4JJ1-Engine Manual (KM-4JJ1-E-00)

I n t roduct ion
This Manual describes the structure and the troubleshooting of electronic control
fuel injection system (common rail type) in 4JJ1 industrial engines.
Use this manual sufficiently to perform service work properly and quickly.
Hitachi Construction Machinery Co., Ltd

General Contents
Disassemble and Assemble Engine

General Information
Engine Mechanical (4JJ1)
Cooling System
Fuel System
Engine Electrical
Exhaust System and Turbocharger
Engine Manual (1/2)

Control System
4JJ1 Electronic control fuel injection system (Common rail type)
General Information
Disassemble and Assemble Engine

General Information
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2
Reading the Model . . . . . . . . . . . . . . . . . . . . . . . 0A-6
General Information . . . . . . . . . . . . . . . . . . . . . . 0A-6
0A-2 General Information
General Information
Service Precautions
In order to carry out work safely
1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical
system, always remove the minus side cable from
the battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.
WSHK0190
6. All regular tools, gauges and special tools should

be regularly inspected, and prepared before
starting work. Do not use bent spanners, hammers
with damaged edges, chipped chisels, or any other
faulty or damaged tools.
4. Do not perform painting work or leave the engine

running for long periods of time in an enclosed or
badly ventilated indoor workshop.
5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may
cause damage to the parts or injury to the person
using the tool.
7. Always pay close attention to safety and handling
requirements when using grinders, cranes,
welders, and other such equipment.
Moreover, always wear the correct protective
garments and use the necessary safety tools for
the job in hand.
General Information 0A-3
WSHK0191 WSHK0192
8. Always check that there are no fuel leaks when

performing maintenance work on the fuel system. Replacement parts and part numbers.
(It may cause a fire.) 1. Always replace packing, oil seals, o-rings, caulking
lock nuts, folding lock plates, split pins and other
such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to
revisions. Therefore, parts should always be
checked against a parts catalogue before use.
Liquid gasket
1. Each time you disassemble parts that use liquid
gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to
completely remove oil, water, and dirt etc. from the
various surfaces. Using the specified type of liquid
gasket, apply new liquid gasket to each of the
surfaces before reassembling the parts.
2. In order to make it easier to clean liquid gasket
9. Pay close attention to the risk of ignition if you are surfaces, apply gasket remover liquid (Pando-
handling parts that carry a high voltage. 391D made by Three Bond Co., Ltd.) and leave
Furthermore, any oil or grease spilt onto rubber the part to stand for approximately 10 minutes,
parts must be wiped off immediately, as it will after which the old liquid gasket residue will be
cause deterioration of the rubber. easier to remove.
However, this should not be used on resin
components or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when re-
installing the liquid gasket parts to each other. If
there are gaps between the two parts, re-apply the
liquid gasket. Some parts, especially the oil pan,
use the same size studs as a guide to eliminate the
need for knock pin positioning etc.
5. Re-install these parts within 5 minutes of applying
the liquid gasket.
If more than 5 minutes passes, remove the
previous liquid gasket and re-apply it.
6. Please wait for at least 30 minutes since the last
part is installed before starting the engine.
Liquid gasket
Seal section Product name Manufacturer's name

Between cylinder head and upper timing chain cover 1207B Three Bond
Between cylinder block and crank case 1207B Three Bond
Between oil cooler ASM and gear case cover 1207B Three Bond
Between gear case and cylinder head 1207B Three Bond
Between gear case and gear case cover 1207B Three Bond
Among gear case and cylinder block and crank case 1207B Three Bond
Between gear case cover and lower timing chain cover 1207B Three Bond
Among cylinder block and crank case and retainer 1207B Three Bond
Between cylinder head and cam end packing 1207B Three Bond
Cylinder block, head plug nipple, unit, switches 262 Loctite
• Always use the liquid gasket products listed above,

or a liquid gasket identical to the ones listed above.
• Use the correct quantity of liquid gasket. Always
follow the handling instructions for each product.
Application procedure
1. Wipe the contact surfaces clean of all water,
grease or oil. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.
Notes:
If there are special regulations concerning the
application procedure in the repair document, please
follow those regulations.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
Important:
screw thread section clean of water, grease, and
After tightening the bolt, do not apply excessive torque
oil. The contact surfaces should be dry.
or try to rotate the bolt until at least one hour has
2. Apply Loctite to the top 1/3 of the screw. passed, and the Loctite has hardened.
3. Tighten the bolt to the correct tightening torque.
Procedure for using the Plastigauge
Type Measurable range mm (in)

PG-1 (Green) 0.025 – 0.076 (0.001 – 0.003)
PR-1 (Red) 0.051 – 0.152 (0.002 – 0.006)
PB-1 (Blue) 0.102 – 0.229 (0.004 – 0.009)
Example: Procedure for measuring the clearance

between the connecting rod bearing and crank pin.
• Clean the connecting rod and bearing, and install • Clean the clamp face of the cylinder block and
the bearing to the rod. crankcase bearing, and also the bearing, and
• Cut the plastigauge to the same width as the crank install the cylinder block to the crankcase.
pin, and while avoiding the oil pore of the crank pin • Gently rest the crankshaft on the cylinder block,
lay the gauge parallel to the pin. and rotate it approximately 30 degree to stabilize it.
• Line up the marks on the connecting rod and cap • Cut the plastigauge to the same size as the journal
and install the crank pin, apply molybdenum width, and while avoiding the oil pore of the journal
disulfide to the thread section and bearing surface lay the gauge parallel to the journal.
of the fastening bolt, and rotate both cap and bolt • Gently rest the crank case on the cylinder block,
to the correct torque. apply molybdenum disulfide to the thread section
and bearing surface of the fastening bolt, and
Important: tighten in sequence to the correct torque.
Do not move the connecting rod while using the
plastigauge. Important:
• Gently remove the cap and connecting rod, and Do not rotate the crankshaft while using the
measure the crushed width of the plastigauge plastigauge.
(clearance between rod and pin) using the scale • Gently remove the crankcase, and measure the
printed on the bag. crushed width of the plastigauge (clearance
between bearing and journal) using the scale
printed on the bag.
Example: Measuring the clearance between the crank

bearing and crank journal
Reading the Model
Engine number stamping position
Front Rear
WSJJ0181
General Information
Terminology, description of abbreviations
Terminology definitions
Term Explanation
Maintenance standard The generic name for reference values required for maintenance, such as nominal
dimension, selection of a reference point, and limit.
Nominal dimension Shows the standard value at the point of manufacture that does not include the
common difference.
Selection of a reference point Shows the standard value after assembling, repairing, or adjusting.
Limit When this value (dimensions) is reached, it shows that the part has reached its full
limit and must be replaced or repaired.
Front ⋅ rear, left ⋅ right, upper ⋅ These show each orientations of parts installed to the vehicle when looking from
lower the vehicle's forward direction.
Unit Units written to SI conventions (mainly torque, pressure, force)
[Example] Length: mm, Torque: N⋅m {kgf⋅m}
Warning Items that carry the warning mark pose a danger to life or threat of serious injury if
not strictly observed.
Caution Items that carry the caution mark may cause injury or lead to accidents if not strictly
observed.
Important Items that carry the important mark may cause the vehicle to break down, or may
prevent the guaranteed normal operation of the system or related parts if not strictly
observed.
Term Explanation
Notes Items that should receive special mention within a work procedure.
Description of abbreviations Abbreviation Description

