (4.65/3.87) (incl. radiator) 17.6 (4.65/3.87) (incl. radiator)
gal.)
Fuel system
Injection pump type Electronic control common rail Electronic control common rail
type type
Governor type Electronic type Electronic type
Timer type Electronic type Electronic type
Injection nozzle type Multi-hole type Multi-hole type
7-holes φ0.14 mm (0.0055 in) 7-holes φ0.14 mm (0.0055 in)
inside diameter inside diameter
Item Engine model 4HK1-TCS Engine model 4HK1-TCN

Charging system
Generator type AC type AC type
Power output V-A 24 - 80, 24 - 60, 24 - 50 24 - 80, 24 - 60, 24 - 50
Regulator type IC IC
Starting system
Starter type Reduction type Reduction type
Power output V-kw 24 - 4.5 24 - 4.5
Preheat system type Glow plug Glow plug
Glow plug standard voltage/ V 24 24
electric current
Special Tool
Tool Number /
Illustration
Description / Remarks
5-8840-2008-0
Compression Gauge Set
(J-26999-12 /
Compression Gauge,
EN-46722 /
Gauge Adapter)
5884020080
Engine Assembly
Removal • Remove the connector of the boost pressure
sensor.
1. Remove a minus (-) terminal of the battery.
2. Drain the coolant.
3. Remove the starter motor.
• Disconnect the front frame harness connector
in the vicinity of the control box of the
transmission and remove each clip that fixes
the harness.
• Remove 2 bolts that fasten the starter and
remove the starter from the clutch housing.
• Fix the starter motor with wire, for instance, in a
place that does not get in the way in removing
the transmission.
4. Remove the transmission assembly.
Refer to “Transmission Assembly”
5. Remove the charge air hose (between
turbocharger and inlet pipe).
N6A6011E
Legend
1. Charge Air Hose
2. Boost Pressure Sensor
8. Remove the upper hose of the radiator.

• Remove the band clip and VSV vacuum hose.
N6A6010E
Legend
1. Duct
2. Charge Air Hose
6. Remove the inlet hose (between air cleaner and

turbocharger).
7. Remove the charge air hose (between intercooler N6A6012E
and inlet duct).
9. Remove a bracket of the fan guide.
10. Remove the fan assembly.
• Remove the nuts and pull them out upward.
11. Remove the heater hoses.
• Remove 2 hoses on the engine side. • Remove the terminal B cable and harness
connector from the generator.
15. Remove the vacuum hose on the vacuum pump
side.
16. Remove a bracket by the blow-by separator and
remove the harness connector and HBB oil hose
bracket.
17. Remove the blow-by separator hose.
18. To prevent oil from flowing out when the hydraulic
booster brake hose is removed, remove the
fastening bolts for the hydraulic booster brake tank
to lower the tank.
19. Remove one side of the hydraulic booster brake
hose on the high-pressure side.
20. To prevent oil from flowing out when the power
steering oil hose is removed, remove the fastening
bolts for the power steering reserve tank to lower
N6A6013E the tank.
12. Remove the engine harness. 21. Remove the power steering oil hose.
• Remove the ECM. 22. Remove the lower hose of the radiator on the
• Disconnect the two main harness connectors engine side.
from the ECM (For SLD equipped, disconnect 23. Hang wire on the engine hanger and hoist to lift up
the unsealed connector.) the engine slightly.
• Remove the engine ground cable. 24. Remove the front exhaust pipe.
13. Remove the A/C compressor. • Remove the front exhaust pipe from the turbo
• Remove the drive belt. and exhaust brake.
• Remove the connector. 25. Remove the fuel hose on the feed and return
sides.
• Remove the A/C compressor and fix it with
wire, for example, to an appropriate place along 26. Remove the engine mount.
with hoses and others. • Remove the fastening bolts for the engine
mount on the chassis frame side.
27. Remove the engine assembly.
• Remove the cab back cover.
N6A6014E
Legend
1. Fixing Bolt
2. Connector N6A6015E
3. Bracket
Legend
4. A/C Compressor
1. Screw
2. Cab Back Cover
14. Remove the AC generator harness.
3. Nut
• Operate a hoist slowly and hoist the engine • Operate a hoist slowly to move the engine to
until it comes up to the surface of the chassis the place where it is to be installed.
frame.
• Turn the engine at an angle of 90 degrees to
move from the surface of the chassis frame and
remove the engine assembly.
N6A6017E
• Turn the engine at an angle of 90 degrees to

lower the engine slowly to the place it is to be
installed.
N6A6016E
N6A6016E
N6A6017E • Make the transmission side lower and operate

a hoist slowly, pulling it backward to the engine.
2. Install the engine mount.
Installation
• Install the engine mount to fit into the holes of
Notice: the engine mounting cross member and tighten
Be absolutely sure that each harness is reconnected to it up with the specified torque.
its original position.
Tighten:
1. Install the engine assembly. Cross member to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
• Hang wire on the engine hanger and hoist to lift 3. Install the feed and return sides of the fuel hose.
up the engine.
4. Install the front exhaust pipe.
5. Install the lower hose of the radiator. • Install the connector.
N6A6018E N6A6014E
6. Install the power steering oil hose. Legend

7. Install the power steering reserve tank. 1. Fixing Bolt
2. Connector
8. Install the hydraulic booster brake hose on the
3. Bracket
high-pressure side.
4. A/C Compressor
9. Install the hydraulic booster brake tank.
10. Install the blow-by separator hose. • Install the drive belt.
11. Install a bracket by the blow-by separator and • Hang the drive belt to adjust its tension with an
install the harness connector and HBB oil hose adjusting bolt of the tension pulley.
bracket. • For further details for adjusting tension of the
12. Install a vacuum hose to the vacuum pump. belt, refer to “Drive Belt” in Section 6B.
• Check if a flexure is within the specified range
when the center part is pressed by the hand
with 98 N (22 lb) by using a scale, for instance.
In addition, check if it is not damaged as well.
• Flexure of the A/C compressor belt.
• 16 – 20 mm (0.62 – 0.79 in) (when the belt is
new)
• 18 – 22 mm (0.71 – 0.87 in) (when the belt is
reused)
N6A6019E
13. Install the AC generator harness.

• Install the terminal B cable and the harness
connector to the generator.
14. Install the A/C compressor.
• After adjusting tension of the belt, tighten up the • Install 2 hoses.
lock nut of the tension pulley.
N6A6013E
N6A6020E
18. Install the fan assembly.
15. Install the cab back cover. 19. Install a bracket for the fan guide.
20. Install an upper hose of the radiator.
• Install the VSV vacuum hose and bundle it and
upper hose with a band clip.
N6A6015E
Legend
1. Screw
2. Cab Back Cover
N6A6012E
3. Nut
21. Install the charge air hose (between intercooler
16. Install the engine harness. and inlet duct).
17. Install the heater hoses.
• Install the connector of the boost pressure Refer to “Transmission Assembly”.
sensor. 25. Install the starter motor.
• Install 2 up and down bolts to fasten the starter.
• Connect the front frame harness connector and
install each clip which fixes the harness.
26. Replenish the coolant.
27. Install a minus (–) terminal of the battery.
N6A6011E
Legend
1. Charge Air Hose
2. Boost Pressure Sensor
22. Install the inlet hose (between air cleaner and

turbocharger).
• Hose is inserted until bumping to turbocharger.
• Clip assembled along the white line on hose.
Clip Tightening torque: 6.3 N⋅m (56 lb ft)
1 2 3
N6A6657E
Legend
1. Turbocharger
2. Clip
3. White Line
4. Hose
23. Install the charge air hose (between turbocharger

and intercooler).
24. Install the transmission assembly.
Engine Mount
Component
N6A6021E
Legend
1. Fan Guide 3. Engine Foot
2. Engine Mount
Removal
1. Remove the fan guide bracket.
2. Remove the engine mount.
• Remove the cab back cover. Installation
1. Install the engine mount and tighten up with the
specified torque.
Tighten:
The nuts on the chassis frame side to 82 N⋅m (8.4kg⋅m/
61 lb⋅ft)
The bolts on the engine foot side to 51 N⋅m (5.2kg⋅m/38
lb⋅ft)
N6A6015E
Legend
1. Screw
2. Cab Back Cover
3. Nut
• Before removing the engine mount, hang the

engine with a hoist.
• Remove the nuts fastened to the engine foot N6A6022E
and engine mount. 2. Install the fan guide bracket.
• Remove the bolts fastened to the engine mount • Check if nothing is wrong with the engine
on the chassis frame side. mount by starting the engine.
• Hoist the engine assembly slightly to remove 3. Install the cab back cover.
the engine mount.
N6A6015E
N6A6016E
Legend
1. Screw
2. Cab Back Cover
3. Nut
Torque Specifications
N6A6655E
Cylinder Head Cover (Except Europe)

Component
N6A6512E
Legend
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
Removal
1. Remove the head cover.
2. Remove the gasket.
N6A6028E
N6A6513E Legend
Legend 1. Head Cover Case
1. Head Cover 2. Fuel Injector Harness Connector
3. Remove the fuel injector harness connector. 4. Install the gasket on the head cover.
4. Remove the head cover case. 5. Install the head cover and tighten up according to
5. Remove the gasket. the orders given on the figure.
Tighten:
Bolts to 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
N6A6028E
Legend
1. Head Cover Case
N6A6029E
2. Fuel Injector Harness Connector
Installation
1. Install the gasket on the lower cover.
2. Install the head cover case.
Tighten:
3. Install the fuel injector harness connector.
Caution:
Push it in thoroughly until the claws of the lock raise.
N6A6517E
Cylinder Head Cover (For Europe)

Components
3
5
N6A6024E
Legend
1. Head Cover 4. Gasket
2. Gasket 5. Head Lower Cover
3. Sound Insulation Cover
Removal
1. Drain engine coolant. Refer to Engine Cooling
System section.
2. Remove EGR valve connector.
3. Remove the EGR pipe.
N6A6027E
N6A6025E
11. Remove the fuel injector harness connector (2).
Legend 12. Remove the head lower cover (1).
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
4. Remove the cooling water pipes.

5. Remove the EGR adapter.
6. Remove the EGR cooler.
7. Remove the EGR valve.
Caution:
After removing the EGR valve and EGR adapter, seal
the opening so that foreign matter does not enter.
N6A6028E
Installation
1. Install the gasket on the head lower cover (1).
2. Install the head lower cover (1).
Tighten:
3. Install the fuel injector harness connector (2).
Caution:
Push it in thoroughly until the claws of the lock raise.
N6A6491E
8. Remove the sound insulation cover (1).

9. Remove the head cover (2)
N6A6028E N6A6027E
4. Install the gasket on the head cover. Legend

5. Install the head cover and tighten up according to 1. Sound Insulation Cover
the orders given on the figure. 2. Head Cover
Tighten: 7. Mount the EGR valve.

Bolts to 18 N⋅m (1.8 kg⋅m/13 lb⋅ft) • Insert the gasket and temporarily fit the EGR
valve.
Notice:
Temporarily tighten the bolts.
8. Install the EGR cooler.

• Temporarily fit the EGR cooler to the bracket.
Notice:
9. Install the EGR adapter.

• Temporarily fit the EGR adapter between the
EGR cooler and exhaust manifold.
Notice:
N6A6029E 10. Install the EGR pipe.

6. Install the sound insulation cover. • Insert the gasket between the two ends of the
EGR pipe and temporarily fit it.
Tightening torque: 8 N⋅m (0.8 kg⋅m/6 lb⋅ft)
Notice:
Tightening Torque Specifications
N m (kg m / lb ft)
18 (1.8 / 13)
8 (0.8 / 6)
18 (1.8 / 13)
N6A6030E
Inlet Cover
Component
N6A6031E
Legend
1. Throttle Assembly 3. Inlet Pipe Gasket
2. Inlet Cover 4. Inlet Pipe
Removal
•
1. Remove the fuel rail.

Refer to “Fuel Rail” in Section 6C.
2. Remove the EGR valve.
Refer to “EGR Valve and EGR Cooler” in Section
6F.
3. Remove the inlet pipe.
4. Remove the throttle assembly.
N6A6032E
5. Remove the inlet cover.

• On the place where the throttle assembly is to 2. Install the throttle assembly.
be installed inside the inlet cover (arrow) is a • Apply the liquid gasket and mount within 7
bolt. Be careful not to forget to remove it. minutes.
• Peel the liquid gasket off carefully.
Tighten:
Bolt and nut to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
N6A6033E
N6A6035E
Installation 3. Install the gasket on the inlet pipe and tighten up
1. Install the inlet cover. with the prescribed torque.
• Apply the liquid gasket (ThreeBond 1207C or Tighten:
equivalent) keeping a bead diameter of 2.5–5.5 Bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
mm (0.1–0.2 in) along the groove of the inlet
cover. 4. Install the EGR valve.
Refer to “EGR Valve and EGR Cooler” in Section
• Install it within 7 minutes after applying the
6F.
liquid gasket.
5. Install the fuel rail.
Tighten: Refer to “Fuel Rail” in Section 6C.
Bolt and nut to 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Caution:
• Be careful not to forget to fasten the bolt indicated
with an arrow.
• Tighten up the stud part together with the fuel rail.
N6A6034E
N6A6036E
Turbocharger and Exhaust Manifold

Component
N6A6037E
Legend
1. Oil Feed Pipe 6. Exhaust Adapter
2. Water Return Pipe 7. Water Feed Pipe
3. Turbocharger Assembly 8. Oil Return Pipe
4. Heat Protector 9. Exhaust Manifold
5. Heat Protector
Removal 6. Remove the A/C compressor harness.

1. Loosen the radiator drain cock to drain coolant. 7. Remove the A/C compressor bracket.
2. Remove the air intake duct from the turbocharger
and the air cleaner.
3. Remove the charge air pipe from the turbocharger
and the charge air cooler.
4. Remove the front exhaust pipe.
5. Remove the EGR pipe.
• Without disconnecting the hose of the A/C • Remove the water return pipe.
compressor, remove the compressor from the
bracket and remove the compressor bracket
from the cylinder head.
N6A6039E
Legend
N6A6014E 2. Rubber Hose
Legend
1. Fixing Bolt • Remove the heat protector on the turbocharger.
2. A/C Compressor Harness • Remove the exhaust adapter bolts.
3. A/C Compressor Bracket
• Remove the four turbocharger clamping nuts.
4. A/C Compressor
• Remove the turbocharger from the exhaust
• Remove the oil feed pipe. manifold.
• Remove the oil return pipe.
• Remove the oil feed pipe.
N6A6040E
Legend
1. Fixing Nut
N6A6038E
2. Exhaust Adapter
Legend 3. Fixing Bolt
1. Oil Feed Pipe 4. Fixing Nut
3. Heat Protector 8. Remove the exhaust manifold.
4. Charge Air Hose
5. Inlet Duct
6. EGR Pipe
• Remove the 2 nuts and 6 bolts to remove the Wheel shaft axle play
exhaust manifold. Use a dial gauge to measure the wheel axle shaft play
when a fore of 12 N (2.6 lb) is alternately applied to
both sides of the compressor wheel.
Axle play mm (in)

Standard 0.013 – 0.097 (0.0005 – 0.0038)
Limit 0.100 (0.0039)
N6A6041E
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.
Manifold installation plane surface mm (in) N6A6043E

Standard 0.3 (0.01) or lower
Wheel shaft and bearing clearance
Limit 0.5 (0.02)
Use a dial gauge to measure the clearance between
the wheel shaft and the bearing.
Caution:
If the plane surface exceeds the limit, replace it.
Clearance mm (in)
Standard 0.069 – 0.140 (0.0027 – 0.0055)
Limit 0.15 (0.0059)
N6A6042E
• 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.
5. Inspect the hose for cracks and other damage.
Replace the hose if necessary.
6. Do not apply a pressure of more than 200 kPa (1.2
kg/cm2 / 29 psi) to the waste gate actuator.
Installation
1. Put the gasket in to install the exhaust manifold.
• Tighten up with the 2 nuts and 6 bolts according
to the order given on the figure.
Tighten:
Bolts (1), (2), (3), (4), (5), (6) and Nuts (7), (8) to 34 N⋅m
(3.5 kg⋅m/25 lb⋅ft)
Caution:
Do not tighten up too much because it hampers
N6A6044E
expansion and contraction due to the heat from the
manifold.
Legend
1. Oil Outlet
2. Oil Inlet
Waste gate operation (absolute pressure)