FWD Forward
Abbreviation Description Forward
AC Alternating Current F/C Fuel Cut
Alternating Current Fuel Cut
ACC Accessory GND Ground
Accessory Earth
ACG Alternating Current Generator IC Integrated Circuit
Alternating current generator Integrated circuit
API American Petrol Institute ID Plate Identification plate
American Petroleum Institute Identification plate, ID plate
ASM (Assy) Assembly IN Intake, Intake
Assembly Intake
ATDC After Top Dead Center ISO International Organization for
After Top Dead Center Standardization
International Organization for
BAT, BATT Battery
Standardization
Battery
I/PUMP Injection Pump
BRG, Brg Bearing
Injection Pump
Bearing
JIS Japanese Industrial Standard
BKT, BRKT Bracket
Japanese Industrial Standard
Bracket
L/H, LH Left Hand
BTDC Before Top Dead Center
Left hand side
Before Top Dead Center
M/V Magnetic Valve
CO Carbon Oxide
Magnetic valve
Carbon Monoxide
NOx Nitrogen Oxide
CONN Connector
Nitrogen Oxide
Connector
N-TDC Number - Top Dead Center
CPU Central Processing Unit
Top dead center rotational frequency
Central processing unit
OPT Option
C/U Control Unit
Option
Control unit
P Pole(S)
DC Direct Current
Pole
Direct current
PCV Pump Control Valve/ Positive
DI Direct Injection
Crankcase Ventilation
Direct injection
Pump control valve/ Positive crankcase
ECU Engine Control Unit / Electronic Control ventilation
Unit
PM Particulate Matter
Engine control unit / control unit
Particulate matter
ECM Engine Control Module
PS Pre-Stroke
Engine control module
Pre-stroke
EGR Exhaust Gas Recirculation
PTO Power Take Off
Exhaust gas recirculation
Power take off
Exh, EXH Exhaust
QOS Quick On System
Exhaust
Rapid preheating system
Ft, FRT Front
Rr, RR Rear
Front
Rear
Abbreviation Description SI (International System of Units)
R/H, RH Right Hand With regards the conversion to SI (International

Right hand side System of Units)
The introduction of the SI systems aims to
R/L Relay
internationally unify the metric system and the various
Relay
units used by different countries (traditional weights
STD Standard and measures, the foot pound method etc.), and to
Standard curb the confusion that occurs between the different
SW Switch units (conversion calculations etc.).
Switch The new calculating method which adopted SI units
was completely adopted in Japan in 1992, and is
TICS Timing & Injection rate Control System standardized by JIS-Z-8203.
A type of injection system All of the units in this manual are written in line with the
VGS Turbo Variable Geometry turbocharger International System of Units SI units, and conventional
System units are written in { } brackets.
Adjustable turbo, VGS turbo SI
W/L Warning Lamp French) Abbreviated name of Le Systeme International
Warning lamp d’Unites
Connection between main SI units and conventional units
SI Conventional Unit Item, unit conversion

Length m m Same as the conventional unit
Weight (Mass) kg kg Same as the conventional unit
Force N * kg, kgf 1 kgf = 9.80665 N
Torque N⋅m * kg⋅m, gf⋅m 1 kgf⋅m = 9.80665 N⋅m
Pressure Pa *kg/cm2, mmHg 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa
Dynamic force, horsepower W PS 1 PS = 0.74 kW
Capacity, air volume displacement m3 Litle, L, cc 1 Litle = 1 dm3, 1 cc = 1mLitle = 1cm3
Fuel consumption g/(kW⋅h) g/(PS⋅h) 1 g/(PS⋅h) = 1.360 g/(kW⋅h)
*1 Published service data may conveniently use kg for

force and mass (weight) instead of kgf.
*2 Some conversion results may be rounded off to 1 or
2 decimal places.
Converting expressions of quantity
When converting, prefixes such as k (kilo) or m (mili)
are used.
M Mega 106 1,000,000

k Kilo 103 1,000
h Hecto 102 100
d Deci 10-1 0.1
c Centi 10-2 0.01
m Milli 10-3 0.001
µ Micro 10-6 0.000001
• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa

• 40 mmHg = 5,332 Pa = 5.3 kPa
Table of standard Isuzu tightening torque
The tightening torque values in the table below apply to
all situations unless a special tightening torque is
specified.
Isuzu standard bolts, nuts
N⋅m {kgf⋅m}
Strength 4.8
7T
classification 4T
Bolt head
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
section shape
* M10 × 1.5 19.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1}
68.1 ~ 102.1 {6.9 ~
M12 × 1.25 49.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}
10.4}
* M12 × 1.75 45.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6}
76.5 ~ 114.7 {7.8 ~ 83.0 ~ 124.5 {8.5 ~ 93.2 ~ 139.3 {9.5 ~ 100.8 ~ 151.1 {10.3 ~
M14 × 1.5
11.7} 12.7} 14.2} 15.4}
71.6 ~ 106.9 {7.3 ~ 77.2 ~ 115.8 {7.9 ~ 88.3 ~ 131.4 {9.0 ~ 94.9 ~ 142.3 {9.7 ~
* M14 × 2
10.9} 11.8} 13.4} 14.5}
104.0 ~ 157.0 {10.6 ~ 115.6 ~ 173.3 {11.8 ~ 135.3 ~ 204.0 {13.8 ~ 150.1 ~ 225.2 {15.3 ~
M16 × 1.5
16.0} 17.7} 20.8} 23.0}
100.0 ~ 149.1 {10.2 ~ 109.4 ~ 164.2 {11.2 ~ 129.4 ~ 194.2 {13.2 ~ 142.5 ~ 213.8 {14.5 ~
* M16 × 2
15.2} 16.7} 19.8} 21.8}
151.0 ~ 225.6 {15.4 ~ 195.2 ~ 293.2 {19.9 ~
M18 × 1.5 — —
23.0} 29.9}
151.0 ~ 225.6 {15.4 ~ 196.1 ~ 294.2 {20.0 ~
* M18 × 2.5 — —
23.0} 30.0}
206.0 – 310.0 {21.0 ~ 269.7 ~ 405.0 {27.5 ~
M20 × 1.5 — —
31.6} 41.3}
190.2 ~ 286.4 {19.4 – 249.1 ~ 374.6 {25.4 ~
* M20 × 2.5 — —
29.2} 38.2}
251.1 – 413.8 {25.6 ~ 362.8 ~ 544.3 {37.0 ~
M22 × 1.5 — —
42.2} 55.5}
217.7 ~ 327.5 {22.2 ~ 338.3 ~ 507.0 {34.5 ~
* M22 × 2.5 — —
33.4} 51.7}
358.9 ~ 539.4 {36.6 ~ 430.5 ~ 711.0 {43.9 ~
M24 × 2 — —
55.0} 72.5}
338.3 ~ 507.0 {34.5 ~ 406.0 ~ 608.0 {41.4 ~
* M24 × 3 — —
51.7} 62.0}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
N⋅m {kgf⋅m}
9.8
Strength classification 8.8
9T
Bolt head section
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
shape
5.6 ~ 11.2 {0.6 ~ 6.6 ~ 12.2 {0.6 ~
M6 × 1 — —
1.1} 1.2}
13.4 ~ 25.7 {1.4 ~ 15.3 ~ 28.4 {1.6 ~ 16.7 ~ 30.4 {1.7 ~ 18.1 ~ 33.6 {1.9 ~
M8 × 1.25
2.6} 2.9} 3.1} 3.4}
31.3 ~ 52.5 {3.2 ~ 35.4 ~ 58.9 {3.6 ~ 37.3 ~ 62.8 {3.8 ~ 42.3 ~ 70.5 {4.3 ~
M10 × 1.25
5.4} 6.1} 6.4} 7.2}
31.3 ~ 51.4 {3.2 ~ 34.5 ~ 57.5 {3.5 ~ 36.3 ~ 59.8 {3.7 ~ 40.1 ~ 66.9 {4.1 ~
* M10 × 1.5
5.2} 5.8} 6.1} 6.8}
69.3 ~ 104.0 {7.1 ~ 77.7 ~ 116.5 {7.9 ~ 75.5 ~ 113.8 {7.7 ~ 85.0 ~ 127.5 {8.7 ~
M12 × 1.25
10.6} 11.9} 11.6} 13.0}
64.8 ~ 96.1 {6.6 ~ 71.4 ~ 107.2 {7.3 ~ 71.6 ~ 106.9 {7.3 ~ 79.5 ~ 119.2 {8.1 ~
* M12 × 1.75
9.8} 10.9} 10.9} 12.2}
106.2 ~ 158.8 {10.8 114.9 ~ 172.3 {11.7 113.8 ~ 170.6 {11.6 123.4 ~ 185.1 {12.6
M14 × 1.5
~ 16.2} ~ 17.6} ~ 17.4} ~ 18.9}
100.6 ~ 149.8 {10.3 108.2 ~ 162.2 {11.1 106.9 ~ 160.0 {10.9 115.5 ~ 173.3 {11.8
* M14 × 2
~ 15.3} ~ 16.6} ~ 16.3} ~ 17.7}
154.3 ~ 232.5 {15.7 171.1 ~ 256.7 {17.4 160.0 ~ 240.3 {16.3 176.9 ~ 265.3 {18.0
M16 × 1.5
~ 23.7} ~ 26.2} ~ 24.5} ~ 27.1}
147.6 ~ 221.4 {15.0 162.5 ~ 243.8 {16.6 153.0 ~ 229.5 {15.6 168.5 ~ 252.7 {17.2
* M16 × 2
~ 22.6} ~ 24.9} ~ 23.4} ~ 25.8}
222.5 ~ 334.3 {22.7 229.5 ~ 345.2 {23.4
M18 × 1.5 — —
~ 34.1} ~ 35.2}
223.6 ~ 335.4 {22.8 230.5 ~ 346.2 {23.6
* M18 × 2.5 — —
~ 34.2} ~ 35.3}
307.4 ~ 461.7 {31.4 316.8 ~ 475.6 {32.3
M20 × 1.5 — —
~ 47.1} ~ 48.5}
284.0 ~ 472.1 {29.0 293.2 ~ 440.3 {29.2
* M20 × 2.5 — —
~ 43.5} ~ 44.9}
413.6 ~ 620.5 {42.2 424.6 ~ 636.5 {43.3
M22 × 1.5 — —
~ 63.3} ~ 64.9}
385.7 ~ 578.0 {39.3 394.2 ~ 592.3 {40.0
* M22 × 2.5 — —
~ 58.9} ~ 60.4}
490.8 ~ 810.5 {50.0 554.1 ~ 830.6 {56.5
M24 × 2 — —
~ 82.7} ~ 84.7}
462.8 ~ 693.1 {47.2 520.7 ~ 781.6 {53.1
* M24 × 3 — —
~ 70.7} ~ 79.7}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
Designations for Isuzu standard bolt heads
Legend
1. Hexagon Head Bolt(4.8, 4T) 9. Hexagon Head Bolt(Un-Refined 8.8)
2. Hexagon Head Bolt(4.8, 4T) 10. Hexagon Head Bolt(Un-Refined 8.8)
3. Flange Bolt(4.8, 4T) 11. Flange Bolt(8.8)
4. Flange Bolt(4.8, 4T) 12. Flange Bolt(8.8)
5. Hexagon Head Bolt(7T) 13. Hexagon Head Bolt(9.8, 9T)
6. Flange Bolt(7T) 14. Hexagon Head Bolt(9.8, 9T)
7. Hexagon Head Bolt (Refined 8.8) 15. Flange Bolt(9.8, 9T)
8. Hexagon Head Bolt (Refined 8.8) 16. Flange Bolt(9.8, 9T)
Flare nut
Pipe diameter tightening torque Flare nut 2 side width (mm)

(for medium and large
Old New
size vehicles)
Flare nut tightening torque (service φ4.76 mm 12.8 ~ 18.6 {1.3 ~ 1.9} 14 14
standard value) N⋅m {kgf⋅m}
φ6.35 mm 23.5 ~ 49 {2.4 ~ 5.0} 17 17
φ8.0 mm 23.5 ~ 49 {2.4 ~ 5.0} 19 17
φ10.0 mm 44.1 ~ 93.2 {4.5 ~ 9.5} 22 19
φ12.0 mm 58.8 ~ 137.3 {6.0 ~ 14.0} 27 24
φ15.0 mm 78.5 ~ 156.9 {8.0 ~ 16.0} 30 30
Taper screw from connectors (brass)
N⋅m {kgf⋅m}
Screw size PT(R) 1/8 PT(R) 1/4 PT(R) 3/8 PT(R) 1/12
— 2.0 ~ 14.7 4.9 ~ 15.7 9.8 ~ 16.7 9.8 ~ 17.7
(0.2 ~ 1.5) (0.5 ~ 1.6) (1.0 ~ 1.7) (1.0 ~ 1.8)
Special Tool Classification
A; Essential tool
Servicing operation cannot be done with any other tools than the essential tool.
B; Recommended tool
Servicing work can be done with a general-purpose tool commercially available.
However, it is advisable to use the recommended tool as much as possible for a reduced work time and an improved
safety in work operations.
C; Available tool
Although it takes a more working time, servicing operations can be made with a tool commercially available as
substitute for the available tool.
Engine
Contents
Diesel Engine (4JJ1) . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52
Precautions on Service Work . . . . . . . . . . . . . . . 1A-3 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-53
Main Data and Specifications. . . . . . . . . . . . . . . 1A-8 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-53
Engine Foot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-53
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1A-58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-64
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 1A-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-67
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-13 Torque Specifications . . . . . . . . . . . . . . . . . . . .1A-75
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Piston, Connecting Rod . . . . . . . . . . . . . . . . . . .1A-77
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-16 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-77
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-77
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-17 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1A-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-17 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-85
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-20 Torque Specifications . . . . . . . . . . . . . . . . . . . .1A-87
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-87
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-88
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-88
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-23 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-89
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-89
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Torque Specifications . . . . . . . . . . . . . . . . . . . .1A-91
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-91
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Gear Case ASM . . . . . . . . . . . . . . . . . . . . . . . . .1A-92
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-29 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-92
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-92
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-93
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-31 Torque Specifications . . . . . . . . . . . . . . . . . . . .1A-94
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-35 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . .1A-95
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-95
Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-95
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-96
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-37 Torque Specifications . . . . . . . . . . . . . . . . . . . .1A-98
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-38 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-98
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-40 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . . .1A-99
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-41 Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-99
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-100
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-43 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-100
Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-44 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-102
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-44 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-102
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-44 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-103
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-45 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-103
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-103
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-47 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .1A-104
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-48 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-105
Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-49 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-105
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-49 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-112
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-50 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-113
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-51 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-113
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-113
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116
Lubrication System . . . . . . . . . . . . . . . . . . . . . . 1A-117
Precautions on Service Work. . . . . . . . . . . . . 1A-117
Functional Check . . . . . . . . . . . . . . . . . . . . . . 1A-118
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Oil Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-121
Oil Port Cover ASM. . . . . . . . . . . . . . . . . . . . . . 1A-122
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-123
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-123
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-123
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-124
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-125
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-125
Oil Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 1A-127
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-127
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-128
Crankcase, Oil Pan . . . . . . . . . . . . . . . . . . . . . . 1A-130
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-130
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-130
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-131
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-132
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-132
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-134
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-135
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-135
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-137
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-137
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 1A-142
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-142
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-142
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-143
Engine Mechanical (4JJ1) 1A-3
Isuzu Diesel Engine (4JJ1)