1. Remove the hose from the waste gate actuator.
2. Install the pressure gauge (general tool). Refer to
the illustration.
N6A6046E
2. Install the gasket and turbocharger to the exhaust

manifold. Tighten the nuts to the specified torque.
Tighten:
Nuts to 52 N⋅m (5.3 kg⋅m/38 lb⋅ft)
3. Tighten the adapter bolts (exhaust manifold side)
to the specified torque.
N6A6045E
Tighten:
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).
4. Check the pressure and control rod movement.
Movement, mm (in) 0.38 (0.0150) 4.00 (0.1575)

Pressure, kPa (psi) 160 (23) 180 (26)
Tighten:
• Install the rubber hose between the water
return pipe and the thermostat housing.
N6A6040E
Legend
1. Fixing Nut
2. Exhaust Adapter
3. Fixing Bolt
4. Fixing Nut N6A6039E
Legend
4. Install the water feed pipe to the turbocharger. 1. Water Return Pipe
• Tighten the joint bolts to the specified torque. 2. Rubber Hose
Tighten: 7. Install the turbocharger oil feed pipe to the top of

Joint bolts to 41 N⋅m (4.2 kg⋅m/30 lb⋅ft) the turbocharger. Tighten the joint bolts to the
• Install the pipe bracket and tighten the bolts to specified torque.
the specified torque. Tighten:
Tighten: Joint bolts to 27 N⋅m (2.8 kg⋅m/19.9 lb⋅ft)
Bolts to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) • Install the pipe bracket and tighten the bolts to
the specified torque.
Tighten:
N6A6047E
5. Install the water return pipe. Tighten the joint bolts

to the specified torque.
Tighten:
Joint bolts to 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
6. Install the water return pipe bracket. Tighten the
bolts to the specified torque.
N6A6038E N6A6049E
Legend 10. Install the air intake duct and tighten the bolts to
1. Oil Feed Pipe the specified torque.
3. Heat Protector Tighten:
4. Charge Air Hose Bolts to 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
5. Inlet Duct 11. Install the charge air pipe in the turbo charger and
6. EGR Pipe the charge air cooler.
Tighten:
8. Tighten the oil return pipe bolts to the specified
Duct bolt to 21 N⋅m (2.1 kg⋅m/15 lb⋅ft)
torque.
Duct clip to 6 N⋅m (0.6 kg⋅m/52 lb⋅in)
Tighten: 12. Install the front exhaust pipe to the turbocharger
Bolts to and tighten the nuts to the specified torque.
Turbocharger side: 9 N⋅m (0.9 kg⋅m/78 lb⋅in)
Tighten:
Cylinder block side: 22 N⋅m (2.2 kg⋅m/15 lb⋅ft)
N6A6654E
N6A6050E
9. Install the heat protector and tighten the bolts to
13. Add cooling water to the radiator.
14. Install the A/C compressor bracket.
Tighten:
• Install the A/C compressor bracket on the
Bolts to 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
cylinder head and tighten up with the
prescribed toque.
Tighten:
• Install the A/C compressor on the bracket and
tighten up with the prescribed torque.
Tighten:
N6A6051E
15. Install the EGR pipe.

• Put the gasket between both ends of the EGR
pipe and install to the specified torque.
Tighten:
N6A6052E
N6A6053E
Timing Gear Train

Component
1 2
4
12
13
18 6
11
14
10
8
9
16
7
15
17
N6A6514E
Legend
1. Power Steering Pump 10. Flywheel (M/T)
2. Idle Gear B Shaft 11. Rear Oil Seal
3. Idle Gear A 12. Flywheel Housing
4. Idle Gear B 13. Slinger
5. Power Steering Pump Idle Gear 14. Plug
6. Power Steering Pump Idle Gear Cover 15. Crankshaft Position Sensor
7. Clutch Pressure Plate 16. Crank shaft End Spacer (Smoother)
8. Driven Plate 17. Oil Pan
9. Flexible Plate (Smoother) 18. Fuel Supply Pump
Removal 3. Remove the camshaft assembly.

Refer to “Camshaft Assembly”.
1. Remove the cylinder head cover.
4. Remove the cylinder head assembly.
Refer to “Cylinder Head Cover”. Refer to “Cylinder Head”.
2. Remove the rocker arm shaft assembly.
Refer to “Rocker Arm Shaft Assembly”.
5. Remove the fuel supply pump assembly. Special tool
Refer to “Fuel Supply Pump” in Section 6C. Crankshaft stopper: 5-8840-2230-0 (EN-47680)
N6A6055E N6A6057E
6. Remove the crankshaft position sensor. • Loosen the fastening bolts of the flywheel little
• Remove the crankshaft position sensor before by little according to the order given on the
remove flywheel. figure.
• After loosening all the bolts, remove the stopper
to remove the flywheel.
In the case of smoother vehicle, after loosening the

bolts to fasten the flexible plate, remove the
washer, the flexible plate, the spacer according to
this order.
N6A6056E
7. Remove the flywheel.

• Install the crankshaft stopper on the starter part
of the flywheel housing to stop the crankshaft
from rotating.
Caution:
N6A6504E
Check if the stopper meshes with the ring gear without
fail and is installed properly. Legend
1. Pilot Bearing
2. Washer
8. Remove the rear oil seal and the slinger.

Refer to “Crankshaft Rear Oil Seal”.
9. Remove the oil pan.
10. Remove the power steering pump.
11. Remove the power steering pump idle gear cover.
12. Remove the power steering pump idle gear. 16. Remove the idle gear B shaft.
N6A6058E N6A6060E
13. Remove the flywheel housing.

• Never fail to remove the bolt(s) given on the Inspection
figure.
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).
• If the measurement exceeds the limit, replace
the idle gear.
Backlash of the timing 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.
N6A6059E
14. Remove the idle gear A.

15. Remove the idle gear B.
N6A6061E
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.
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.
N6A6063E
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.
either the idle gear or the shaft.
Clearance between the idle gear and the

shaft mm (in)
N6A6062E Standard 0.020 – 0.062 (0.0007 – 0.0024)

3. External diameter of the idle gear shaft Limit 0.200 (0.0079)
• Use a micrometer to measure an external
diameter of each idle gear shaft.
the shaft.
External diameter of the idle gear shaft mm (in)

Standard 29.959 – 29.980 (1.179 – 1.180)
Limit 29.80 (1.173)
N6A6064E
2
1
3
9
0 L 0
5
7 6
N6A6653E
Legend
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. Power Steering Pump Gear 9. Idle Gear A
5. Power Steering Pump Idle Gear
4. Install the flywheel housing. • As the figure shows, apply the liquid gasket
• Clean the rear side of the cylinder block. In (ThreeBond 1207C or equivalent) inside a hole
particular, remove overflow liquid gasket of the bolt (except the bolt holes indicated with
thoroughly when the crankcase is installed. an arrow) evenly.
N6A6069E
• Along with the dowel pin of the cylinder block,

install the flywheel housing.
• Tighten up the Mark 3 from the cylinder block
Tighten:
side.
Bolts (1) to 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
N6A6070E
5. Install the power steering pump idle gear.

• Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.
• Put the idle gear and the shaft together and
install it on the location given on the figure and
tighten up with the prescribed torque.
Tighten:
N6A6071E
Without HBB
N6A6072E
6. Install the power steering pump idle gear cover. N6A0775E
• Install the O-ring on the cover and install it on With HBB

the flywheel housing and tighten up the
tightening bolts with the prescribed torque.
Tighten:
N6A6074E
Legend
1. Flywheel Housing Fixing Bolt
2. Cylinder Block Fixing Bolt
N6A6073E 8. Install the oil pan

7. Install the power steering pump. • Apply the liquid gasket (ThreeBond1207C or
• Install the power steering pump and tighten up equivalent) on a joint between the cylinder
with the prescribed torque. block, the front cover and the flywheel housing
with a beat diameter of 3 mm (0.1 in).
Tighten:
Fixing bolts to
Flywheel housing side (1): 43 N⋅m (4.4 kg⋅m/32 lb⋅ft)
Cylinder block side (2): 44 N⋅m (4.5 kg⋅m/32 lb⋅ft)
• Install the oil pan within 7 minutes after applying • After fastening the oil pan at the respective
the liquid gasket. points of (1), (2), (3), and (4), fasten other parts.
Tighten:
Bolts and nuts to 11 N⋅m (1.1 kg⋅m/95 lb⋅in)
N6A6075E
• With the flywheel housing, the front cover and

the stud of the crankcase as a guide, put
N6A6077E
together the gasket and put the oil pan on it.
Then, put the rubber assembly on the oil pan 9. Install the rear slinger and the oil seal.
and fix it by fastening bolts and nuts. Refer to “Crankshaft Rear Oil Seal”.
10. Install the flywheel.
• Along with the knock pin of the crankshaft,
install the flywheel and tighten up with the
prescribed torque according to the order given
on the figure.
Tighten:
Bolts to
1st step: 78 N⋅m (8.0 kg⋅m/57 lb⋅ft)
2nd step: 120° – 150° (degrees)
N6A6076E
N6A6078E
Legend
1. Rubber Assembly
2. Oil Pan
3. Gasket
11. Turn the crankshaft in the normal direction of Caution:
engine rotation until the No. 1 or No. 4 cylinder is • If the stud bolts (cylinder block side) have been
at TDC on the compression stroke. loosened or replaced, apply Loctite No. 262 to the
Refer to illustration. recessed portion of the bolts.
N6A6003E N6A6079E
Notice: • Check if the meeting mark of the gear painted white

There are 2 timing marks on the crankshaft pulley. is at the location given on the figure when viewed
Mark (1) is near the front cover and is used to bring the from the plug hole and tighten up with the
4HK1-TC engine to TDC. prescribed torque.
Mark (2) is not applicable to this engine. Tighten:
Be sure to use mark (1) when bringing the engine to Nut to 50 N⋅m (5.1 kg⋅m/36 lb⋅ft)
TDC. Bolt to 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
• If the location of the teeth of the painted gear is not
in the right place, put it together all over again.
N6A6002E
12. Remove the oil drain adapter.

13. Install the O-ring on the fuel supply pump.
N6A6080E
14. Align the slits as shown in the illustration.
15. Insert the stud bolts into the guides and Legend
temporarily tighten them. 1. Plug Hole
2. Meeting Mark
16. Install the adapter assembly: oil drain on the plug

hole and tighten up with the prescribed torque.
Tighten:
Bolt to 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
• Apply engine oil over the O-ring nice and thin
and install it.
N6A6081E
Legend
1. Adapter
2. O-ring
17. Install the cylinder head assembly.

Refer to “Cylinder Head”.
18. Install the camshaft assembly.
19. Install the rocker arm shaft assembly.
20. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
Rocker Arm Shaft Assembly

Component
N6A6083E
Legend
1. Camshaft Bracket 5. Rocker Arm Bracket
2. Rocker Arm 6. Camshaft Bracket
3. Wave Washer 7. Rocker Arm Shaft
4. Rocker Arm
Removal
• Along with the camshaft bracket, remove the
rocker arm shaft assembly.
• Keep the 2-bolts (arrowed in the figure) fixing 6. Remove the camshaft bracket to take the shaft out.
the rocker arm shaft to the camshaft bracket,
before removal of all the rocker arm brackets
N6A6085E
Legend
N6A6084E 1. Camshaft Bracket
2. Rocker Arm
Caution: 3. Wave Washer
Pay full attention so as not to drop the bridge cap in the 4. Rocker Arm
gear case of the rear part of the cylinder head or the 5. Rocker Arm Bracket
hole into which oil pours back in the front. 6. Camshaft Bracket
7. Rocker Arm Shaft
Dismount 7. Check if the oil hole of the camshaft bracket (on
1. Remove the camshaft bracket. the rear side) is clogged.
2. Remove the rocker arm.
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
• Repeat the procedure of (2) to (5).
N6A6086E
8. Check if the rocker arm shaft is warpage.

• Place the rocker arm shaft on a V block.
• Mesure the runout of the rocker arm shaft with
a dial gauge on the center of the shaft.
• As a result of measurement, if its bend is slight,
press it to rectify it (do not heat).
• If the warpage of the shaft exceeds the limit,
replace the shaft.
• Use a cylinder gauge to measure an inside
diameter of the bush of the rocker arm to
Bend of the rocker arm shaft mm (in)
measure a clearance between the external
Limit 0.3 (0.012) diameter of the shaft.
the rocker arm and the shaft.
Clearance between the rocker arm and

rocker arm shaft mm (in)
Standard 0.010 – 0.056 (0.0004 – 0.0022)
Limit 0.2 (0.0079 )
N6A6087E
9. Check if the rocker arm shaft is worn.

• Use a micrometer to measure 8 places rubbed
by the rocker arms.
• Replace the shaft if the diameter is less than
the limit.
External diameter of the rocker arm shaft mm (in) N6A6089E

Standard 21.979 – 22.000 (0.865 – 0.866) 11. Inspect a clearance between the roller of the
Limit 21.85 (0.860) rocker arm and the rocker arm pin.
a. Pass a string, through the opening between the
rocker arm and the roller, pull it strongly in the
direction indicated with arrows and measure
the gap between the rocker arm and the roller
with the roller being hulled out. (Figure 1)
b. After marking the measuring point, pull the
string out push the roller fully into the rocker
arm, and measure the gap of the marked place.
(Figure 2)
c. The gap between the measurement taken
under a. and that under b. Is the a clearance
between the roller and the rocker arm pin. If it
exceeds the limit, replace the rocker arm.
Clearance between the roller and the

rocker arm pin mm (in)
Standard 0.068 – 0.100 (0.0026 – 0.0039)
N6A6088E
Limit 0.2 (0.0079)
10. Inspect a clearance between the rocker arm and
the rocker arm shaft.
• Apply engine oil to the hole of the rocker arm,
the roller and the rocker arm pin.
N6A6090E
N6A6092E
Reassembly 3. Install the wave washer between the rocker arm.
1. Install the camshaft bracket to one side of the 4. Install the rocker arm bracket.
rocker arm shaft tentatively first. (Tighten them up,
• Paying attention to the direction of the rocker
after the rocker arm shaft assembly is installed on
arm bracket, repeat the step 2 to 4.
the cylinder head.)
5. Install the camshaft bracket.
• Assemble in the reverse order to dismounting.
• Install the camshaft bracket on the rocker arm
shaft with the bolts indicated with an arrow
tightened tentatively. (Tighten them up, after the
rocker arm shaft assembly is installed on the
cylinder head.)
N6A6091E
2. Install the rocker arm.
N6A6085E
Legend
1. Camshaft Bracket
2. Rocker Arm
3. Wave Washer
4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
7. Rocker Arm Shaft
Installation • Apply engine oil on threads of the bolts and
nuts, and fix them tentatively (about tighten up).
• Tighten them up according to the order
• If the bridge cap comes off, apply engine oil
specified below gradually, taking care not to
over the inside of the bridge cap and put it
incline the entire rocker arm assembly.
together with the bridge.
Tightening order:
Caution: 1. Nuts (1) from near side of the rocker arm
Pay full attention so as not to drop the bridge cap in the shaft
gear case of the rear part of the cylinder head or the 2. Bolts (2)
hole into which oil pours back in the front. 3. Bolts (3) from out side
4. Bolts (4)
Tighten:
Bolt (3) to 56 N⋅m (5.7 kg⋅m/41 lb ft)
Nut (1), Bolt (2), (4) to 27 N⋅m (2.8 kg⋅m/20 lb ft)
N6A6093E
Legend
1. Bridge Cap
2. Bridge
N6A6094E
1) Temporarily tighten the bolts marked with the Legend

arrow in the illustration. 1. Camshaft Bracket Fixing Nut
2) Loosen the rocker arm adjust screws and apply 2. Camshaft Bracket Fixing Bolt
engine oil to the rocker arm roller portions. 3. Rocker Arm Bracket Fixing Bolt
4. Rocker Arm Shaft Set Bolt
3) Install the rocker arm assembly on the cylinder
head.
• Adjust valve clearance.
Refer to “Functional Inspection”.
N6A6084E
N6A6095E
Camshaft Assembly
Component
3
4
5
6
7
8
N6A6096E
Legend
1. Bearing Cap 5. Dish Washer
2. Bearing 6. Sub Gear
3. Knock Pin 7. Spring
4. Snap Ring 8. Camshaft Gear
Removal
1. Rotate the crank shaft to make the No. 1 cylinder
meet the compression TDC.
Refer to the “cylinder head cover.”
Refer to the “rocker arm shaft assembly.”
4. Remove the camshaft bearing cap.
• Before removing the camshaft from the cylinder Disassembly
head, rotate the sub gear using the special tool
1. Remove the scissors gear assembly.
to prevent the spring force which acts on the
sub gear from affecting. Align the hole of the • Fix the hexagon portion of the camshaft in a
sub gear with the camshaft main gear and vise using a mouth ring. Use snap ring pliers to
install the phase alignment pin from the sub remove the sub gear.
gear side to match the teeth.
Caution:
Special tool
Take care not to damage to the cam portion and the
Scissors gear spring wrench: 5-8840-2674-0
journal portion of the camshaft.
N6A6660E
5. Remove the bearing upper. N6A6098E
6. Remove the camshaft assembly.

7. Remove the bearing lower.
Caution:
Put the removed bearings in order with a tag, for
example, by cylinder. 1 2 3 4 5
N6A6099E
Legend
1. Snap Ring
2. Dish Washer
3. Sub Gear
4. Spring
5. Camshaft Gear
N6A6097E
2. Remove the camshaft gear.
• Remove the fastening bolts of the camshaft End clearance of the camshaft mm (in)
gear and put the block of wood in a puller to
remove the camshaft gear. Standard 0.085 – 0.205 (0.033 – 0.008)
Limit 0.25 (0.009)
Caution:
Measure an end clearance of the camshaft before
disassembling.
N6A6100E
Legend
1. Wood
3. Remove the dowel pin.

4. Inspect the camshaft visually.
• Check if the journal and cam parts of the N6A6102E
camshaft are worn or damaged, if so, replace it. 6. Check if the cam lobe is worn.
• Measure the height “H” of the cam lobe with a
micrometer.
• If the height of the cam lobe is the limit or less,
replace the camshaft.
Height of the cam lobe mm (in)

Inlet Exhaust
Standard 52.8 (2.08) 54.5 (2.15)
Limit 51.8 (2.04) 53.5 (2.11)
N6A6101E
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.
• Rotate the camshaft slowly and measure the
range of fluctuation. If it exceeds the limit,
Warpage of the camshaft mm (in)

Limit 0.05 (0.0019 )
H
N6A6652E
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,
External diameter of the camshaft journal N6A6105E

part mm (in) 9. Measure camshaft journal oil clearance.
Standard 39.950 – 39.975 (1.5728 – 1.5738) a. Measure the inside diameter of the camshaft
Limit 39.850 (1.5688) bearing with a dial gauge.
b. Read the difference between the inside
diameter of the camshaft bearing and the
Partial wear of the camshaft journal part mm (in) diameter of the camshaft journal.
Limit 0.05 (0.0019) If the measured oil clearance exceeds the limit,
replace the camshaft bearing.
Clearance of the journal part mm (in)

Standard 0.025 – 0.087 (0.0009 – 0.0034)
Limit 0.15 (0.0059)
N6A6104E
8. Check if the camshaft is warpage.

• Place the camshaft on a V block to measure a
runout with a dial gauge.
N6A6106E
Reassembly
1. Install the knock pin.
2. Install the camshaft gear.
• With the side of the camshaft gear center boss
part stuck out being on the camshaft side, 1 2 3 4 5
install the camshaft gear along with the knock
pin.
Tighten:
Bolt to 142 N⋅m (14.5 kg⋅m/105 lb⋅ft)
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
N6A6099E
Legend
1. Snap Ring
2. Dish Washer
3. Sub Gear
4. Spring
5. Camshaft Gear
• Use snap ring pliers to assemble the snap ring

and the dish washer securely.
N6A6102E
3. Install the scissors gear assembly.

• Fix the hexagon portion of the camshaft in a
vise using a mouth ring. Assemble the spring
with its left end contacting the pin of camshaft
main gear to make a gap on the right.
• Assemble the sub gear so that its pin is inserted
into the gap between the right side of pin of the
camshaft main gear and the right end of the
spring.
N6A6098E
• Before installing the camshaft to the cylinder
head, rotate the sub gear using the special tool
to prevent the spring force which acts on the
sub gear from affecting. Align the hole of the
sub gear with the camshaft main gear and
install the phase alignment pin from the sub
gear side to match the teeth.
Special tool
Scissors gear spring wrench: 5-8840-2674-0
N6A6003E
2. Install the camshaft bearing lower.

• Apply engine oil over the camshaft bearing
lower and install it on the cylinder head.
• The camshaft assembly ‘B’ mark must be
facing the cylinder head upper face. If not,
serious engine damage will result.
N6A6107E
Installation
1. Turn the crankshaft in the normal direction of
engine rotation until the No. 1 or No. 4 cylinder is
at TDC on the compression stroke.
Notice:
There are 2 timing marks on the crankshaft pulley.
Mark (1) is near the cylinder block and is used to bring
the 4HK1-TC engine to TDC.
Mark (2) is not applicable to this engine.
Be sure to use mark (1) when bringing the engine to
TDC.
N6A6651E
4. Install the baring upper to the bearing cap.

5. Install the bearing cap.
• Apply engine oil on the bearing upper.
N6A6002E
• Direct the front mark of the bearing cap toward
the front of the engine and put it together with
the cylinder head in numerical order.
1
N6A6644E
Legend
1. Phase Alignment Pin
N6A6109E
• Apply engine oil to the thread and tighten up the 6. Install the rocker arm shaft assembly.
bearing cap with the prescribed torque. Refer to “Rocker Arm Shaft Assembly”.
Tighten:
Nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
N6A6110E
• Pull out the phase alignment pin of the gear (1)

carefully so that it does not fall into inside the
engine.
Caution:
Be careful not to forget to pull out the phase alignment
pin of the gear.
N m (kg m / lb ft)
27 (2.8 / 20)
142 (14.5 / 105)
N6A6111E
Special Tool
Tool Number /
Illustration
5-8840-2674-0
Scissors Gear Spring
Wrench
5884026740
Valve Stem Seal and Valve Spring

Component
N6A6112E
Legend
1. Camshaft Bearing Cap 6. Valve Spring
2. Camshaft Bearing 7. Spring Upper Seat
3. Camshaft Assembly 8. Split Collar
4. Rocker Arm Shaft Assembly 9. Bridge
5. Valve Stem Oil Seal
Removal 5. Remove the bridge (2).

1. Remove the cylinder head cover. Caution:
Refer to “Cylinder Head Cover”. Keep the removed bridge and bridge cap properly so
2. Remove the rocker arm shaft assembly. that they may be put back to the original position.
4. Remove the bridge cap (1).
8. Remove the valve spring.
Put the removed valve springs in order by cylinder
number.
9. Remove the valve stem oil seal.
• Use pliers to remove the oil seal.
N6A6093E
Legend
1. Bridge Cap
2. Bridge
N6A6114E
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or a hole Caution:
into which oil pours back in the front. Do not use the removed oil seal again.
6. Remove the split collar.

Inspection
• Apply compressed air over the cylinder from a
glow plug hole to keep the valve at the home Inspect the valve spring
position. Caution:
• Use a replacer to compress the valve spring to Check the valve spring visually and if there is clear
remove the split collar. damage or wear-out, replace it.
Special tool 1. Free length

Valve spring replacer: 5-8840-2621-0 (J-43263) • Measure free length of the spring and if it is
Pivot: 5-8840-2808-0 (EN-46721) shorter than the prescribed limit, replace the
spring.
Free length of the valve spring mm (in)

Inlet Exhaust
Standard 59.9 (2.36) 70.3 (2.76)
Limit 56.9 (2.24) 67.3 (2.65)
N6A6113E
7. Remove the spring upper seat.

• Remove the special tool to remove the upper
seat.
Tension of the valve spring

Inlet Exhaust
Installation
47.0 (1.85) 47.0 (1.85)
length mm (in)
Standard N (lb) 333 (74.9) 490 (110.2)
Limit N (lb) 315 (71.0) 463 (104.3)
N6A6115E
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, replace the valve spring.
Valve spring squareness mm (in)

Limit 1.0 (0.04)
N6A6117E
Installation
1. 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.
Caution:
After installing the valve stem oil seal, check if it is
inserted deeply enough and the oil seal is not tilted or
the garter spring has not come off.
N6A6116E
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.
Special tool • Apply compressed air over the cylinder from the
Valve stem seal installer: 5-8840-2833-0 glow plug holes to keep the valve at the home
(EN-47685) position.
• Use a replacer to compress the valve spring
and install the split collar.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)
N6A6118E
2. Install the valve spring.

• Install it with the paint mark or the narrow side
of the spring pitch being the lower side (cylinder
head side).
N6A6113E
Paint mark
5. Apply engine oil over the bridge and install it.
Inlet Blue
Caution:
Exhaust Red Move it up and down to check if them moves smoothly.
6. Apply engine oil over the bridge cap and install it.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
N6A6119E
Legend
1. Spring Pitch
2. Paint Mark
3. Install the spring upper seat.

4. Install the split collar.
Tool Number /
Illustration
5-8840-2833-0
(EN-47685)
Valve Stem Seal Installer
EN47685
N6A6093E
Legend
1. Bridge Cap
2. Bridge

Special Tool
Tool Number /
Illustration
5-8840-2621-0 (J-43263)
Valve Spring Replacer
5-8840-2808-0
(EN-46721)
Pivot Assembly
Cylinder Head
Component
N6A6120E
Legend
1. Bridge Cap 9. Idle Gear C Cover
2. Bridge 10. Idle Gear C
3. Bridge Guide 11. Glow Plug
4. Split Collar 12. Intake and Exhaust Valves
5. Spring Upper Sheet 13. Cylinder Head
6. Valve Spring 14. A/C Compressor Bracket
7. Valve Stem Oil Seal 15. Thermostat
8. Valve Guide 16. Water Outlet Pipe
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the ‘OFF’ position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Remove the front exhaust pipe.
4. Remove the turbocharger.
Refer to “Turbocharger and Exhaust Manifold”.
5. Remove the left-hand EGR adapter and right-hand • Loosen the tension pulley nut and the adjust
EGR pipe. bolt and remove the drive belt.
6. Remove the EGR water feed pipe.
7. Remove the EGR water return pipe.
8. Remove the EGR cooler.
9. Remove the water feed pipe for coolant water for
the EGR cooler and the water return pipe.
N6A6122E
Legend
1. Tension Pulley Nut
2. Adjust Bolt
13. Remove the A/C compressor.

N6A6025E
• Remove the A/C compressor harness
Legend connector, remove the compressor from the
1. EGR Adapter A/C compressor bracket, and fix it with wires
2. Water Return Pipe and others.
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
10. Remove the fan guide bracket.

11. Remove the left-hand intake pipe between the
inter-cooler and the inlet duct.
N6A6123E

Refer to “Cylinder Head Cover.”
15. Remove radiator upper hose.
16. Loosen the fuel injector terminal nuts alternately to
the same level, and remove the terminal.
N6A6121E 17. Loosen the fuel injector harness bracket bolt,
12. Remove the A/C compressor drive belt. remove the inside connector, and remove the
harness bracket.
18. Remove the nozzle leak-off pipe (4).
N6A6126E
N6A6124E
22. Remove the EGR valve and EGR valve connector.
Legend 23. Remove the camshaft position sensor connector.
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal Nut
4. Nozzle Leak-off Pipe 25. Remove the camshaft assembly.
19. Remove the fuel leak-off hose. 26. Remove the bridge cap carefully so that it does not
20. Remove the fuel leak-off pipe (2). fall into inside the engine.
27. Remove the bridge.
Caution:
Store the removed bridge and bridge cap so that they
can be placed in their original locations.
28. Remove the glow plug connector.

29. Remove the glow plug.
N6A6125E
Legend
1. High Pressure Pipe
2. Leak-off Pipe
21. Remove the water bypass hose from the cylinder

head side.
• Remove the engine coolant temperature sensor
N6A6127E
connector.
30. Remove the injection pipe clip, and remove the 34. Mark each fuel injector with the number of the
injection pipes. cylinder from which it was removed. Store the fuel
injectors in a safe place. Position the fuel injector
so that the nozzle is protected.
Caution:
• Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
will result in injector failure.
N6A6128E
Legend
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip

• Remove the fuel rail pressure sensor
N6A6129E
connector.
32. Remove the fuel injector bracket. Legend
1. Sliding Hammer
33. Loosen the fuel injector clamp fixing bolts and
2. Fuel Injector Remover
remove the fuel injectors.
3. Fuel Injector Assembly
If the fuel injectors are difficult to remove, use the fuel
injector remover. Install the fuel injector remover to the
leak-off pipe attachment part on the fuel injector. Use a Caution:
sliding hammer to force the fuel injector clamp off the Attach a cylinder number to the removed fuel injectors
fuel injector. til re-install them.
Be sure not to make the nozzle touch something.
Caution:
Do not remove the fuel injector sleeve.
Special tool
Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)
• Remove liquid gasket adherent to the removed
inlet cover.
N6A6130E
35. Remove the lower head cover.

N6A6034E
3. Remove the A/C compressor bracket.
• Loosen the cylinder head bolts in the described
order in the drawing. 4. Remove the exhaust manifold.
Refer to “Exhaust”.
Caution: 5. Remove the exhaust gasket.
Be sure not to overlook (1) and (2) because they are 6. Remove the water outlet pipe.
attached with the flywheel housing with M10 bolts.
7. Remove the thermostat.
• Remove the cylinder head gasket.
Caution:
Replace the head gasket with a new one once it was
removed.
N6A6132E
8. Remove the idle gear C cover.
N6A6131E
Disassembly
1. Remove the throttle assembly.
• Remove the intake throttle valve connector.
2. Remove the inlet cover.
• Put the edge of a driver on the outer circle of • Remove the special tool, then remove the
the sealing cup as shown in the drawing, tap it upper sheet and springs.
lightly, reverse it, then pull it out with pliers or
other equipment. Sort the removed valve springs by cylinder
number.
N6A6133E
N6A6113E
9. Remove the idle gear C.
13. Remove the intake and exhaust valves.
• Sort the removed valves according to cylinders
by using tags and others.
N6A6134E
Legend
1. Idle Gear C
2. Shaft N6A6135E
14. Remove the valve stem oil seals.

10. Remove the split collar.
11. Remove the spring upper sheet.
12. Remove the valve spring.
• Use a replacer to compress the valve spring,
then remove the split collar.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)
• Use pliers to remove the oil seals.
N6A6137E
N6A6114E Legend
15. Remove the valve guides. 1. Nozzle Sleeve
• Use the valve guide replacer to press out the
valve guides from the bottom side of the 17. Remove the bridge guide.
cylinder head. • Electrically weld the nut on the head of the
bridge guide, attach the sliding hammer and
Special tool pull it out.
Valve guide replacer: 5-8840-2628-0 (J-43272)
N6A6138E
N6A6136E Legend
16. Put the nozzle sleeve remover on the nozzle 1. Nut
sleeve from the bottom side of the cylinder head,
then pull out the nozzle sleeve. 18. Remove the oil seal.
Special tool
Nozzle sleeve remover: 5-8840-2623-0 (J-43265)
Caution:
• Be sure not to scratch the bottom side of the
cylinder head.
• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.
• Press the tool against the oil seal. Strike the • Check whether there is a crack between the
tool to remove the seal from the inside of the valve sheets and in the cylinder head of the
cylinder head. exhaust port part, and replace the cylinder
head if there is serious damage or crack.
Check the collar if necessary.
N6A6139E
N6A6140E
Inspection c. Flatness of the under surface of the cylinder
1. Inspect the cylinder head assembly. head
• Remove varnish, soot and others adhered on • Use a straight edge ruler and thickness
the metal surface completely. Use metal brush gauge to measure the four sides and
and others so that the seal surface of the diagonal lines as shown in the drawing, and
surface where the gasket is installed is not replace if they exceed the limit.
damage.
• Check the following causes in the case of leak Distortion of the under surface of the
of the seal surface of the cylinder head, cylinder head mm (in)
corrosion, air leak and defective gasket.
- Defective installation. Standard 0.05 (0.002) or less
- Defective tightening of the cylinder head. Limit 0.20 (0.0079)
- Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening torque
Caution:
Replace suspicious bolt.
b. Inside the combustion chamber, glow plug hole.
N6A6141E
d. Flatness of the surface where the exhaust

manifold and inlet cover are installed
• Use a straight edge ruler and thickness 2. Bridge
gauge to measure the four sides and • Make sure the bridge moves smoothly along
diagonal lines as shown in the drawing, and the bridge guide.
replace if they exceed the limit.
• Measure the gap between the bridge and
bridge guide.
Distortion of the surface where the
manifold and cover are installed mm (in)
Gap between the bridge guide and bridge
Standard 0.05 (0.002) or less guide mm (in)
Limit 0.2 (0.0079) Assembly standard 0.020 (0.00079) –
0.056 (0.00220)
Usage limit 0.1 (0.0039)
N6A6142E
e. Flatness of the exhaust manifold

• Use a straight edge ruler and thickness N6A6145E
gauge to measure the flatness. If it exceeds Legend
the limit, replace the exhaust manifold. 1. Bridge
2. Bridge Guide
Distortion of the exhaust manifold mm (in)
3. Inspect the valve guide.
Standard 0.3 (0.0118)or less
Caution:
Limit 0.5 (0.0197)
If there is a scratch or abnormal abrasion in the valve
stem and the inner diameter part of the valve guide,
replace it with new one along with valve guide.
a. Measure the valve guide clearance.