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

with this engine.
Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
are made with extreme precision. They are therefore
highly sensitive to foreign matter and the entry of
foreign matter could cause serious damage. Take
1A-4 Engine Mechanical (4JJ1)
How to read the model
Front Rear
WSJJ0005
Name
1. Stamped Engine Model 2. Stamped Engine Number
Explanations on functions and operation EGR system

Based upon data, including coolant temperature,
Electronic engine control
engine speeds or engine loads, it is controlled via
With the control unit, the range from injection to air
Engine Control Module (ECM) to purify exhaust by
intake/exhaust, including fuel injection quantity,
recycling part of it.
injection timing, EGR and idling speed, is controlled.
Its main components include an EGR valve, an EGR
Cylinder block cooler and various sensors.
The cylinder block is cast-iron with the center distance
Connecting rod cap bolt
of each bore being equal, is of the highly rigid, and is
The angular tightening method of the connecting rod
linerless.
cap bolt further increases reliability and durability.
Piston
Common rail-type electronic control injection system
The piston is aluminum-alloy and a thermal-flow piston
The common rail-type electronic control injection
with a strut cast, while the combustion chamber is a
system is composed of a fuel supply pump that sets the
round reentrant type.
target pressure of high-pressure fuel and supply it, a
Cylinder head common rail that measures such high-pressure fuel
The cylinder head is aluminum-alloy and there are 4 and a fuel injector that turns it into a fine spray and
valves per cylinder. The angular tightening method of injects it. Each is controlled via ECM based upon
the cylinder head bolt further increases reliability and various signals, while injection timing or fuel injection
durability. quantity is controlled under every possible driving
condition.
Crankshaft
Do not grind the crankshaft to reuse, as tufftride Fuel injector
treatment has been performed to the surface. Replace The fuel injector is a 6-hole nozzle that adjusts fuel
with new one if fault is present. injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the
fuel injector.
ECM corrects the dispersion of fuel injection quantity • Insert a 0.15 mm (0.006 in) thickness gauge into a
among fuel injectors according to ID code data in clearance between the rocker arm roller and the
memory. At the replacement of fuel injectors, ID code camshaft to check it and adjust it if needed.
data should be stored in ECM. It is recommended to use a long thickness gauge.
Fuel filter with sedimenter Valve clearance mm (in)
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between Intake valve 0.15 (0.006)
light oil and water, which comes with an indicator that Exhaust valve 0.15 (0.006)
notifies you that it is filled with water.
Preheating system Caution:
The preheating system consists of the ECM, the glow Perform adjustment when it is cold.
relay, glow plugs and the glow indicator lamp. The 2. Adjustment of valve clearance
preheating system is operated when the engine coolant a. Completely loosen all of the rocker arm
temperature is low, and make the engine easy to start. adjusting nuts and adjusting screws (16 nuts
Lubrication system and 16 screws).
It is an oil filter with full-flow bypass, which uses a b. Place a 0.15 mm (0.006 in) thickness gauge
water-cool oil cooler and oil jet to cool the piston. between the No. 1 cylinder rocker arm roller
and the camshaft.
Function check c. With a thickness gauge kept inserted, tighten
Inspection/adjustment of valve clearance an adjusting screw of the rocker arm lightly and
make sure that the tip of the adjusting screw
1. Inspection of valve clearance
touches the end of valve axis and the
• Disconnect the fuel injector connector. movement of the thickness gauge has become
• Disconnect the leak off hose. tight.
• Remove the cylinder head cover. d. Use a valve clearance adjusting nut wrench to
• Rotate the crankshaft to make the No.1 cylinder tighten the rocker arm lock nut.
meet the compression top dead center (TDC).
Special tool
Valve clearance adjusting nut wrench:
5-8840-2822-0
e. Remove the thickness gauge.
f. Repeat above steps for the remaining
cylinders.
Tightening torque: 18 N⋅m (1.8 kg⋅m/13 lb ft)
WSJJ0001
Name
1. TDC
2
1
WSJJ0274
Name
1. Valve Clearance Adjusting Nut Wrench
2. Thickness Gauge
• If the No. 1 cylinder is the compression TDC,
adjust a valve clearance with { mark given on
the table and if the No. 4 cylinder is the
compression top dead center, that with ↔
mark.
2 2
1 3
WSJJ0038
Name
1. Exhaust Rocker Arm Shaft ASM
2. Valve Clearance
3. Intake Rocker Arm Shaft ASM WSJJ0184
Adjustment table
Cylinder No. 1 2 3 4
Valve IN EX IN EX IN EX IN EX
arrangement
No. 1 cylinder
Compression { { { {
top dead center
position
No. 4 cylinder
Compression × × × ×
top dead center
position
WSJJ0185
• Install the cylinder head cover.

Refer to the “Cylinder Head Cover”.
• Connect the leak off hose.
• Connect the fuel injector connector.
Compression pressure inspection
• Warm-up the engine.
• Remove a negative terminal of the battery and
remove all the glow plugs.
• Remove the connector of the fuel injector (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 the Engine
Control System Section) Compression pressure MPa (psi) / 200 rpm
Standard 2.84 — 3.24 (412 — 469)
Limit 1.96 (284)
1 Differences among 294 kPa (43)
the cylinders
• Measure each cylinder one by one.
Caution:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge (special tool).
• Remove a negative terminal of the battery.
• Connect the fuel injector connector.
• Install all the glow plugs.
Tightening torque: 15 — 20 N⋅m (1.5 — 2.0 kg⋅m/11 —
WSJJ0222 15 lb ft)
Name • Install the negative terminal of the battery.

1. Fuel Injector Connector
• Install the negative terminal of the battery.

• Turn on the starter to emit foreign matter within the
cylinders.
• Install an adapter and a gauge of a compression
gauge (special tool).
WSJJ0275
Compression gauge:
5-8840-2675-0 (J-26999-12)
Compression gauge adapter:
5-8840-2815-0
• Turn on the starter to inspect compression
pressure.
Main Data and Specifications
Items Engine model 4JJ1

Type Diesel/4-cycle/water cooled-type, in-line four-
cylinder DOHC
Combustion chamber form Direct injection type
Cylinder liner type Linerless
Number of cylinders - cylinder bore × mm (in) 4-95.4 (3.76) × 104.9 (4.13)
strokes
Displacement cc (cu.in) 2999 (183)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idle speed rpm 800 ± 25
Valve clearance Intake 0.15 (0.006) (cold)
mm (in) Exhaust 0.15 (0.006) (cold)
Ignition type Compressed ignition
Injection order 1-3-4-2
Lubricating system
Lubricating type Pressure type
Oil pump type Gear type
Volume of lubricating oil L (qts) 15.0 (15.8)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in, water-cooling
Cooling system
Cooling type Water cooling type
Water pump type Centrifugal, belt type
Thermostat type Wax-type unit
Thermostat valve-opening °C (°F) 85 (185)
temperature
Volume of coolant L (qts) 6 (6.3) (Engine only)
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Injection nozzle type Multi-hole type
6-hole
Charging system
Generator type AC type
Power output V/A 24 - 50
Regulator type IC
Items Engine model 4JJ1

Starting system
Starter type Reduction type
Power output V-kw 24 - 4.0
Preheat system type Glow plug
Glow plug standard voltage/electric V/A 23 - 3.8
current
Special tool
Tool Number/Description /
Illustration
Special Tool Rank
5-8840-2675-0
J-26999-12
Compression gauge
Rank B
5-8840-2815-0
Compression gauge
adapter
Rank A
5884028150
5-8840-2822-0
Valve clearance adjust
nut wrench
Rank A
5884028220
Engine Foot
Components
WSJJ0002
Name
1. Engine Foot RH 2. Engine Foot LH
Removal
1. Lower the engine ASM.
2. Remove the fan shroud and fan guard.
Refer to the “Water Pump” in the Cooling System
Section.
3. Remove the generator.
Refer to “Generator” in Engine Electrical section.
4. Remove the fan shroud bracket RH and fan shroud
stay RH.
7. Remove the relief valve.
WSJJ0252
5. Remove the bolt with arrow mark which holds the WSJJ0260
water intake pipe to the engine foot RH. 8. Remove the engine foot.
Installation
1. Install the engine foot.
• Temporarily tighten the engine foot bolt.
• Install the bolt which holds the water intake pipe to
the engine foot RH.
• Tighten each bolt to the specified torque.
Tightening torque:
M8 bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft),
M10 bolt: 51 N⋅m (5.2 kg⋅m/38 lb ft)
2. Install the relief valve.
• Install so as not to let the pipe stick out of the
bottom of the engine foot.
WSJJ0237
6. Remove the bolt with arrow mark which holds the

blow-by hose to the engine foot RH.
WSJJ0250
3. Install the bolt which holds the blow-by hose to the

engine foot LH.
WSJJ0259

4. Install the fan shroud bracket RH and fan shroud
stay RH.
Tightening torque:
M8 bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft),
M10 bolt: 51 N⋅m (5.2 kg⋅m/38 lb ft)
Nut: 25 N⋅m (2.5 kg⋅m/18 lb ft)
5. Install the fan shroud and fan guard.
Section.
6. Install the generator.
7. Put the engine ASM on.
Cylinder Head Cover

Components
WSJJ0208
Name
1. Head Cover 2. Head Cover Packing
Removal
1. Remove the air intake duct. 1
2. Disconnect the connector of the fuel injector.
• Remove the cover. (Varies depending on the
machine.)
WSJJ0039
Name
1. Cam End Packing
WSJJ0276
Name
1. Cover
3. Disconnect the leak-off hose.

4. Disconnect the blow-by hose.
5. Remove the head cover.
WSJJ0209
Name
1. Head Cover
6. Remove the packing.

7. Remove the cam end packing.
Installation 2. Install the packing on the head cover.
1. Install the cam end packing. 3. Install the head cover and tighten up according to
the order shown in the illustration.
• Apply liquid gasket (ThreeBond 1207B or
equivalent). Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)
• Install within five minutes after applying liquid
gasket.
12 11 10 2 9 8
2
1
3 4
7
13 14 1 5 6
WSJJ0168
4. Connect the blow-by hose.

WSJJ0040
5. Connect the leak-off hose.
Name 6. Connect the fuel injector connector.
1. Cam End Packing
2. Liquid Gasket Applied Area. Caution:
3. 2.0 — 3.0 mm (0.079 — 0.118 in) Push it in thoroughly until the claw of the lock is lifted.
• Install the cover.
• Install the cam end packing. 7. Install the air intake duct.
Apply liquid gasket (ThreeBond 1207B or
equivalent) as shown in the illustration.
• Install within five minutes after applying liquid
gasket.
1
1
WSJJ0041
Name
1. 3.0 — 5.0 mm (0.118 — 0.179 in)
2. 3.0 — 5.0 mm (0.118 — 0.179 in)
Torque Specifications
N m(kg m/lb ft)
10 ( 1.0 / 87 lb in )
10 ( 1.0 / 87 lb in )
WSJJ0210
Intake Manifold
Components
1 2 3
WSJJ0261
Name
1. Intake Manifold 3. EGR Valve
2. Air Intake Pipe
Removal
1. Remove the fuel injector, EGR valve, glow plug,
boost pressure sensor and boost temperature
sensor connector. 1
2. Remove the air intake duct.
3. Remove the leak-off pipe.
WSJJ0004
Name
1. Leak-Off Pipe
4. Remove the EGR valve.
2
1
WSJJ0007
WSJJ0223
Name
Name 1. Intake Manifold
1. EGR Valve 2. Gasket
5. Disconnect the fuel injection pipe (common rail to

fuel injector).
Installation
Important: 1. Install the intake manifold and gasket, and tighten
Do not reuse the high-pressure pipe in fuel system if it up according to the order shown in the illustration.
has been removed.
Refer to “Fuel Injector” in the Fuel System section.
6. Remove the air intake pipe.
6
4
2
8
7
5 3 1
3 1
WSJJ0246
WSJJ0006 2. Connect the air intake pipe.

Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)
Name
1. Air Intake Pipe
2. Intake Manifold
3. Gasket
7. Remove the intake manifold and gasket.

3 1
WSJJ0006 WSJJ0004
Name Name
1. Air Intake Pipe 1. Leak-Off Pipe
2. Intake Manifold
3. Gasket 6. Install the air intake duct.
7. Install the fuel injector, EGR valve, glow plug,
3. Connect the fuel injection pipe (common rail to fuel boost pressure sensor and boost temperature
injector). sensor connector. Each composite connector
should make a loud click when it is securely
Important: attached.
Replace the high-pressure pipe in fuel system with new
one if it has been removed.
4. Install the EGR valve.
WSJJ0223
Name
1. EGR Valve
5. Install the leak-off pipe.

N m(kg m/lb ft)
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
10 ( 1.0 / 87 lb ft )
25 ( 2.5 / 18 )
10 ( 1.0 / 87 lb ft )
WSJJ0268
Exhaust Manifold
Components
6 7
5 4 3 2 1
WSJJ0008
Name
1. Turbocharger ASM 5. Exhaust Manifold
2. Exhaust Adapter 6. Water Feed Pipe
3. Oil Return Pipe 7. Water Return Pipe
4. Oil Feed Pipe
Removal
1. Loosen the radiator drain cock to drain coolant.
2. Disconnect the intake pipe from the intake duct
and charge air cooler.
3. Disconnect the air intake pipe from the
turbocharger and air cleaner.
4. Remove the charge air pipe from the turbocharger
and the charge air cooler.
5. Remove the oil level gauge guide tube.
1 3 2
WSJJ0009 WSJJ0218
6. Remove the EGR cooler.

Refer to “EGR Cooler” in the Exhaust System Name
section. 1. Exhaust Manifold
2. Turbocharger
7. Remove the oil feed pipe. 3. Exhaust Adapter
8. Remove the oil return pipe.
9. Remove the water feed pipe.
10. Remove the water return pipe. Inspection
• Inspection of exhaust manifold
2 1
Inspect for distortion of the plane on which the
manifold and the cylinder head are to be installed.
Distortion of manifold installation surface mm (in)

Standard 0.3 (0.01) or less
Limit 0.5 (0.02)
3
Caution:
4
If the distortion exceeds the limit, replace it.
WSJJ0010
Name
1. Water Feed Pipe
2. EGR Cooler
3. Oil Feed Pipe
4. Water Return Pipe
5. Oil Return Pipe
11. Disconnect the front exhaust pipe.