• Measure the diameter of the valve stem with
a micro meter.
If the diameter of the valve stem is smaller
than the limit, replace the valve and valve
stem altogether.
The external diameter of the valve

stem mm (in)
Standard Limit
7.946 (0.3128) –
Intake valve 7.88 (0.3102)
7.961 (0.3134)
7.921 (0.3118) –
Exhaust valve 7.80 (0.3071)
N6A6143E 7.936 (0.3124)
• If the abrasion exceeds the limit, or there is an
abnormal abrasion (zonal abrasion), replace
the bridge cap.
Abrasion of the bridge cap mm (in)

Limit 0.1 (0.00394)
N6A6146E
• Measure the gap between the valve guide

and valve stem within 10 mm (0.39 in) from
the valve guide, using a dial gauge.
• If the measured value exceeds the limit,
replace the valve guide and valve
altogether.
N6A6148E
Gap between the valve guide and
valve stem mm (in) 5. Inspect the valve.
Thickness of the valve
Standard Limit • Measure the thickness of the valve.
0.039 (0.00153) – • If the measured value exceeds the limit, replace
Intake valve 0.20 (0.00787)
0.071 (0.00280) the valve and valve guide altogether.
0.064 (0.00252) –
Exhaust valve 0.25 (0.00984)
0.096 (0.00378) Thickness of the valve mm (in)
Standard Limit
Intake valve 1.71 (0.0673) 1.3 (0.0512)
Exhaust valve 1.75 (0.0689) 1.3 (0.0512)
N6A6147E
4. Inspect abrasion of the bridge gap.

• Measure the contact surface of bridge cap and
the rocker arm, using a dial gauge.
N6A6149E
Valve sheet
• Remove carbon, water stain and others on the
under surface of the cylinder head.
Install the valve in the cylinder head.
Measure the depth of the valve from the under
surface of the cylinder head, using a depth
gauge or straight edge ruler.
If it exceeds the limit, replace the valve insert or
cylinder head assembly.
Depth of the valve mm (in)

Standard 0.7 (0.0276) – 1.2 (0.0472)
Limit 2.5 (0.0984)
N6A6151E
Contact surface of the valve seat

• If the contact surface of the valve seat is
defective, modify it or replace the valve, valve
guide and valve seat altogether.
Angle of the contact surface: 45° (degrees)
N6A6150E
• Measure the contact width of the valve seat. If

the seat contact surface has a scratch or is
rough, or if the abrasion of the contact surface
exceeds the limit, modify or replace it.
Contact width of the valve seat mm (in)

N6A6152E
Standard Limit
Repair of the seat surface
Intake valve 2.5 (0.0984) 3.0 (0.1181)
• Remove carbon from the surface of the valve
Exhaust valve 2.0 (0.0787) 2.5 (0.0984) insert seat.
• 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.
N6A6155E
Replace the valve seat insert

Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve
N6A6153E
seat insert.
Caution: • Cool the valve seat insert for two to three
Remove only scratches and roughness, and do not cut minutes. Contraction fur to cooling makes it
the surface too much. easier to remove the valve seat insert.
Use the free adjustment valve cutter pilot. • Remove the valve seat insert, using a screw
Do not let the valve cutter pilot waver inside the valve driver. Be sure not to damage the cylinder
guide. head.
N6A6156E
N6A6154E
Legend
• Attach abrasives in the valve insert seat. 1. Arc-weld
• Insert the valve into the valve guide. 2. Valve Seat Insert
• Attach abrasives on the valve seat surface, 3. Screw Driver
rotate the valve and hit it lightly to grind them, Install the valve seat insert
and confirm that it has even contact all round.
• Carefully place an attachment (the outer
Caution: diameter is smaller than the valve seat insert)
Remove abrasives completely after grinding. on the valve seat insert.
• Use the press to apply pressure gradually on
the washer, thereby pushing the valve seat
insert.
Caution:
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 them, and confirm that it
has even contact all round.
N6A6158E
Legend
1. Cylinder Head
2. Oil Seal Installer
2. Install the bridge guide.

N6A6157E
• Apply engine oil on the outer diameter of the
Legend guide, then use the installer to hammer it into
1. Attachment the depth of the finishing part of the hole of the
2. Valve Seat Insert cylinder head.
3. Press (Note: the height of the bridge guide is about
37.5 mm (1.48 in) from the upper surface of the
head)
Reassembly
Special tool
1. Install the oil seal.
Bridge guide installer: 5-8840-2626-0 (J-43268)
• Install on the surface of injection pipe insert.
• Hammer it in so that the seal does not incline.
Caution:
Be sure not to damage the rip.
Special tool
Oil seal installer: 5-8840-2627-0 (J-43269)
N6A6159E
Legend
1. 122.5 ± 0.5 mm (4.82 ± 0.02 in)
2. 37.5 mm (1.48 in)
3. Install the nozzle sleeve.

• Install the O-ring on the nozzle sleeve, apply
N6A6139E engine oil.
• Apply seal material on the taper section.
Special tool
Loctite No.TL290 Nozzle sleeve installer: 5-8840-2624-0
(J-43266)
N6A6650E
Legend N6A6161E
1. O-ring (White Paint) Legend

2. O-ring 1. Punch Bar
3. Apply the Loctite 2. Ball
4. Engine Oil 3. Guide Sleeve
4. Nozzle Sleeve
• Install the nozzle sleeve on the cylinder head, 5. Bracket
insert the guide sleeve. 6. Bolt
• Use the guide sleeve to push in so that the
nozzle sleeve fully contacts with the under 4. Install the valve guide.
surface of the cylinder head.
• Insert the sleeve and fix it with the tighten and
bolt.
• Insert the ball (bearing steel ball 9.525 mm
(0.375 in)) into the guide sleeve, attach the
punch bar and hammer out the ball.
Caution:
• Leave the cylinder head floating so that the ball
comes off from the under surface.
• Hammer in the valve guide from the upper Special tool
surface of the cylinder head, using the valve Valve stem seal installer: 5-8840-2833-0
guide replacer. (EN-47685)
Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272)
N6A6118E
6. Install the intake and exhaust valves.

N6A6162E
• Apply engine oil on the valve stem part and
install the valve.
Height from the upper surface of the cylinder

head to the edge surface of the valve guide:
18.75 – 19.25 mm (0.7381 – 0.7578 in)
Caution:
When replacing the valve guide, it must be replaced
together with the valve.
N6A6164E
7. Install the valve spring.

• Install the valve spring with the paint mark or
the narrower side of the spring pitch on the
under side (the cylinder head side).
Paint mark
N6A6163E Intake side Blue
5. Install the valve stem oil seal. Exhaust side Red
• Apply engine oil on the outer diameter of the
valve guide, use the valve stem seal installer to
install the oil seal.
Caution:
After installation of the valve stem seal, confirm that the
oil seal is not inclining and the garter spring is in place.
Tighten:
N6A6119E
Legend
1. Spring Pitch
2. Paint Mark N6A6134E
Legend
8. Install the spring upper sheet. 1. Idle Gear C
9. Install the split collar. 2. Shaft
• Use the replacer to compress the valve spring
11. Install the idle gear C cover.
and install the split collar.
• Apply liquid gasket (Loctite 262) on the outer
Special tool diameter of the idle gear C cover, use the
Valve spring replacer: 5-8840-2621-0 (J-43263) sealing cup setting tool to hammer it in so that
Pivot: 5-8840-2808-0 (EN-46721) the measurements follow the drawing.
Special tool
Sealing cup installer: 5-8840-2222-0
(EN-47690)
N6A6113E
10. Install the idle gear C.

• Apply engine oil on the idle gear C shaft and
the inner diameter of the idle gear, install the N6A6165E
idle gear C so that the side with gear groove is
12. Install the thermostat.
on the side of the rear surface of the engine.
• Tighten the idle gear C with the designated
torque.
• Do not use impact wrench and like.
• Install the thermostat on the position shown in • Install the distance tube conical spring and the
the drawing. nut on the stud of the cylinder head in this
order.
N6A6166E
Legend N6A6168E
1. Thermostat Legend
1. Distance Tube
13. Install the water outlet pipe. 2. Conical Spring
• Tighten the water outlet pipe with the 3. Nut
designated torque.
• Tighten the exhaust manifold in the order
Tighten: described in the drawing.
Tighten:
Bolt (1),(2),(3),(4),(5),(6) and Nut (7), (8) to 34 N⋅m (3.5
kg⋅m/25 lb⋅ft)
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
N6A6167E
14. Install the exhaust gasket.

15. Install the exhaust manifold.
N6A6046E
• Install the heat protector.

Tighten:
16. A/C compressor bracket.
Install the bracket, tighten the bolt with the
designated torque.
Tighten:
N6A6170E
18. Install the throttle assembly.

• Coat the liquid gasket and mount within 7
minutes.
Tighten:
N6A6051E Bolt and nut to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
17. Install the inlet cover. • Install the intake throttle valve connector.
• Apply liquid gasket (ThreeBond1207C or
equivalent) in accordance with the groove of
the inlet cover, with the bead diameter of φ2.5 –
5.5 mm (0.0984 – 0.2165 in).
N6A6035E
Installation
N6A6169E 1. Install the cylinder head gasket.
• Tighten in the order described in the drawing. • Select the cylinder head gasket.
• Tighten the stud bolts (6) and (9) jointly with the • Clean the head of the piston and the upper
fuel rail. surface of the cylinder block.
Tighten: • Use a dial gauge to measure the extrusion of
Stud bolts to 22 N⋅m (2.2 kg⋅m/16 lb⋅ft) the piston. Measure at two points of each
cylinder.
• The following drawing shows the measurement
points and the standard point of the cylinder
Gasket Recognized Piston extrusion
block.
Grade by amount mm (in)
A (no hole) 0.439 (0.01728) –
0.519 (0.02043)
B (1 hole) 0.519 (0.02043) –
0.589 (0.02319)
C (2 holes) 0.589 (0.02319) –
0.669 (0.02633)
N6A6171E
Measurement
Head of the piston (2) and (3)
points:
Standard point: Upper surface of the
(1)
cylinder block
Caution:
Note that there are three options for the head gasket N6A6173E
according to the amount of extrusion of piston shown in Legend

the following table. 1. Grade Recognition Hole
• Calculate the average piston extrusion amount • Apply liquid gasket

of each cylinder. • Apply liquid gasket (ThreeBond 1207C or
• Calculate the maximum amount of the average equivalent) on the joint (1) of the cylinder block
amount of each cylinder. and the flywheel housing with the bead
• Select a gasket of an appropriate grade based diameter of 3 mm (0.118 in).
on Timax. • Install the cylinder head within seven minutes
after applying liquid gasket.
N6A6172E
N6A6174E
• Install the cylinder head gasket.
Tighten:
• Install the cylinder head gasket with the parts M14 bolts (1 – 18) to
number upside, along with the cylinder head
rear gear case and dowel.
2nd step: 147 N⋅m (15.0 kg⋅m/108 lb⋅ft)
3rd step: 30° – 60° (degrees)
M10 bolts (19, 20) to
4th step: 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
• Tighten bolts from 1-18 (M14) and confirm that
they are tightened to a torque of 167 N⋅m (17.0
kg⋅m/123 lb⋅ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
N6A6175E

• Install the cylinder head, adjusting the dowel of
the cylinder block.
Caution:
Be sure not to damage the head gasket when installing
it.
N6A6177E
3. Install the fuel injector on the cylinder head.

4. Apply molybdenum disulfide on the thread and
setting face of the fuel injector tighten bolt and
tighten it tentatively.
Important:
Reinstall each fuel injector to the original cylinder from
which it was removed during the disassembly
procedure.
N6A6176E
• Apply molybdenum disulfide on the thread and

setting face of the head bolt of M14, and apply
engine oil on the thread and setting face of the
head bolt of M10.
• Use a torque wrench and angle gauge to
tighten the head bolts in the order described in
the drawing.
N6A6178E
Legend
1. Fuel Injector Assembly
2. Fuel Injector Tighten Bolt

Tighten:
Fuel rail to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• Install the fuel rail pressure sensor.
N6A6128E
6. Install the injection pipe.
Legend
• Apply a thin coat of engine oil on the outer 1. Fuel Injection Pipe
diameter of the sleeve nut on the side of the 2. Fuel Injection Pipe Clip
fuel injector and install the injection pipe.
• Use a spanner to tighten the sleeve nut until it 7. Final tighten the injection clamp bolts to the
completely contacts both on the fuel injector specified torque.
and fuel rail.
Tighten:
• Tighten the injection pipe clip with the Bolts to 30 N⋅m (3.0 kg⋅m/22 lb⋅ft)
designated torque.
8. Tighten the injection pipes to the specified torque.
Tighten:
Clip to 6 N⋅m (0.6 kg⋅m/52 lb⋅in) Tighten:
15. Install and tighten the camshaft position sensor
with the designated torque.
Tighten:
N6A6179E
Legend
1. Injection Clamp Bolt
2. Injection Pipe Sleeve Nut
9. Install the glow plug.

Tighten:
Glow plug to 20 N⋅m (2.0 kg⋅m/15 lb⋅ft)
10. Install and tighten the glow connector with the N6A6180E
designated torque.
16. Install the water bypass hose.
Tighten: 17. Install the engine coolant temperature sensor on
Glow connector to 1.2 N⋅m (0.1 kg⋅m/10.5 lb⋅in) the thermostat housing.
11. Apply engine oil on the bridge, install it. Tighten:
Caution: Engine coolant temperature sensor to 25 N⋅m (2.5 kg⋅m/
Move it up and down to confirm that it moves smoothly. 18.4 lb⋅ft)
18. Install the leak-off pipe.
12. Apply a thin coat of engine oil inside the bridge
cap, install it. Tighten:
Leak-off pipe to 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
19. Install the fuel leak-off hose.
20. Clip a new gasket to the fuel nozzle leak-off pipe
and install the fuel leak-off pipe.
Tighten:
Nozzle leak-off pipe (injector to cylinder head) to 12 N⋅m
(1.2 kg⋅m/104 lb⋅in)
Fuel leak-off pipe (cylinder head side) 12 N⋅m (1.2 kg⋅m/
104 lb⋅in)
Fuel leak-off pipe (supply pump side) 18 N⋅m (1.8 kg⋅m/
13.3 lb⋅ft)
Caution:
Use new gaskets.
N6A6093E
Legend
1. Bridge Cap
2. Bridge
N6A6181E N6A6627E
21. Install the fuel injector harness connectors. Legend

22. Install the harness bracket and tighten the bolts to 1. Fuel Injector
the specified torque. 2. Fuel Injector Harness
3. Fuel Injector Terminal Nut
Tighten:
Bolt to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) 24. Install the cylinder head cover.
25. Install the radiator upper hose.
26. Install the A/C compressor.
• Install the A/C compressor bracket on the A/C
compressor and tighten it with the designated
torque.
Tighten:
• Install the A/C compressor harness connector.
N6A6182E
23. Install the terminal nuts on the fuel injector.