12. Remove the exhaust adapter.
13. Remove the four turbocharger clamping nuts.
WSJJ0245
14. Remove the turbocharger from the exhaust
manifold.
15. Remove the exhaust manifold.
• 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.
Refer to “Turbocharger” in the Exhaust System section
for inspection of turbocharger.
Installation
1. Put the gasket in to install the exhaust manifold.
Install the gasket so that the projection shown in
the illustration faces the rear side of the engine.
• Tighten up with the eight nuts according to the
order shown in the illustration.
1 3 2
Caution:
Do not tighten up too much because it hampers WSJJ0218
expansion and contraction due to the heat from the
manifold. Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
7 3 1 5 4. Connect the front exhaust pipe.

5. Install the water feed pipe to the turbocharger.
• Tighten the joint bolts to the specified torque.
8 4 2 6 Tightening torque: 22.5 N⋅m (2.3 kg⋅m/17 lb ft)

• Install the pipe bracket and tighten each bolt and
nut to the specified torque.

• Connect the rubber hose between the water feed
pipe and the thermostat housing.
WSJJ0244
2. Install the gasket and turbocharger to the exhaust

manifold. Tighten the nuts to the specified torque.
1
3. Install the gasket and exhaust adapter. Tighten to
the specified torque.
WSJJ0011
Name
1. Water Feed Pipe
6. Install the water return pipe. Tighten the joint bolts Tightening torque (crankcase side):
to the specified torque.
24.7 N⋅m (2.5 kg⋅m/18 lb ft)
Tightening torque: 22.5 N⋅m (2.3 kg⋅m/17 lb ft)
WSJJ0220
WSJJ0219
Name
Name 1. Oil Return Pipe
9. Install the EGR cooler.
7. Install the turbocharger oil feed pipe to the top of Refer to “EGR Cooler” in the Exhaust System
the turbocharger. Tighten the joint bolts to the section.
specified torque. 10. Install the oil level gauge guide tube.
Tightening torque: 22.5 N⋅m (2.3 kg⋅m/17 lb ft) • Apply a thin coat of engine oil to the O-ring.
Tightening torque: Bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft)
Nut: 51 N⋅m (5.2 kg⋅m/38 lb ft)
WSJJ0224
Name
WSJJ0009
1. Oil Feed Pipe
11. Connect the charge air pipe to the turbocharger
8. Tighten the oil return pipe bolts to the specified and the charge air cooler.
torque. 12. Connect the air intake pipe to the turbocharger and
the air cleaner.
Tightening torque (turbocharger side):
10 N⋅m (1.0 kg⋅m/87 lb in) 13. Connect the intake pipe to the intake duct and the
charge air cooler.
14. Add cooling water to the radiator.
15. Replenish the coolant.
N m(kg m/lb ft)

10 ( 1.0 / 87 lb ft )
22.5 ( 2.3 / 16.6 )
22.5 ( 2.3 / 16.6 ) 10 ( 1.0 / 87 lb ft )
10 ( 1.0 / 87 lb ft )
35 ( 3.6 / 25.8 ) 35 ( 3.6 / 25.8 )
22.5 ( 2.3 / 16.6 )
35 ( 3.6 / 25.8 )
25 ( 2.5 / 18 )
WSJJ0254
Timing Gear Train

Components
8
9
10
7 5
WSJJ0187
Name
1. Crankshaft Gear 6. Idle Gear D Sprocket
2. Oil Pump Gear 7. Idle Gear D
3. Idle Gear A 8. Exhaust Camshaft Gear
4. Fuel Supply Pump Gear 9. Intake Camshaft Gear
5. Fuel Supply Pump Sprocket 10. Timing Chain
Removal Refer to the “Water Pump” in the Cooling System

Section.
1. Drain the coolant.
5. Remove the fan belt.
2. Disconnect the radiator upper hose.
3. Remove the fan shroud and fan guard. Section.
6. Rotate the crankshaft to make the No.1 cylinder
Section.
4. Remove the fan ASM and water pump pulley.
Special tool
Crankshaft stopper
WSJJ0001
Name
1. TDC 9. Remove the power steering pump hole cover.
7. Remove the starter motor.
• Remove the mounting bolt, and remove the starter
motor and ground cable.
WSJJ0226
Name
1. Power Steering Pump Hole Cover
WSJJ0032
8. Remove the crank pulley. 10. Remove the fan shroud bracket LH and fan shroud
stay LH.
• Install the crankshaft stopper on the starter part of
the flywheel housing to stop the crankshaft from
rotating.
Caution:
• Check if the stopper meshes with the ring gear
without fail and is installed properly.
• Do not reuse the crankshaft pulley bolt and
washer.
WSJJ0257 WSJJ0169
13. Install the M6 bolt to the idle gear A.

Name
1. Fan Shroud Bracket LH
2. Fan Shroud Stay LH
11. Remove the vacuum pump hole cover.
WSJJ0277
14. Remove the idle gear A, idle gear A flange and idle
gear A shaft.
WSJJ0225
Name
1. Vacuum Pump Hole Cover
12. Remove the gear case cover.
WSJJ0286
15. Remove the crankshaft gear. Reassembly
1. Install the scissors gear ASM.
• Fix the idle gear A in a vise using a mouth ring.
Assemble the spring with its left end contacting the
pin of idle gear A 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 idle
gear A main gear and the right end of the spring.
WSJJ0043
1
Disassembly
1. Remove the scissors gear ASM.
• Fix the idle gear A in a vise using a mouth ring.
Use snap ring pliers to remove the sub gear.
WSJJ0044
4
Name
3
1. Snap Ring
2. Sub Gear
2 3. Spring
4. Idle Gear A
1 • Use snap ring pliers to assemble the snap ring

securely.
WSJJ0044
Name
1. Snap Ring
2. Sub Gear
3. Spring
4. Idle Gear A
Inspection 2. Measurement of end clearance of the idle gear.
1. Measurement of idle gear backlash • Insert a thickness gauge between the idle gear and
the thrust collar to measure a clearance.
• Apply a dial gauge on the teeth of the idle gear to
be measured and move the gear to right and left • If the measurement exceeds the limit, replace
lightly to read how much the dial gauge shook either the idle gear or the thrust collar.
(never fail to fix the gear).
Axial play of idle gear mm (in)
• If the measurement exceeds the limit, replace the
idle gear. Standard 0.080 — 0.155 (0.003 — 0.006)
Limit 0.20 (0.008)
Backlash of the timing gear mm (in)
Standard 0.10 — 0.17 (0.004 — 0.006) • Measure an end clearance of the idle gear before
Limit 0.30 (0.01) removing the idle gear A.
• Measure backlash of the idle gear before removing

the idle gear A.
WSJJ0285
3. Outside diameter of idle gear shaft

• Use a micrometer to measure an external diameter
WSJJ0284 of the idle gear A shaft.
shaft.
External diameter of the idle gear A mm (in)

shaft
Standard 44.950 — 44.975
(1.7697 — 1.7707)
Limit 44.80 (1.764)
Installation
1.Install the crankshaft gear.
2.Install the idling gear A.
•Fix the idle gear A in a vise using a mouth ring.
•Rotate the sub gear clockwise using the M6 bolt
and lever to align the M6 bolt hole of the sub gear
with that of the idle gear A.
• Tighten the M6 bolt to the appropriate torque to
prevent rotation of the sub gear.
WSJJ0045
4. Clearance between the idle gear and the idle gear

shaft
• Measure an inside diameter of the idle gear
bushing to calculate a clearance between the idle
gear and the idle gear shaft.
• If the measurement exceeds the limit, replace
either the idle gear or the shaft.
Clearance between the idle gear A and mm (in)

the shaft WSJJ0046
Standard 0.020 — 0.062 (0.0007 — 0.0024) • Install the idle gear A, idle gear A flange and idle
gear A shaft so that the marks on the flange and
Limit 0.200 (0.0079) shaft face upward and the mark on the flange also
faces outside.
• Apply engine oil to the part where the gear of the
shaft is to be put together.
• Apply engine oil to the thread part and seating
surface of the bolt, and temporarily tighten
together with the flange.
WSJJ0042
Name
1. Flange Mark
2. Shaft Mark
• Install so that the timing marks of the crankshaft

gear, idle gear A and fuel supply pump gear are
aligned as shown in the illustration.
WSJJ0047
3. Tighten the idle gear A installing bolt to the

specified torque.
WSJJ0186 WSJJ0049
6. Install the vacuum pump hole cover.