Tighten:
Terminal nuts to 2 N⋅m (0.2 kg⋅m/17 lb⋅in)
Caution:
• Do not over tighten the nuts. Damage to the terminal
studs will result.
• The terminal nut with two wires is engine front side.
N6A6123E
27. Install the A/C compressor drive belt.

• Place the drive belt and adjust its tension with
the adjust bolt of the tension pulley.
• Use a scale or other equipment to inspect
•
whether the flexure of the belt when it was

pushed by hand with pressure of 98 N (22 lb) is
within the designated range.
A/C belt flexure mm (in)

New belt 16 (0.63) – 20 (0.79)
Reused belt 18 (0.71) – 22 (0.87)
• Tighten the locknut of the tension pulley with

the designated torque after adjusting the
tension of the belt.
Tighten:
Lock nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
N6A6121E
• Install the fan guide bracket.

29. Install the EGR valve and EGR cooler.
For details of installation, refer to “EGR Valve and
EGR Cooler” in Section 6F.
N6A6122E
Legend
1. Tension Pulley Lock Nut
2. Tension Pulley Adjusting Bolt
28. Install the intake pipe.

• Install the bolt and clip band, tighten the bolt N6A6025E
with the designated torque. Legend
Tighten: 1. EGR Adapter
Bolt to 10 N⋅m (1.0 kg⋅m/87 lb⋅in) 2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
30. Install the oil level gauge and guide tube.

31. Install the exhaust pipe.
• Install the front exhaust pipe and tighten with
the designated torque.
Tighten:
Nuts to
Exhaust manifold side: 67 N⋅m (6.8 kg⋅m/49 lb⋅ft)
Exhaust brake side: 17 N⋅m (1.7 kg⋅m/13 lb⋅ft)
32. Install the engine harness.
N6A6184E
Special Tool
Tool Number / Tool Number /
Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2833-0
5-8840-0019-0 (J-23907)
(EN-47685)
Sliding Hammer
Valve Stem Seal Installer
584000190 EN47685
5-8840-2628-0 (J-43272) 5-8840-0266-0 (J-45059)

Valve Guide Replacer Angle Gauge

5-8840-2808-0
5-8840-2624-0 (J-43266)
(EN-46721)
Nozzle Sleeve Installer
Pivot Assembly
5-8840-2222-0
5-8840-2626-0 (J-43268)
(EN-47690)
Bridge Guide Installer
Sealing Cup Installer
5-8840-2627-0 (J-43269)
Oil Seal Installer
5-8840-2623-0 (J-43265)
Nozzle Sleeve Remover
5-8840-2826-0
(EN-46720)
Fuel Injector Remover
EN46720
5-8840-2621-0 (J-43263)
Valve Spring Replacer
Piston and Connecting Rod

Component
7
1
2
1
N6A6649E
Legend
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
Refer to “Oil Pan”.
5. Remove the cylinder head.
6. Remove the connecting rod cap.
Caution: Caution:
Sort the removed bearings according to cylinders by Sort the piston rings in the order of cylinders when
using tags. reusing them so that they will not be confused with the
pistons and piston rings of other cylinders.
N6A6186E
7. Remove the piston and connecting rod.

N6A6188E
• Remove carbon on the upper side of the
cylinder liner with a scraper. 2. Remove the snap ring.
• Pull out the piston and connecting rod towards 3. Remove the piston pin.
the cylinder head.
Caution:
Caution: Sort the disassembled piston pins, pistons and
Be sure not to damage the oil jet and cylinder liner connecting rods together in the order of cylinders.
when pushing out the connecting rod.
N6A6189E
N6A6187E
4. Remove the connecting rods from the piston.
8. Remove the connecting rod bearing.
5. Piston
Caution: • Clean carbon carefully that is adhered to the
Arrange the bearings in the order of cylinders. Be sure head of the piston and the groove of the piston
to put them back to the original cylinders. ring.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Caution:
Do not use wire brush to clean the piston because it
Piston diameter mm (in)
scratches the piston.
Inspect the piston with eyes for cracks, burns and other Standard 114.924 – 114.939
excessive wear, and replace it if there is any (4.52456 – 4.52515)
abnormality.
6. Measure the gap between the piston and the inner Gap between the piston and the inner
diameter of the cylinder liner. diameter of the cylinder liner mm (in)
Inner diameter of the cylinder liner. Standard 0.082 – 0.126
• Use a cylinder bore dial indicator to measure (0.0032 – 0.0050)
the liner inner diameter both in the thrust and
radial directions in the designated position. Caution:
• Measurement position (from the upper surface If it is found that the gap between the cylinder liner
of the cylinder block) inner diameter and the piston exceeds the standard
1. 20 mm (0.79 in) value, replace the piston or cylinder liner.
2. 110 mm (4.33 in)
3. 190 mm (7.48 in)
• Measure the liner inner diameter based on the
average value of the actual measurement
values on 6 positions.
Cylinder liner inner diameter mm (in)

115.021 – 115.050 (4.52838 – 4.52952)
N6A6191E
7. Piston replacement
• You do not need to select grades because there
is only one grade for each of the piston and the
cylinder liner inner diameter.
If you replace the cylinder liner, you must select
the cylinder block (1, 2, 3) because there are
two types of the liner outer diameter.
• Refer to “Cylinder Block” if you replace the
N6A6190E cylinder liner.
Legend
1. 20 mm (0.79 in) Caution:
2. 110 mm (4.33 in) The head of piston has a marking of grade B or C when
3. 190 mm (7.48 in) it is shipped from the factory.
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.
• Measurement position (from the upper surface
of the piston) 82 mm (3.2 in).
• Use a thickness gauge to measure the gap of
the ring joint.
N6A6192E
Legend
1. Front Mark Cut N6A6194E

8. Inspect the piston ring. the piston ring.
Measure the joint of the piston ring (remove carbon
on the ring joint)
Piston ring gap mm (in)
• Insert the piston ring into the cylinder liner.
• Use the piston to push the ring to reach the Standard Limit
under edge of the cylinder liner. 1st compression 0.20 – 0.30 1.20
ring (0.0079 – 0.0118) (0.047)
2nd compression 0.30 – 0.45 1.20
ring (0.0118 – 0.0177) (0.047)
Oil ring 0.20 – 0.40 1.20
(0.0079 – 0.0157) (0.047)
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.
N6A6193E
Piston ring and piston ring groove

clearance mm (in)
Piston ring Standard Limit
1st compression 0.07 – 0.11 0.20
ring (0.0028 – 0.0043) (0.0079)
2nd compression 0.03 – 0.07 0.15
ring (0.0012 – 0.0028) (0.0059)
Oil ring 0.03 – 0.07 0.15
(0.0012 – 0.0028) (0.0059)
• If it feels a large looseness or instability in
normal temperatures, replace the piston or
piston pin.
N6A6195E
9. Inspect the piston pin.

• Inspect the piston pin with eyes for cracks, N6A6197E
scratches and other damages, replace it if
necessary. • Measure the bush of the small edge of the
connecting rod. If the clearance of the bush
• Use a micrometer to measure the outer
inner diameter and the pin diameter exceeds
diameter of the piston pin. If the measured
the limit, replace the bush or connecting rod
value exceeds the limit, replace the piston pin.
assembly, and the pin.
Piston pin outer diameter mm (in)

Piston pin and connecting rod small end
Standard 39.995 – 40.000 (1.5746 – 1.5748) bushing clearance mm (in)
Limit 39.970(1.5736) Standard 0.012 – 0.027
(0.0005 – 0.0011)
Limit 0.05(0.0020)
N6A6196E
• Inspect to make sure that there is a resistance

to the extent which the piston can push the N6A6198E
piston pin lightly in normal temperatures.
10. Measure the clearance between the piston and the
piston pin.
• Apply engine oil on the piston pin. Use your • Use the bench press to replace the bush.
finger to push it in hole of the piston and rotate
it. If the pin smoothly rotates without instability, Special tool
the clearance is normal. If there is instability, Connecting rod bush replacer: 5-8840-2340-0
measure the clearance. If the clearance (EN-47682)
exceeds the limit, replace the piston and the
piston pin.
Piston pin and piston pin hole clearance mm (in)

Standard 0.004 – 0.017 (0.00016 – 0.00067)
Limit 0.04 (0.0016)
11. Remove the bush.

• Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
• Tighten the nut.
N6A6200E
Legend
1. Bolt
2. Connecting Rod Bush Replacer
12. Measure the connecting rod alignment.

• Use a connecting rod aligner to measure the
parallelism of the big end hole and the small
end hole. If the measured value exceeds the
limit, replace it.
Connecting rod alignment

N6A6199E
(par length of 100 mm (3.94 in)) mm (in)
Legend Standard Limit
1. Setting Bar Distortion and 0.20
2. Connecting Rod 0.05 (0.002)
Parallelism (0.008)
3. Nut
4. Collar
5. Bush
6. Collar
• Place the connecting rod bush replacer base on

press, tighten the fixation bolt.
N6A6201E
13. Measure the bearing oil clearance. - Remove the plastigauge from the bearing
• Measure the oil clearance between the and crankpin.
connecting rod bearing and the crank pin with
the following method.
- Remove the connecting rod cap. Sort the
removed caps according to the cylinder
number.
- Clean the bearing and the shaft pin.
- Inspect the bearing. If it is damaged or worn
seriously, replace the entire bearing.
• Place the plastigauge on the crankshaft pin.
• Install the bearing cap and tighten the bolt with
the designated torque.
Apply molybdenum disulfide on the screw part
and the bearing surface.
Tighten:
Connecting rod bearing cap bolt to
1st step: 39 N⋅m (4.0 kg⋅m/29 lb⋅ft) N6A6203E
2nd step: 60° (degrees) 14. Select the connecting rod bearing.
3rd step: 30° (degrees)
• Select bearings carefully by the grade of big
Caution: end hole diameter of the connecting rod
Do not rotate the crankshaft. according to the selection table.
2 3
N6A6648E
N6A6202E Legend
- Remove the cap. 1. Top and Back Recognition Boss
2. Big End Diameter Grade Mark
- Measure the largest width of the plastigauge
3. Cylinder Number
to calculate the oil clearance. If the
clearance exceeds the limit, replace the Bearing selection table
entire bearing.
Big end hole Bearing
diameter recognition Oil clearance
Crankpin and bearing clearance mm (in)
Grade color mm (in)
Standard 0.037 – 0.077 (0.0015 – 0.0030)
A Green 0.037 – 0.077
Limit 0.10 (0.0039) (0.0015 – 0.0030)
B Yellow 0.037 – 0.077
(0.0015 – 0.0030)
• Adjust the oil hole of the connecting rod and the
oil hole of the bush, and use the bench press to
install the bush.
N6A6205E
Legend
1. Grade Recognition Color
N6A6199E
Legend
1. Setting Bar
Reassembly
2. Connecting Rod
1. Install the bush 3. Nut
• Place the connecting rod bush replacer base on 4. Collar
a press, set the connecting rod and tighten the 5. Bush
fixation bolt. 6. Collar
Special tool • After installing the new bush, use a grinder to

Connecting rod bush replacer: 5-8840-2340-0 machine the pin hole so that the pin clearance
(EN-47682) equals the standard value.
N6A6200E N6A6206E
Legend 2. Install the piston.

1. Bolt 3. Install the connecting rod.
2. Connecting Rod Bush Replacer • Install it so that the front mark of the head of the
piston and the connecting rod forging mark
• Set the collar, new bush and collar on the
(projecting) on the connecting rod face the
setting bar as shown in the drawing.
same direction.
• Tighten the nut.
• Use snap ring pliers to install the snap ring of • Install 2nd and 1st compression rings in this
one side. order so that the marks “2T” and “1T” face
upward.
N6A6645E
Legend N6A6209E
1. Front Mark Legend

2. Forging Mark (Projecting) 1. Oil ring
2. Compression Ring 2nd
4. Apply enough engine oil on the piston pin, push it 3. Compression Ring 1st
in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring. Caution:
Note that the shapes of compression rings 1st and 2nd
Caution:
are different.
Make sure that the snap ring is installed in the ring
Make sure that there is no gap in the position indicated
groove properly. Make sure that the connecting rod
in the drawing when the oil ring coil expander was
moves smoothly.
installed.
N6A6210E
N6A6208E
6. Use ring pliers to install the piston ring.

• Install the oil ring so that the joint angle of the Installation
ring and coil expander is in the opposite 180° 1. Install the connecting rod bearing.
direction.
• Install the bearing on the connecting rod, apply
engine oil on the bearing.
2. Install the piston and connecting rod assembly.
• Apply enough engine oil on the piston ring, ring • Install the cap, matching the numbers (1, 2, 3,
groove and piston side surface. 4) of the caps and connecting rods.
• Dislocate the piston ring joint so that (1) is 1st
ring, (3) is 2nd ring and (2) is oil ring, as shown
in the drawing.
• Face the piston front mark cut to forward, use
the piston ring compressor to insert the piston
in the cylinder liner.
Caution:
1
• Be sure not to make the connecting rod touch the oil
jet when pushing in the piston.
1
• Be sure not to damage the inside of the liner when
pushing in the piston. 2 3
Special tool
Piston ring compressor: 5-8840-9018-0
(J-8037)
N6A6648E
Legend
1. Back and Top Recognition Boss
2. Big End Hole Diameter Grade Mark
3. Cylinder Number
• Apply molybdenum disulfide on the screw part

and the setting face of the tightening bolt and
tighten it with the designated torque.
• Tighten two bolts alternately in each step.
Tighten:
Tightening bolt to
2nd step: 60° (degrees)
3rd step: 30° (degrees)
N6A6211E
3. Install the connecting rod cap. Special tool

Angle gauge: 5-8840-0266-0 (J-45059)
• Install the bearing on the connecting rod cap
and apply engine oil. Caution:
Make sure that the crankshaft smoothly rotates.
8. Install the oil pan.
N6A6212E
4. Install the cylinder head.

1st 39 (4.0 / 29)

2nd 60
3rd 30
N6A6646E
Special Tool
Tool Number /
Illustration
5-8840-2340-0
(EN-47682)
Connecting Rod Bush
Replacer
5-8840-9018-0 (J-8037)
Piston Ring compressor
5-8840-0266-0 (J-45059)
Angle Gauge
Flywheel
Component
N6A6214E
Legend
1. Flywheel Housing 6. Pilot Bearing (MT)
2. Flywheel Assembly (MT) 7. Crankshaft Position Sensor
3. Washer 8. Flexible Plate (Smoother)
4. Clutch Assembly (MT) 9. Crankshaft End Spacer (Smoother)
5. Clutch Pressure Plate Assembly (MT)
Removal
1. Remove the starter motor.
• Remove the earth cable of the starter motor.
• Disconnect the front frame harness connector • Remove the clutch pressure plate assembly
near the control box of the transmission, from the flywheel.
remove the clips that fix the harness.
N6A6217E
N6A6215E
4. Remove the clutch plate assembly.
• Remove the two bolts on the upper side and • Remove the clutch plate assembly from the
lower side that fix the starter, remove the starter flywheel along with the clutch aligner (1).
from the clutch housing.
• Use wire to secure the starter to the
transmission. Position the wire and starter so
that it does not interfere with the transmission
removal procedure.
N6A6218E
Legend
1. Clutch Aligner
• Install the crankshaft stopper in the starter

N6A6216E installation part of the flywheel housing.
2. Remove the transmission assembly.
Refer to “Engine Assembly”. Caution:
Make sure that the stopper is applied with the ring gear
3. Remove the clutch pressure plate assembly.
and installed properly.
• Insert the clutch aligner on the spline of the
driven plate.
• Remove the clutch pressure plate assembly
installation bolts in the order shown in the
drawing.
Special tool • In the case of smoother vehicle, after loosening
Crankshaft stopper: 5-8840-2230-0 (EN-47680) the flexible plate installation bolts, remove the
washer, flexible plate, spacer in this order.
N6A6057E
N6A6078E
5. Remove the crankshaft position sensor.
• Remove to prevent contact damage when the 8. Remove the pilot bearing.
flywheel is removed. • Remove the pilot bearing from the flywheel.
• Do not throw or drop because it is vulnerable to
shock.
N6A6219E
Legend
N6A6056E 1. Washer
6. Remove the washer. 2. Pilot Bearing
3. Flywheel
• Gradually loosen the flywheel installation bolts 9. Remove the ring gear.
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.
• Put a bar on the ring gear and hit it with a Depth = From the pressure installation surface
hammer to remove it. to the friction surface.
N6A6220E N6A6221E
Inspection Installation
1. Inspection with eyes 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks • After heating the ring gear with a gas burner
and damages, and replace it if it has equally, install it in the flywheel.
abnormality. • During shrinkage cooling of the ring gear,
• Inspect the tooth part of the ring gear, replace maintain the flatness by applying force of
the ring gear if it has damage or serious wear. 68.6 kN (15,400 lbf).
2. Measurement of the friction surface
Caution:
• Measure the depth of the friction surface of the
flywheel. • Install the ring gear in the direction within the
chamfered face comes to the side of pressure
• Adjust it if the measured value is between the installation surface.
standard value and the limit.
• Shrink fit the ring gear to the flywheel.
• If the measured value exceeds the limit, replace Make sure that flywheel and ring gear adhesion is
the flywheel. complete.
Depth of the friction surface of the

flywheel mm (in)
Standard 19 (0.75 )
Limit 20 (0.79)
N6A6222E

3. Install the washer.
M/T specification Smoother specification
1) Align the flywheel with the crankshaft knock pin 1) Align the knock pin on the crankshaft to install
and temporarily tighten the flywheel bolts. the spacer.
2) Use the crankshaft stopper to prevent the 2) Install the flexible plate and washer, also
crankshaft from turning. aligning to the knock pin on the crankshaft.
Crankshaft stopper: 5-8840-2230-0 (EN-47680) 3) Apply molybdenum disulfide grease to the bolt
• Apply molybdenum disulfide on the thread and thread and seat to install the flywheel fixing hole.
setting face of the bolt. Tighten bolt to two stage tightening method in
3) Install the washer and the flywheel bolts and the numerical order.
tighten to the specified torque in numerical order 1st step; 78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
show in the illustration. 2nd step; 90° – 120° (degrees)
Tighten:
Bolts to
2nd step: 120° – 150° (degrees)
Special tool
Crankshaft stopper: 5-8840-2230 (EN-47680)
Angle gauge: 5-8840-0266-0 (J-45059)
N6A6078E
4. Install and tighten the crankshaft position sensor

with the designated torque.
Tighten:
5. Hammer in the pilot bearing until it reaches the
edge surface of the crank.
6. Install the clutch plate assembly.
N6A6078E
N6A6057E
• Use a clutch aligner to install the clutch plate
assembly on the flywheel.
N6A6216E
• Install the earth cable of the starter motor.