Name
1. Idle Gear A Bolt • Apply engine oil to the packing.
4. Remove the M6 bolt from the idle gear A.
5. Install the gear case cover.
equivalent) to the position shown in the illustration.
• Apply the liquid gasket and install the gear case
cover within 5 minutes.
• Install the packing in the groove of the gear case
cover.
• Tighten the installing bolt to the specified torque.
Tightening torque: 3.5 N⋅m (0.4 kg⋅m/31 lb in) 1
WSJJ0225
Name
1. Vacuum Pump Hole Cover
7. Install the fan shroud bracket LH and fan shroud

stay LH.
• After temporarily tightening the nut (1) as shown in
the illustration, temporarily tighten the bolt (2).
• After fully tightening the nut (1) as shown in the
illustration, fully tighten the bolt (2).
WSJJ0048 Tightening torque:
M8 bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft)
Name
M10 bolt: 51 N⋅m (5.2 kg⋅m/38 lb ft)
1. Liquid Gasket Applied Area.
Nut: 25 N⋅m (2.5 kg⋅m/18 lb ft)
WSJJ0251 WSJJ0113
8. Install the power steering pump cover. 10. Install the starter motor and ground cable to the
• Apply a coat of engine oil to the O-ring. flywheel housing and tighten the bolt to the
specified torque.
11. Install the water pump pulley, fan belt and fan
ASM.
Section.
Section.
13. Connect the radiator upper hose.
WSJJ0226
Name
1. Power Steering Pump Cover
9. Install the crank pulley.

equivalent) to the tip of the key.
Caution:
Replace the crankshaft pulley bolt and washer with new
ones.
N m(kg m/lb ft)
3.5 ( 0.4 / 31 lb in )
32 ( 3.2 / 24 )
25 ( 2.5 / 18 ) 25 ( 2.5 / 18 )
WSJJ0238
Special Tool
Illustration
Special Tool Rank
Crankshaft stopper
Camshaft ASM
Components
6
5
4
2 3
1
WSJJ0050
Name
1. Snap Ring 5. Camshaft Gear
2. Camshaft Scissors Gear 6. Camshaft
3. Knock Pin 7. Bearing Cap
4. Damper Spring 8. Bolt
Removal
1. Rotate the crankshaft to make the No.1 cylinder
1
WSJJ0171
Name
1. Baffle Plate
WSJJ0001
5. Remove the camshaft bearing cap.

Name
1. TDC • Check the stamp mark on the top of the bearing
cap.
2. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
3. Install the M5 lock bolt which fixes the sub gear.
1E
2E
3E
4E
1I
5E
2I
3I
4I
5I
WSJJ0172
WSJJ0051
4. Remove the baffle plate.

6. Remove the camshaft ASM.
WSJJ0170
WSJJ0052 2. Remove the camshaft gear.
• Pull out the camshaft gear using a press and
Disassembly socket.
1. Remove the scissors gear ASM.

• Fix the hexagon portion of the camshaft in a vise
using a mouth ring.
1
• Rotate the sub gear clockwise using the camshaft
gear tool and remove the M5 lock bolt.
Special tool 2
Camshaft gear tool: 5-8840-2591-0
3
WSJJ0054
Name
1. Press
2. Socket
3. Camshaft Gear
3. Remove the knock pin.
WSJJ0053
• Use snap ring pliers to remove the sub gear.
Caution:
Take care not to damage the cam portion and the
journal portion of the camshaft.
4. Inspect the camshaft visually. 6. Check if the cam lobe is worn.
• Check if the journal and cam parts of the camshaft • Use a micrometer to measure the height of the
are worn or damaged, if so, replace it. cam lobe.
• If the height of the cam lobe is the limit or less,
replace the camshaft.
Height of the cam lobe mm (in)

Intake air Exhaust
Standard 40.6 (1.60) 40.6 (1.60)
Limit 39.6 (1.56) 39.6 (1.56)
5. Check the axial play of the camshaft.

• Use a thickness gauge to measure an end
clearance of the camshaft gear and the camshaft
bracket.
camshaft gear or the camshaft.
End clearance of the camshaft mm (in)

Standard 0.085 — 0.205 (0.033 — 0.008)
7. Check if the camshaft journal is worn.
Limit 0.25 (0.009)
• Use a micrometer to measure wear which is not
even with a diameter of the camshaft journal.
Caution:
Measure an end clearance of the camshaft before • If the measured uneven wear exceeds the limit,
disassembling. replace the camshaft.
External diameter of the camshaft journal mm (in)

part
Standard 29.909 — 29.930 (1.1775 — 1.1783)
Limit 29.809 (1.1736)
Partial wear of the camshaft journal part mm (in)

Limit 0.05 (0.0019)
WSJJ0055
Clearance of the journal part mm (in)

Standard 0.025 — 0.087 (0.0009 — 0.0034)
Limit 0.15 (0.0059)
8. Check for bent of the camshaft.

• Place the camshaft on a V block to measure a
bend with a dial gauge.
• Rotate the camshaft slowly to measure how much
the dial indicator shook. If it exceeds the limit,
replace the camshaft.
Bent of the camshaft mm (in) Reassembly

Limit 0.05 (0.0019) 1. Install the knock pin.
2. Install the camshaft gear.
• Align the groove of the camshaft gear with the
knock pin of the camshaft. Install the camshaft
gear to the camshaft using a press.
9. Measure a camshaft journal oil clearance.

a. Measure an inside diameter of the camshaft
bearing with a dial gauge. WSJJ0056
b. Read the difference between the inside

Name
diameter of the camshaft bearing and the
1. Camshaft
diameter of the camshaft journal.
2. Knock Pin
If the measured oil clearance exceeds the limit,
3. Camshaft Gear
replace the camshaft bearing.
3. Install the scissors gear ASM. • Tighten the M5 bolt to the appropriate torque to
• Fix the hexagon portion of the camshaft in a vise prevent rotation of the sub gear.
using a mouth ring. Assemble the spring with its
left end contacting the pin of camshaft main gear to Special tool
make a gap on the right. Camshaft gear tool: 5-8840-2591-0
• 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.
1
2
WSJJ0053
• Assemble it onto the cylinder head.
WSJJ0057
Installation
Name 1. Rotate the crankshaft to make the No. 1 cylinder
1. Snap Ring meet the compression TDC.
2. Sub Gear
3. Spring
4. Camshaft Gear
• Use snap ring pliers to assemble the snap ring

securely.
WSJJ0001
Name
1. TDC
WSJJ0170
• Before installing the camshaft to the cylinder head,

rotate the sub gear clockwise using the camshaft
gear tool to prevent the spring force which acts on
the sub gear from affecting. Align the M5 hole of
the sub gear with that of the camshaft main gear.
2. Install the camshaft ASM.
• Before installing the camshaft, completely loosen
all of the rocker arm adjusting nuts and adjusting 1
screws.
• Put together the camshaft ASM so as to make the
“•” mark of the camshaft gear aligned with the “•”
mark of the idle gear.
WSJJ0059
1 2 Name
1. Camshaft Alignment Marks
2. Bearing Cap Alignment Marks
3 • Apply engine oil to the thread part and seating

surface, and tighten the bearing cap to the
WSJJ0058 specified torque.
Name Tightening torque: 18 N⋅m (1.8 kg⋅m/13 lb ft)
1. Exhaust Camshaft Gear 4. Remove the M5 lock bolt which fixes the sub gear.
2. Intake Camshaft Gear
3. Idle Gear D
3. Install the bearing cap.