N6A6218E
• Connect the front frame harness connector.
Legend
1. Clutch Aligner
7. Install the clutch pressure plate assembly.

• Install the clutch pressure plate assembly on
the flywheel so that the installation hole of the
clutch pressure plate assembly matches with
the dowel pins of the flywheel.
• Tighten the clutch pressure plate assembly in
the order shown in the drawing.
Tighten:
N6A6215E
N6A6217E
8. Install the transmission assembly.

Refer to “Engine Assembly”.
9. Install the starter motor on the clutch housing with
bolts.
Tighten:
N6A6223E
Special Tool
Tool Number /
Illustration
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
5-8840-0266-0 (J-45059)
Angle Gauge
Front Cover
Component
N6A6224E
Legend
1. Adjust Plate 8. Front Oil Seal
2. Generator 9. Crankshaft Pulley
3. Front Cover 10. Water Pump Assembly
4. Oil Pan Gasket 11. Fan Belt
5. Oil Pan 12. Water Pump Pulley
6. Rubber Assembly (For Europe) 13. Fan Assembly
7. Front Slinger
Removal 4. Remove the front cover.

1. Remove the front oil seal.
Refer to “Crankshaft Front Oil Seal”.
2. Remove the oil pan
3. Remove the water pump.
Refer to “Water Pump” in Section 6B.
• Remove the generator adjust plate. • Pull out the oil cooler bypass valve from the
cylinder block.
N6A6225E
N6A6227E
• Remove the oil relief valve (arrowed), loosen
the front cover installation bolts and remove the
front cover.
Installation
1. Install the oil cooler bypass valve.
• Insert the oil cooler bypass valve into the
cylinder block. Be sure not to insert in a wrong
direction.
N6A6226E
5. Remove the oil cooler bypass valve.
N6A6228E
2. Install the front cover.

• Clean the cylinder block front surface. In
particular, remove liquid gasket leaked during
installation of the crankcase.
• Install two O-rings and apply liquid gasket
(ThreeBond 1207B, 1207C, 1207F or
equivalent) along with the groove of the front
cover installation surface.
Beat width: 1.5 – 5mm (0.059 – 0.20 in)

Beat height: 0.3 – 1.5mm (0.012 – 0.059 in) from
the joint surface
• Install within seven minutes after applying liquid
gasket.
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
N6A6230E
Legend
1. BOLT : L = 35 mm (1.38 in)
2. BOLT : L = 25 mm (0.98 in)
3. BOLT : L = 65 mm (2.56 in)
4. BOLT : L = 30 mm (1.18 in)
N6A6229E
5. Oil Relief Valve
Legend 3. Install the water pump.

1. O-ring Refer to “Water Pump” in Section 6B.
• Install the front cover to match with the dowel
Refer to the “Oil Pan”.
pins of the cylinder block.
5. Install the front oil seal.
Caution: Refer to the “Crankshaft Front Oil Seal”.
Along with the front cover, install the water pump
assembly (before liquid gasket becomes dry)
Tighten:
Front cover bolt to 24 N⋅m (2.4 kg⋅m/18 lb⋅ft)
• Tighten bolts with (*) mark together with the
adjust plate of the generator.
• Tighten the oil relief valve (5) with the
designated torque.
Tighten:
Oil relief valve to 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
N6A6231E
Crankshaft Front Oil Seal

Component
N6A6232E
Legend
1. Crankshaft Pulley 3. Crankshaft Front Slinger
2. Crankshaft Front Oil Seal
Removal • Fix the detached starter with a wire or the like at

a position where it will not be a hindrance to
1. Drain coolant.
removing the transmission.
2. Remove the starter.
• Disconnect the starter ground cable.
• Disconnect the front frame harness connector
at a position near the transmission control box
and unlatch fixing clips from the harness.
N6A6216E
3. Disconnect the upper radiator hose on the engine

side.
4. Disconnect the coolant reserve tank hose on the
radiator side.
N6A6215E
5. Disconnect the lower radiator hose on the engine
• Remove two mounting bolts. side.
6. Remove the radiator (with the fan guide) detaching
right and left brackets.
7. Remove the fan assembly.
• Remove the fan assembly unscrewing four • Remove only the oil seal off with a screwdriver
mounting nuts. or the like avoiding damage to the oil seal
8. Remove the fan belt. contact surface on the front cover and the shaft.
N6A6233E N6A6235E
9. Remove the crankshaft pulley. Legend

1. Felt
• Loosen the pulley bolts blocking the crankshaft
2. Slinger
from turning by placing a crankshaft stopper on
3. Oil Seal
the starter mounting position on the flywheel
housing. 11. Remove the crankshaft front slinger.
Caution: • Pull out the slinger using a slinger puller.
Make sure that the stopper is properly fitted and (Fixing the circumference of the puller with a
engaged with the ring gear. clip band will make the procedure easier.)
Special tool Special tool

Crankshaft stopper: 5-8840-2230-0 (EN-47680) Slinger puller: 8-9439-6858-0 (J-43285)
N6A6234E N6A6236E
10. Remove the crankshaft front oil seal.

Installation • Put the sleeve over the adapter, place a washer
on the center bolt and tighten the bolt until the
1. Install the crankshaft front slinger.
sleeve touches the adapter to press fit the front
• Press-fit the slinger using an oil seal installer slinger.
kit.
N6A6238E
N6A6237E
• After you have pressed the front slinger, confirm
Legend the measurement shown (depth from the end
1. Front Slinger surface of the crankshaft to the flange of the
2. Adapter (Front) slinger) and check for deflection of the slinger.
3. Fixing Bolt
4. Sleeve (Front) Caution:
5. Washer (Front) Be careful not to put the slinger inside out or mistake
6. Center Bolt front side slinger for rear one, and vice versa. Rear side
slinger has four right-hand threads on it while front one
Special tool has four left-hand threads. Slinger and oil seal should
Oil seal installer kit: 5-8840-2703-0 (J-43282) always be replaced in pairs.
(Use the parts listed below for the front oil seal.)
No. Part Name Slinger Oil seal

1 Sleeve (front) { {
2 Adapter (front) { {
3 Adapter ring (front) — {
4 Washer (front) { {
5 Center bolt { {
6 Fixing bolt { {
• Insert the front slinger into the end of the

adapter and fit them on the crankshaft.
N6A6239E
Legend
1. Adapter
2. Sleeve
3. Slinger
4. 40.5 ± 0.3 mm (1.594 ± 0.012 in)
5. 34 ± 0.1 mm (1.339 ± 0.004 in)
2. Install the crankshaft front oil seal. • Tighten the bolt until the sleeve touches the
• Press fit the oil seal using an oil seal installer adapter to press fit the front oil seal.
kit.
N6A6242E
N6A6240E Legend
Legend 1. Oil Seal
1. Oil Seal 2. Adapter Ring
2. Adapter (Front) 3. Sleeve
3. Adapter Ring (Front) 4. Bolt and Washer
4. Fixing Bolt
5. Sleeve (Front)
6. Washer (Front)
7. Center Bolt
• Mount the adapter onto the crankshaft with

fixing bolts.
N6A6238E
N6A6241E
Legend
1. Adapter
• Apply engine oil to the lip of the oil seal and

place it on the front side adapter.
• Put the front side adapter ring in the sleeve and
fix the sleeve on the adapter with the center bolt
and a washer.
• After you have press-fitted the front oil seal, 4. Install the fan belt.
confirm the measurement shown (depth from • When adjusting the fan belt, you should also
the end surface of the crankshaft to the oil seal) adjust ACG belt and air conditioner belt at the
and check for deflection of the oil seal. same time.
• Fit the fan belt and adjust the tension following
the below procedures.
• Refer to “Drive Belt” in Section 6B for details of
the belt tension adjustment.
a. Inspection of fan belt deflection
• Check with a scale if the belt deflection is
within the specified limits when pressure of
98 N (22 lb) is applied mid-way along the
belt’s longest run. Also check the belt for
damage.
Fan belt deflection mm (in)

New belt 8 – 12 (0.31 – 0.47)
Reused belt 10 – 14 (0.39 – 0.55)
N6A6243E A/C belt deflection mm (in)
Legend New belt 16 – 20 (0.630 – 0.787)
1. Adapter Ring Reused belt 18 – 22 (0.709 – 0.866)
2. Sleeve
3. Adapter
4. Oil Seal
5. 31 ± 0.3 mm (1.220 ± 0.012 in)
3. Install the crankshaft pulley.

• Apply engine oil to the threads of the fastening
bolts.
• Install the crankshaft pulley aligning with the
dowel pins on the crankshaft.
• Tighten in the sequence shown.
Tighten:
N6A6245E
Legend
1. Crankshaft Pulley
2. Generator
3. Fan Pulley
b. Adjustment of the fan belt

• Loosen (2) and (3), adjust the fan belt
moving the generator.
Tighten:
Bolt (2) to 24 N⋅m (2.4 kg⋅m/18 lb⋅ft)
Bolt (3) to 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
N6A6244E
Rigid suspension model
N6A6246E
N6A6247E
Legend
1. Adjustment Bolt Legend
2. Fixing Nut 1. Flange Nut
3. Fixing Bolt 2. Rubber
3. Stud Bolt
5. Tighten the fan assembly to the specified 4. Frame Side Bracket
tightening torque. 5. Radiator Side Bracket
6. Washer
Tighten:
Nuts to 24 N⋅m (2.4 kg⋅m/18 lb⋅ft) 7. Connect the lower radiator hose.
8. Connect the coolant reserve tank hose.
9. Connect the upper radiator hose.
10. Install the starter in the clutch housing with bolts
and tighten to the specified tightening torque.
Tighten:
• Connect the starter ground cable.
• Connect the front frame harness connector.
N6A6233E
6. Install the radiator.

• Attach right and left brackets of the radiator to
the brackets on the frame as illustrated.
Tighten:
Brackets to 55 N⋅m (5.6 kg⋅m/41 lb⋅ft)
N6A6216E
11. Refill the radiator with coolant.

N6A6248E
Special Tool
Tool Number /
Illustration
5-8840-2230-0
(EN-47680)
Crankshaft Stopper
8-9439-6858-0 (J-43285)
Slinger Puller
5-8840-2703-0 (J-43282)
Oil Seal Installer Kit
Crankshaft Rear Oil Seal

Component
N6A6249E
Legend
1. Starter 6. Crankshaft Rear Oil Seal
2. Transmission Assembly 7. Crankshaft Rear Slinger
3. Clutch Pressure Plate Assembly (MT) 8. Flexible Plate (Smoother)
4. Clutch Plate Assembly (MT) 9. Crankshaft End Spacer (Smoother)
5. Flywheel (MT)
Removal
Refer to “Flywheel”.
2. Remove the crankshaft rear oil seal.
• Remove only the oil seal off with a screwdriver • Press fit the rear sling using the oil seal installer
or the like avoiding damage to the oil seal kit.
contact surface on the flywheel housing and the
shaft.
N6A6251E
Legend
N6A6235E 1. Rear Slinger
Legend 2. Fixing Bolt
1. Felt 3. Center Bolt
2. Slinger 4. Sleeve (Rear)
3. Oil Seal 5. Collar (Rear)
6. Adapter (Rear)
3. Remove the crankshaft slinger.
• Pull out the slinger using a slinger puller. Special tool
(Fixing the circumference of the puller with a Oil seal installer kit: 5-8840-2703-0 (J-43282)
clip band will make the procedure easier.)
Special tool No. Part Name Slinger Oil seal

Slinger puller: 8-9439-6858-0 (J-43285) 1 Sleeve (rear) { {
2 Adapter (rear) { {
3 Collar (rear) { {
4 Adapter ring (rear) — {
5 Center bolt { {
6 Fixing bolt { {
N6A6250E
Installation
1. Install the crankshaft rear slinger.
• Insert the rear slinger into the end of the rear
side adapter and mount the adapter on the
crankshaft with the fixing bolt with a collar
placed on it.
3 N6A6254E
Legend
1. Rear Part of The Crankshaft
2. Adapter
N6A6252E 3. 17.3 ± 0.3 mm (0.681 ± 0.012 in)
Legend 4. 10.8 ± 0.1 mm (0.425 ± 0.004 in)
1. Collar 5. Slinger
2. Fixing Bolt 6. Sleeve
3. Adapter 7. Collar
• Put a sleeve over the adapter and tighten the 2. Install the crankshaft rear oil seal.
center bolt until the sleeve touches the adapter • Press-fit the rear oil seal using an oil seal
to press fit the rear slinger. installer kit.
N6A6253E N6A6255E
• After you have press-fitted the rear slinger, Legend
confirm the measurement shown (depth from 1. Adapter (Rear)
the end surface of the crankshaft to the slinger) 2. Fixing Bolt
and check for deflection of the slinger. 3. Center Bolt
4. Sleeve (Rear)
Caution: 5. Collar (Rear)
Be careful not to put the slinger inside out or mistake 6. Adapter Ring (Rear)
the front slinger for the rear one, and vice versa. Rear 7. Oil Seal
side slinger has four right-hand threads on it while front
one has four left-hand threads. Slinger and oil seal
should always be replaced in pairs.
• Put a collar on the fixing bolt and mount the • Tightening the center bolt until the sleeve
adapter onto the crankshaft. touches the adapter to press fit the oil seal.
N6A6252E N6A6253E
Legend • After you have pressed in the rear oil seal,

1. Collar confirm the measurement shown (depth from
2. Fixing Bolt the end surface of the crankshaft to the oil
3. Adapter seal).
• Apply engine oil to the lip of the oil seal and

place it in the rear side adapter.
• Put the rear side adapter ring in the sleeve and
put the sleeve on the adapter and fix with the
center bolt.
N6A6257E
Legend
1. Rear Part of The Crankshaft
2. Oil Seal
3. 7.8 ± 0.3 mm (0.31 ± 0.012 in)
4. Collar
N6A6256E 5. Adapter Ring
Legend 6. Sleeve
1. Sleeve 7. Adapter
2. Adapter Ring
Special Tool
Tool Number /
Illustration
5-8840-2703-0 (J-43282)
Oil Seal Installer Kit
8-9439-6858-0 (J-43285)
Slinger Puller
Crankshaft
Component
N6A6258E
Legend
1. Upper Bearing 5. Lower Bearing
2. Upper Thrust Bearing 6. Lower Thrust Bearing
3. Gear 7. Crankcase
4. Crankshaft
Removal 5. Remove the cylinder head.

1. Demount the engine assembly.
Refer to “Engine Assembly”. 6. Remove the fuel supply pump.
Refer to “Fuel Supply Pump” in Section 6C.
Refer to “Cylinder Head Cover”. 7. Remove the crankshaft front oil seal.
3. Remove the rocker arm shaft.
Refer to “Rocker Arm Shaft Assembly”. 8. Remove the crankshaft rear oil seal.
4. Remove the camshaft.
Refer to “Camshaft Assembly”. 9. Remove the oil pan.
Refer to the “Oil Pan”.
10. Remove the water pump. 20. Remove the upper crankshaft bearings.
11. Remove the front cover.
Refer to “Front Cover”.
12. Remove the timing gear train.
Refer to “Timing Gear Train”.
13. Remove the oil pump.
Refer to “Oil Pump”.
14. Remove pistons and connecting rods.
Refer to “Pistons and Connecting Rod”.
15. Remove the crankcase.
• Gradually loosen crankcase mounting bolts in
the sequence shown and remove the
crankcase using the three replacer holes
(arrowed holes in the figure).
N6A6261E
Disassembly
1. Remove the gear.
• Remove the gear using a gear puller.
Special tool
Crankshaft gear puller: 8-9439-1097-0
(EN-47684)
N6A6259E
16. Remove the lower thrust bearing.

17. Remove the lower crankshaft bearings.
N6A6262E
Reassembly
1. Install the gear.
• Heat the gear to 170 – 250°C (338 – 482°F)
and install it aligning the groove on the gear
with the pin on the crankshaft.
N6A6260E
18. Remove the crankshaft assembly.

19. Remove the upper thrust bearing.
• Insert the gear at one push into the flange with
its end side with the alignment mark “S” facing
outward. If you are fitting the gear while it is
cold, beat the gear in until it impinges on the
end using the installer.
Special tool
Crankshaft gear installer: 5-8840-2667-0
(J-41222)
N6A6264E
2. Main bearing clearance

• Remove the crankshaft. Remove the main
bearings.
Set out disassembled main bearings in the
order of the numbers.
• Clean the crankshaft journal upper and lower
bearings and upper and lower thrust bearings.
N6A6263E • Check the bearings for damage or excessive
Legend wear. If you find damage or excessive wear in
1. Alignment Mark the check, replace the bearings in pairs.
• Place the upper bearings and the crankshaft on
the cylinder block. Install the crankshaft so that
it becomes horizontal.
Inspection
1. Thrust clearance Caution:
• Set a dial gauge as shown and measure the Turn the crankshaft about 30 degrees to allow the
crankshaft thrust clearance. bearings to settle in.
• If the thrust clearance exceeds the limit, replace
the thrust bearings in a pair.
Axial play of the crankshaft mm (in)

Standard 0.104 – 0.205 (0.0041 – 0.0081)
Limit 0.35 (0.0138)
Caution:
Measure the thrust clearance before dismounting.
N6A6265E
• Place Plastigage on the crankshaft journal as

shown.
• Place the lower bearings at original positions on
the crankcase.
N6A6268E
N6A6266E Tighten:
M14 bolts (1 – 10) to
• Install the crankcase and tighten bolts to the
specified tightening torque. 1st step: 98 N⋅m (10.0 kg⋅m/72 lb⋅ft)
2nd step: 132 N⋅m (13.5 kg⋅m/97 lb⋅ft)
• Tighten the crankcase in the sequence shown
using a torque wrench and an angle gauge. 3rd step: 30° – 60° (degrees)
M10 bolts (11 – 27) to
• Tighten the bolts (M14) from 1-10 and confirm
that they are tightened to a torque of 167 N⋅m
(17.0 kg⋅m/123 lb⋅ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
Caution:
Do not turn the crankshaft after you have tightened the
crankcase.
• Loosen the bolts and gently remove the

crankcase.
• Measure the widest part of the Plastigage
flattened by tightening the crankcase to
N6A6267E determine the clearance.
Journal oil clearance mm (in)

Standard Limit
No.1, 2, 4, 5 0.039 – 0.070 0.11
(0.0015 – 0.0028) (0.0043)
No.3 0.053 – 0.084 0.11
(0.0021 – 0.0033) (0.0043)
N6A6269E N6A6270E
• If the journal oil clearance exceeds the limit, 4. Measure the journal and the crankpin diameters
replace the main bearings altogether or the and uneven wear.
crankshaft. • Measure outer diameters of the journal and the
• Remove the Plastigage from the bearings and pin and calculate differences between the
the crankshaft. maximum and the minimum values. Take
measurements at four positions for both the
Inspection of the crankshaft journal and the pin.
• 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 mm (in)

Standard 0.05 or less (0.0020 or less)
Limit 0.30 (0.012)
N6A6271E
Crankshaft outside diameter mm (in)

Standard Limit
Journal #1, 2, 4, 5 81.905 – 81.925 81.85
(3.22460 – 3.22538) (3.222)
Journal #3 81.891 – 81.911 81.85
(3.22408 – 3.22483) (3.222)
Pin 72.902 – 72.922 72.850
(2.87015 – 2.87094) (2.8681)
Difference mm (in)
Limit 0.005 (0.0002)
Caution:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, do not
polish the surface of the crankshaft.
Crankshaft bearing selection

• When installing new crankshaft bearings or
replacing bearings in use, make reference to the
Bearing Selection Table.
• Select and install new bearings paying close
attention to the cylinder block journal internal
diameter grade and the crankshaft journal
diameter grade.
• Journals are numbered from 1 to 5 from left to right
when viewed so that the numbers are in normal
reading orientation.
N6A6274E
Legend
1. Upper Bearing
2. Oil Gallery
3. Grade Identification Color
4. Oil Groove
5. Lower Bearing
6. Grade Identification Color
N6A6272E
N6A6273E
Caution:
Be careful about difference in the shape of the bearings
when installing them.
Bearing Selection Table
Combination of grades Oil clearance mm (in)
Cylinder block Crank journal Bearing identification
#1, 2, 4, 5 #3
Grade Grade color
1 1 Black 0.039 – 0.070 0.053 – 0.084
(0.00154 – 0.00276) (0.00209 – 0.00331)
1 2 Brown 0.037 – 0.068 0.051 – 0.082
(0.00146 – 0.00267) (0.00201 – 0.00323)
2 1 Blue 0.041 – 0.072 0.055 – 0.086
(0.00161 – 0.00283) (0.00217 – 0.00339)
2 2 Black 0.039 – 0.070 0.053 – 0.084
(0.00154 – 0.00276) (0.00209 – 0.00331)
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing in the cylinder block
and apply oil.
Caution:
When replacing the crankshaft bearings, select grades
referring to the Bearing Selection table. Do not apply oil
to the bearing installation surface on the cylinder block
and external surface of the bearing.
N6A6276E
3. Install the crankshaft assembly.

• Apply engine oil to the crankshaft journal and
gently place the crankshaft on the cylinder
block.
• Press the crankshaft to the rear and insert the
upper thrust bearing in the rear side of the
cylinder block journal No.5.
Caution:
N6A6275E Install the thrust bearing so that the oil groove contacts
2. Install the upper thrust bearing. the crankshaft.
• Install the upper thrust bearing in the front side
of the cylinder block journal No.5. In doing this,
you may attach the upper thrust bearing to the
cylinder block with grease. Then, be sure to
wipe up excess grease.
Caution:
Install the thrust bearing so that the oil groove contacts
the crankshaft.
• Install the thrust bearing so that the oil groove
contacts the crankshaft.
N6A6277E
4. Install the lower crankshaft bearing.

N6A6278E
5. Install the lower thrust bearing.
6. Install the crankcase.
• Install the lower thrust bearing in the rear side
of the crankcase journal No.5. • Apply liquid gasket (ThreeBond 1207C or
equivalent) to the crankcase forming beads
with diameters of 3 – 4 mm (0.12 – 0.16 in).
• Install the crankcase within 7 minutes after you
have applied the liquid gasket.
• Gently place the crankcase on the cylinder
block.
N6A6279E
• Apply Molybdenum Disulfide to M14 bolt’s the specified tightening torque in the sequence
threads and setting faces and tighten them to shown.
• Do not apply any oil to M10 bolts. 17. Install the camshaft assembly.
Tighten:
M14 bolts (1 – 10) to 18. Install the rocker arm shaft assembly.
2nd step: 132 N⋅m (13.5 kg⋅m/97 lb⋅ft) 19. Install the cylinder head cover.
3rd step: 30° – 60° (degrees)
20. Mount the engine assembly on the chassis.
M10 bolts (11 – 27) to
Refer to “Engine Assembly”.
• Tighten bolts from 1-10 (M14) and confirm that
they are tightened to a torque of 167 N⋅m (17.0
kg⋅m/123 lb ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
Caution:
Confirm that the crankshaft turns smoothly.
N6A6268E
7. Install pistons and connecting rods.

Refer to “Piston and Connecting Rod”.
8. Install the oil pump.
9. Install the timing gear train.
10. Install the front cover.
Refer to the “Front Cover”.
11. Install the water pump.
13. Install the crankshaft rear oil seal.
14. Install the crankshaft front oil seal.
15. Install the fuel supply pump.
N6A6280E
Special Tool
8-9439-1097-0
5-8840-2667-0 (J-41222)
(EN-47684)
Crankshaft Gear Installer
Crankshaft Gear Puller
Tool Number /
Illustration
5-8840-0266-0 (J-45059)
Angle Gauge
Cylinder Block
Component
N6A6281E
Legend
1. Cylinder Liner 3. Cover (For Europe)
2. Cylinder Block
Removal 6. Remove the fuel supply pump.

1. Demount the engine assembly.
7. Remove the crankshaft front oil seal.
Refer to “Engine Assembly”. Refer to “Crankshaft Front Oil Seal”.
2. Remove the cylinder head cover. 8. Remove the crankshaft rear oil seal.
Refer to “Cylinder Head Cover”. Refer to “Crankshaft Rear Oil Seal”.
3. Remove the rocker arm shaft assembly. 9. Remove the oil pan.
Refer to “Rocker Arm Shaft Assembly”. Refer to “Oil Pan”.
4. Remove the camshaft assembly. 10. Remove the water pump.
Refer to “Camshaft Assembly”. Refer to “Water Pump” in Section 6B.
5. Remove the cylinder head. 11. Remove the front cover.
Refer to “Cylinder Head”. Refer to the “Front Cover”.
12. Remove the timing gear train. • Conduct color check and hydraulic (or
Refer to “Timing Gear Train”. pneumatic) test and if you find crack or other
13. Remove the oil pump. damage, replace the cylinder block.
14. Remove pistons and connecting rods.
15. Remove the crankshaft.
Refer to “Crankshaft”.
16. Remove piston oil jet.
N6A6283E
5. Cylinder liner wear measurement

• Check the internal surface of the liner for flaw or
damage.
• Measure the liner bore diameter at the most
worn part (it wears more in the rotation
N6A6282E direction) at 15 – 20 mm (0.59 – 0.79 in) from
the top end of the liner with the liner installed in
17. Remove the cylinder liner.
the cylinder block. If the wear is over the
If the cylinder liner cannot be pulled free by hand,
application limit, replace it.
tap around the lower side of the liner with a
hammer grip or similar object loosen it.
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
• 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.
N6A6284E
Cylinder liner bore diameter mm (in)

Standard 115.021 – 115.050
(4.52837 – 4.52952)
Limit 115.20 (4.5354)
Caution:
You need not select piston grade since cylinder liner
bore is only available in one size against the liner grade
selection of its outer diameter.
6. Cylinder block upper face warpage

• Pull out the cylinder liners and remove water
stains on the cylinder block.
• Measure four sides and two diagonals of the
top surface of the cylinder block using a straight
edge and a thickness gauge.
• Replace the cylinder block if the measurements
exceed limit values.
Cylinder block upper face warpage mm (in)

Standard 0.05 or less (0.002 or less)
N6A6286E
Limit 0.20 (0.079)
Cylinder block bore and liner grade

(for reference) mm (in)
Grade (1,2)/(1X) (3)/(3X)
Cylinder
118.001 – 118.020 118.021 – 118.030
block
(4.64699 – (4.64649 –
Bore
4.64654) 4.64684)
diameter
Liner 117.991 – 118.000 118.001 – 118.010
outside (4.64531 – (4.64570 –
diameter 4.64566) 4.64605)
(Reference)
When replacing liners, a “liner set” let you
obtain a piston of proper grade for a given liner
bore diameter only by specifying a liner outside
diameter grade.
N6A6285E
2. Install the cylinder liners.
• Install the cylinder liners perpendicular to the
Installation cylinder block.
1. Cylinder liner grade selection • Do not hammer the liner or apply excessive
force to insert it.
• Select liner outer diameter grades according to
the cylinder block bore grades stamped on the Caution:
cylinder block at arrowed positions in the figure. Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
Grade matching of cylinder block and liner
Grade of Cylinder block (stamp) 1, 2 3
Grade of Liner outside diameter 1X 3X
Caution:
Be careful not to deform or damage the oil jet nozzle.
N6A6287E
3. Amount of the cylinder liner extrusion

Measure the amount of the cylinder liner extrusion
N6A6289E
using a dial gauge.
Difference of the amount of the extrusion between 5. Install the crankshaft.
adjacent two cylinders should be within 0.03 mm Refer to “Crankshaft”.
(0.0012 in). 6. Install pistons and connecting rods.
7. Install the oil pump.
Amount of the cylinder liner extrusion mm (in)
Standard 0.05 – 0.10 (0.0020 – 0.0039) 8. Install the timing gear train.
Caution: 9. Install the front cover.
Be sure to measure the cylinder liner extrusion Refer to “Front Cover”.
whenever you have replaced cylinder liners.
10. Install the water pump.
12. Install the crankshaft rear oil seal.
13. Install the crankshaft front oil seal.
N6A6171E Refer to “Cylinder Head Cover”.
4. Install the piston oil jet. 19. Mount the engine assembly on the chassis.
• Align the dowel pin of the oil jet with the pin hole Refer to “Engine Assembly”.
on the cylinder block and tighten with the check
valve.
Tighten:
Lubrication System
Service Precautions • Avoid excessive or insufficient coating amount.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the starting and ending piston of
and apply the specified new fluid gasket at each application should be overlapped.
location.
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
N6A6647E
Functional Check
Oil pressure check
1. Check whether the engine oil is contaminated with
dirt, fuel or water. If contaminated with dirt, fuel, or
water (after examining the cause and taking the
appropriate measures for fuel 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 oil filter
body.
4. Install the oil pressure gauge on the oil filter body. Engine oil
• Ensure the car is at a level ground. Before starting
Special tool the engine or when 5 minutes or more have
Oil pressure gauge set: elapsed after stopping the engine, check the
5-8840-2843-0 engine oil volume using the level gauge. The
(Oil pressure gauge: J-43630-20) volume is appropriate if the engine oil is between
(Hose: J-43630) the upper and lower limits of the level gauge.
(Connector: J-43630-14) Replenish the engine oil, if level is below the lower
(Oil pressure testing adapter: EN-46333) limit. Also, check for contamination of the engine
oil.
N6A6292E
N6A6291E
Legend
1. Oil Filter Cartridge
2. Oil Pressure Testing Adapter
3. Connector
4. Hose
5. Oil Pressure Gauge
5. Warm the engine.

6. Measure the oil pressure, to check whether it is
more than 343 kPa (3.5 kg/cm2 / 50 psi) at N6A6293E
3200 rpm. Legend

7. Stop the engine. 1. Upper Limit
8. Remove the oil pressure gauge. 2. Lower Limit
9. Install the oil pressure switch.
10. Start the engine and check for oil leakage. Engine oil leakage
• In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
Special Tool
Tool Number /
Illustration
5-8840-2843-0
Oil Pressure Gauge Set
(J-43630-20 /
Oil Pressure Gauge,
J-43630 / Hose,
J-43630-14 / Connector,
EN-46333 / Oil Pressure
5884028430 Testing Adapter)
Oil Filter Assembly

Components
N6A6294E
Legend
1. Oil Pressure Switch 3. O-ring
2. Oil Filter Body
Removal
1. Place a tray under the oil filter cartridge.
2. Remove the oil filter cartridge.
3. Remove the oil pressure switch.
4. Remove the oil filter body.
5. Remove the O-ring.
Installation
1. Install the O-rings and on the oil filter body.
N6A6297E
N6A6295E
Legend
1. O-ring
2. O-ring
2. Install the oil filter on the cylinder block and tighten

it using the specified torque.
Tighten:
Nuts and bolts to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
N6A6296E
3. Install the oil pressure switch on the oil filter body.

• Apply the liquid gasket (Loctite 262) on 2 to 3
peaks from the tip of the threaded part of the oil
pressure switch and install it at the position
shown in the figure.
Tighten:
Oil pressure switch to 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
Oil Filter Cartridge

Components
N6A6298E
Legend
1. Oil Filter Cartridge
Removal • Tighten the cartridge using the specified torque.

1. Place a tray under the oil filter cartridge. Tighten:
2. Remove the oil filter cartridge using the oil filter Cartridge to 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
wrench. After it comes in contact with the oil seal, tighten it
through an additional turn of 1 and 1/4.
Special tool
Oil filter wrench: 1-8522-1097-0 (EN-47683) Special tool
Oil filter wrench: 1-8522-1097-0 (EN-47683)
N6A6299E
Installation
1. Install the oil filter cartridge.
• Apply grease or engine oil to the seal in the
cartridge and install it using the oil filter wrench.
Special Tool
Tool Number /
Illustration
1-8522-1097-0
(EN-47683)
Oil Filter Wrench
Oil Cooler
Components
N6A6300E
Legend
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Fuel Rail
Removal 2. Remove the fuel supply pump.

Refer to “Fuel Rail” in Section 6C.
N6A6055E
3. Remove the A/C drive belt.

4. Remove the idling pulley bracket. • Screw the removed fixing bolt of the oil cooler
• Remove the drive belt for A/C and the bracket into the replacer hole at the location 1 of the
fixing bolts, and then remove the bracket along figure and remove the oil cooler.
with tensioner and idling pulley.
N6A6303E
N6A6301E Legend
5. Remove the EGR cooler water return pipe. 1. Oil Cooler Assembly
• Remove the brackets to the water pipe at three 9. Remove the O-ring.
locations to make the pipe unsupported.
6. Remove the EGR cooler water feed pipe.
7. Remove the clip on the head side of the water Disassembly
bypass hose and remove the hose from the 1. Remove the element mounting bolts.
suction pipe and assembly. 2. Remove the element.
3. Remove the O-ring.
N6A6302E
Legend N6A6304E
1. Bypass Hose
Legend
2. EGR Cooler Water Return Pipe
1. Element
3. EGR Cooler Water Feed Pipe
2. O-ring
4. Suction Pipe
8. Remove the oil cooler assembly.

Reassembly
1. Install the O-ring on the oil cooler case.
2. Install the element.
3. Tighten the element fixing bolts using the specified • Install the O-rings (1) and (2) to the oil passage
torque. inlet and outlet. Do not allow the liquid gasket to
contact the O-ring.
Tighten:
N6A6305E
Legend
N6A6304E
1. O-ring
Legend 2. O-ring
1. Element 3. Liquid Gasket
2. O-ring
- Align the oil cooler holes with the cylinder
block studs.
Installation - Install the oil cooler and glow plug controller
bracket to the cylinder block.
1. Install the oil cooler assembly.
- Tighten the bolts to the specified torque in
• Apply liquid gasket (ThreeBond1207C or the order shown in the illustration.
equivalent) to the flange surface groove
(cylinder block). Bead diameter must be Tighten:
between 2 and 4 mm (0.08 and 0.16 in). Bolts to 24 N⋅m (2.4 kg⋅m/18 lb⋅ft)
Refer to the illustration for the offset position • Liquid gasket quickly hardens.
(no more than 1 mm (0.04 in)). Make it complete within 7 minutes after
applying the liquid gasket.
N6A6306E
Legend
1. Oil Cooler Assembly
2. Install the water suction pipe. • Install the O-ring on the EGR cooler water feed
• Apply liquid gasket (ThreeBond 1207C) to the pipe.
flange of the water suction pipe. Bead diameter • Install at the position shown in the figure and
must be between 2 and 5 mm (0.008 and 0.20 tighten using the specified torque.
in). Refer to the illustration for the offset
Tighten:
position (no more than 1 mm (0.04 in)).
• Install the water suction pipe to the oil cooler.
Refer to the illustration.
• Tighten the bolts to the specified torque.
Tighten:
N6A6308E
4. Install the EGR cooler water pipe.

5. Install the body cover assembly LH on the surface
of the oil cooler and cylinder block and tighten it
using the specified torque.
N6A6307E
Tighten:
Legend Body cover assembly LH to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
1. Liquid Gasket
6. Install the idling pulley bracket and tighten it using
Caution:
The water suction pipe must be installed immediately Tighten:
after the oil cooler (the pipe and cooler use the same Idling pulley bracket to 24 N⋅m (2.4 kg⋅m/18 lb⋅ft)
liquid gasket). 7. Install the A/C drive belt.
Refer to “Drive Belt” in Section 6B.
N6A6308E
N6A6310E
3. Install the EGR cooler water feed pipe. 8. Remove the oil drain adapter.
• Refer to “Fuel Supply Pump” in Section 6C.
• Refer to “Fuel Rail” in Section 6C.
Oil Pan
Components
N6A6311E
Legend
1. Oil Pan Gasket 3. Oil Pan Rubber (For Europe)
2. Oil Pan
Removal Installation
1. Drain out the engine oil. 1. Install the oil pan.
• Install the drain plug. • At the seam between the cylinder block and the
front cover with the flywheel housing, apply the
Tighten:
liquid gasket (ThreeBond 1207C or equivalent)
Drain plug to 8.5 N⋅m (0.9 kg⋅m/61 lb⋅ft)
to a bead diameter of 3 mm (0.12 in).
• Apply the liquid gasket and install the oil pan • Tighten the locations (1), (2), (3), and (4) as
within 7 minutes. shown in the figure and then tighten others. (In
any sequence)
N6A6075E
For Europe N6A6077E
• Install the gasket using the studs of the Tighten:

crankcase, flywheel housing, and front cover as Nuts and bolts to 11 N⋅m (1.1 kg⋅m/95 lb⋅in)
guide and mount the oil pan.
Install the rubber assembly on the oil pan and Except Europe
secure it using nuts and bolts. • As the figure shows, apply the liquid gasket
(Three bond 1207C or equivalent) inside a hole
of the bolt evenly.
mm (in)
1 - 3 (0.04 - 0.12)
N6A6518E
• Tighten the oil pan nut and bolts to the specified

torque in the numerical order as shown in the
figure.
▲ marks are located on nut positions.
Tighten:
Star mark bolt to 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
N6A6076E
Other bolts and nuts to 24N⋅m (2.4 kg⋅m/17 lb⋅ft)
Legend
1. Rubber Assembly (For Europe)
2. Oil Pan
3. Gasket
N6A6519E
Oil Pump
Components
N6A6312E
Legend
1. Oil Pump Assembly 5. Driven Gear and Shaft
2. Spring 6. Oil Pump Body
3. Ball 7. Slinger
4. Split Pin
Removal 10. Remove the flywheel.

1. Drain out the engine oil.
11. Remove the rear oil seal of the crankshaft.
2. Drain out the cooling water.
13. Remove the power steering pump.
Refer to “Rocker Arm Shaft Assembly”. 14. Remove the idle gear cover of the power steering
pump.
7. Clutch pressure plate assembly
8. Driven plate
9. Remove the fuel supply pump assembly.
15. Remove the idle gear of the power steering pump. 17. Remove the idle gear A.
N6A6058E N6A6313E
16. Remove the flywheel housing. 18. Remove the oil pump assembly.
• Make sure you remove the bolts shown in the
figure.
N6A6314E
N6A6059E
Disassembly
1. Remove the driven gear and shaft.
2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin and fold it according to (1).
N6A6316E
N6A6315E
2. Measure the clearance between the gear side
4. Apply engine oil on the driven gear and shaft and surface and the upper surface of the oil pump
mount them on the oil pump body. body.
• Measure the clearance between the gear
surface and the upper surface of the oil pump
body using the thickness gauge and square.
• If the clearance between the gear and inner
wall of the body exceeds the limit, replace the
gear assembly or the driven gear assembly.
Clearance between the gear side surface

and the upper surface of the oil pump
body mm (in)
Standard 0.064 – 0.109 (0.0025 – 0.0043)
Limit 0.20 (0.0079)
N6A6316E
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Measure the clearance between the gear and
oil pump body using a thickness gauge.
• If the clearance between the gear and inner
wall of the body exceeds the limit, replace the
gear assembly or the driven gear assembly.
Clearance between the gear and inner

wall of the body mm (in)
N6A6318E
Standard 0.125 – 0.220 (0.0049 – 0.0087)
3. Measure the clearance between the driven gear
Limit 0.30 (0.0118) shaft and the bush.
• Measure the outside diameter of the driven
gear shaft using a micrometer.
Installation
Outside diameter of the driven gear shaft mm (in) 1. Install the oil pump assembly.
Standard 15.989 – 16.000 (0.62949 – 0.62992) • Apply the liquid gasket (ThreeBond 1141E or
equivalent) as shown in the figure, mount it on
Limit 15.900 (0.62598) the cylinder block within one hour, and tighten it
Tighten:
Oil pump assembly to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Caution:
Apply the fluid gasket such that it does not enter the
holes shown by arrows in the figure, gear, and the oil
pump body.
N6A6319E
• Measure the inside diameter of the bushes of

the oil pump body and cylinder block using the
dial gauge.
• If the clearance between the driven gear shaft
and bush exceeds the limit, replace the driven
gear assembly.
N6A6321E
2. Install the idling gear A.

Clearance between the driven gear shaft
and bush mm (in) • Install the idling gear shaft at the position
shown in the figure and apply engine oil on the
Standard 0.04 – 0.07 (0.0016 – 0.0028) shaft.
Limit 0.20 (0.0079) • Rotate the crankshaft clockwise and bring the
piston of the No.1 cylinder to the top dead
center.
N6A6320E
N6A6067E
• Match the coincidence marks of the crankshaft
Tighten:
gear and the idle gear A, and install them on
the cylinder block.
• The seal is tightened from the cylinder block
side.
N6A6322E
• Tighten the mounting bolts using the specified

torque.
Tighten:
3. Install the flywheel housing.
• Clean properly the rear surface of the cylinder
block. Remove the protruding fluid gasket
thoroughly, especially, when mounting the
crankcase.
• Apply the liquid gasket (ThreeBond1207C)
uniformly on the inside surface of the bolt holes
(excluding the bolt holes indicated by arrows)
as shown in the figure.
• After applying the liquid gasket, quickly install it.
N6A6069E
• Match the dowel pin of the cylinder block and

then install the flywheel housing.
N6A6070E
4. Install the power steering pump idling gear.

• Apply the engine oil on the gear assembly unit
of the idling gear shaft.
• Assemble the idling gear and the shaft in the
direction shown in the figure, mount it on the
flywheel housing, and tighten it using the
specified torque.
Tighten:
N6A6071E
5. Install the idling gear cover of the power steering

pump.
• Install the O-ring on the cover and on the
flywheel housing, and tighten the fixing bolts
Tighten:
N6A6072E
With HBB
N6A6073E
6. Install the power steering pump and tighten it using N6A6074E
the specified torque. Legend

1. Flywheel Housing Bolt
Tighten:
2. Cylinder Block Bolt
Flywheel housing fixing bolt (1) to 43 N⋅m (4.4 kg⋅m/32
lb⋅ft)
Cylinder block fixing bolts (2) to 44 N⋅m (4.5 kg⋅m/33 Refer to “Oil Pan”.
lb⋅ft)
8. Install the rear seal of the crankshaft.
Without HBB Refer to “Crankshaft Rear Oil Seal”.
10. Install the fuel supply pump assembly.
11. Install the clutch plate assembly.
12. Install the clutch pressure plate assembly.
• Insert the clutch aligner in the spline of the
clutch plate assembly.
• Install the clutch plate assembly on the
flywheel.
N6A0775E
• Match the mounting hole of the clutch pressure
plate assembly with the dowel pin of the
flywheel, and install the clutch pressure plate
assembly on the flywheel.
N6A6218E
Legend
1. Clutch Aligner
• Tighten the clutch pressure plate assembly in

the sequence shown in the figure using the
specified torque.
Tighten:
N6A6217E

16. Tighten the cylinder head cover.
Oil Pressure Switch

Inspection
Check the continuity between the switch terminal and
the body grounding in the no-load condition.
If there is no connectivity, replace with normal parts.
(Refer to “Oil Filter Assembly”)
N6A6323E
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.
N6A6324E
Air Cleaner Element

Removal
1. Remove the air cleaner cover fixing bolt.
2. Remove the air cleaner element assembly.
Inspection
• Check for damage to the element or clogging due
to dirt. If the element is damaged, then replace it. If
clogged, then clean it.
• The viscous-type (wet type) element cannot be
cleaned; therefore, it has to be replaced if it is very
dirty.
Replacement period Every 40,000 km (24,000

miles) or every two years
Installation
1. Install the air cleaner element assembly.
2. Tighten the air cleaner cover fixing bolt.
Cleaning
Dry type element
• While rotating the element, blow air under 690 kPa
(7.0 kg/cm2 / 100 psi) and remove the dust.
N6A6325E
• Dissolve the filter cleaner ND1500 in water and

soak the element for approximately 30 minutes.
Then wash it properly with water and allow it to dry
in natural conditions (two to three days.)

6a 4hk1 Engine Mechanical

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Engine Mechanical (4HK1-TC) 6A-1

ISUZU DIESEL ENGINE (4HK1-TC)

Explanation of Functions and Operations Cylinder Liner

• Install the minus terminal of the battery.

Compression gauge set: 5-8840-2008-0

Compression pressure MPa (kg/cm2 / psi) /

• Measure each cylinder one by one.

• Remove a compression gauge of the special tool.

Condition Possible Cause Correction

Engine turns over but does not start

Condition Possible Cause Correction

Condition Possible Cause Correction

Excessive white exhaust smoke

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Abnormal engine rotation

Condition Possible Cause Correction

Abnormal battery charging

Condition Possible Cause Correction

Condition Possible Cause Correction

Condition Possible Cause Correction

Item Engine model 4HK1-TCS Engine model 4HK1-TCN

Item Engine model 4HK1-TCS Engine model 4HK1-TCN

8. Remove the upper hose of the radiator.

6. Remove the inlet hose (between air cleaner and

• Turn the engine at an angle of 90 degrees to

N6A6017E • Make the transmission side lower and operate

6. Install the power steering oil hose. Legend

13. Install the AC generator harness.

22. Install the inlet hose (between air cleaner and

23. Install the charge air hose (between turbocharger

• Before removing the engine mount, hang the

Cylinder Head Cover (Except Europe)

Cylinder Head Cover (For Europe)

4. Remove the cooling water pipes.

8. Remove the sound insulation cover (1).

4. Install the gasket on the head cover. Legend

Tighten: 7. Mount the EGR valve.

8. Install the EGR cooler.

9. Install the EGR adapter.

N6A6029E 10. Install the EGR pipe.

1. Remove the fuel rail.

5. Remove the inlet cover.

Turbocharger and Exhaust Manifold

Removal 6. Remove the A/C compressor harness.

Axle play mm (in)

Manifold installation plane surface mm (in) N6A6043E

• Check a crack in the exhaust manifold visually.

Waste gate operation (absolute pressure)

2. Install the gasket and turbocharger to the exhaust

3. Use the pressure gauge pump to apply pressure

Movement, mm (in) 0.38 (0.0150) 4.00 (0.1575)

Tighten: 7. Install the turbocharger oil feed pipe to the top of

5. Install the water return pipe. Tighten the joint bolts

15. Install the EGR pipe.

Timing Gear Train

Removal 3. Remove the camshaft assembly.

In the case of smoother vehicle, after loosening the