• Apply engine oil to the camshaft journal portion
and the bearing surface of the bearing cap.
• Confirm the stamp mark on the top of the bearing
cap and install it on the cylinder head.
1E
2E
3E
4E
1I
5E
WSJJ0051
2I
3I
5. Adjust the valve clearance.
Refer to “Function Check”.
4I
6. Install the baffle plate. Tighten the bolt to the
5I
specified torque.
7. Install the cylinder head cover.
WSJJ0172 Refer to “Cylinder Head Cover”.
• Check that the alignment marks on the camshaft
and bearing cap are aligned.
N m(kg m/lb ft)
18 (1.8 / 13)
10 (1.0 / 87 lb in)
WSJJ0173
Special Tool
Illustration
Special Tool Rank
5-8840-2591-0
Camshaft gear tool
Rank A
5884025910
Rocker Arm Shaft ASM
Components
2
3
2
3
1 4
WSJJ0283
Name
1. Exhaust Rocker Arm Shaft ASM 3. Bolt (Short)
2. Bolt (Long) 4. Intake Rocker Arm Shaft ASM
Removal
Refer to “Camshaft ASM”.
3. Disconnect the fuel injection pipe (common rail to
fuel injector).
Important:
Do not reuse the high-pressure pipe in fuel system if it
has been removed.
4. Remove the fuel injector.
5. Remove the rocker arm shaft ASM.
Caution:
Keep the removed rocker arm shaft ASM properly so
that they may be put back to the original place.
2
3
2 3 1
1 4 2
WSJJ0060 WSJJ0297
Name Name
1. Exhaust Rocker Arm Shaft ASM 1. Rocker Arm
2. Bolt (Long) 2. Rocker Arm Shaft
3. Bolt (Short) 3. Snap Ring
4. Intake Rocker Arm Shaft ASM
3. Check if the oil hole is clogged of the rocker arm
and the rocker arm shaft.
Caution:
Pay full attention so as not to drop the parts in the gear
case of the front part of the cylinder head or the hole
into which oil pours back in the front.
2
Disassembly
1. Remove the snap ring.
WSJJ0298
Name
1. Rocker Arm Oil Hole
2. Rocker Arm Shaft Oil Hole
4. Check if the rocker arm shaft is worn.

• Measure the outside diameter of the rocker arm
WSJJ0296 shaft using a micrometer.
2. Remove the rocker arm. • If the measurement falls is the limit or less, replace
the rocker arm shaft ASM.
6. Inspect a clearance between the roller of the
rocker arm and the rocker arm pin.
External diameter of the rocker arm shaft mm (in)
a. Pass a string, for instance, through an opening
Standard 14.0 (0.551) between the rocker arm and the roller, pull it in
Limit 13.85 (0.545) the direction indicated with an arrow strongly
and measure the gap between the rocker arm
and the roller with the roller stuck out. Figure 1
b. After marking the measuring point, pull the
string out and measure the gap of the marked
place with the roller pushed deep into the end.
Figure 2
c. The gap between the measurement taken
under a. and that under b. will be a clearance
between the roller and the rocker arm pin. If it
exceeds the limit, replace the rocker arm shaft
ASM.
Clearance between the roller and the mm (in)

rocker arm pin
Standard 0.068 — 0.099 (0.0026 — 0.0038)
Limit 0.2 (0.0079)
WSJJ0301
5. Inspect a clearance between the rocker arm and

the rocker arm shaft.
• Use a cylinder gauge to measure an inside
diameter of the rocker arm to measure a clearance
between the external diameter of the shaft.
• Replace the rocker arm shaft ASM if the
measurements exceed limit values.
Clearance between the rocker arm and mm (in)

rocker arm shaft
Standard 0.010 — 0.046 (0.0004 — 0.0018)
Limit 0.2 (0.0079)
1 2
WSJJ0300
WSJJ0299
Reassembly Caution:
Pay full attention so as not to drop the parts in the gear
1. Install the rocker arm.
case of the front part of the cylinder head or the hole
• Apply engine oil in an inside diameter of the rocker into which oil pours back in the front.
arm, the roller and the rocker arm pin and install it
on the rocker arm shaft. 2
3
2 3
1 4
WSJJ0060
WSJJ0302 Name
1. Exhaust Rocker Arm Shaft ASM
2. Install the snap ring.
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft ASM
1
• Adjustment of valve clearance
Refer to “Function Check”.
2
2. Install the fuel injector.
3. Connect the fuel injection pipe (common rail to fuel
injector).
Important:
3 Refer to “Camshaft ASM”.
WSJJ0297
Name
1. Rocker Arm
2. Rocker Arm Shaft
3. Snap Ring
Installation
1. Install the rocker arm shaft ASM.
• Loosen an adjusting screw of the rocker arm, apply
engine oil over the roller part of the rocker arm and
install it on No.1 to No.4 one by one.
N m(kg m/lb ft)
21 ( 2.1 / 15 ) 21 ( 2.1 / 15 )
WSJJ0262
Valve Stem Seal, Valve Spring

Components
2
3
2
3
1 4
5
6
7
14
13
12
11
10
WSJJ0211
Name
1. Exhaust Rocker Arm Shaft ASM 8. Pin
2. Bolt (Long) 9. Valve Spring Seat
3. Bolt (Short) 10. Valve Stem Oil Seal
4. Intake Rocker Arm Shaft ASM 11. Valve Spring
5. Fuel Injector 12. Spring Upper Seat
6. Bolt 13. Split Collar
7. Nozzle Bracket 14. Valve Stem End Cap
Removal 4. Remove the valve stem end cap.

Refer to “Rocker Arm Shaft ASM”.
Caution: Put the removed valve springs in order by cylinder
• Keep the removed valve stem end caps properly number.
so that they may be put back to the original place. 8. Remove the valve stem oil seal.
• Pay full attention so as not to drop the valve stem • Use pliers to remove the oil seal.
end cap in the gear case of the front part of the
cylinder head or the hole into which oil pours back
in the front.
5. Remove the split collar.
• Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home
position.
• Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0
Pivot: 5-8840-2819-0
WSJJ0062
Caution:
Do not reuse the removed oil seal.
9. Remove the valve spring seat.
Inspection
Check the valve spring.
Caution:
Check the valve spring visually and if there is clear
damage or wear-out, replace it.
1. Free length
WSJJ0061
• Measure free length of the spring and if it is shorter
6. Remove the spring upper seat. than the specified limit, replace the spring.
• Remove the special tool to remove the upper seat.
7. Remove the valve spring. Free length of the valve spring mm (in)
Intake air Exhaust
Standard 53.32 (2.099) 53.32 (2.099)
Limit 52.43 (2.064) 52.43 (2.064)
Tension of the valve spring N (lb)

Intake air Exhaust
Installation
37.80 (1.488) 37.80 (1.488)
length mm (in)
Standard 213 (157) 213 (157)
Limit 188 (138) 188 (138)
2. Valve spring squareness

• Use a surface plate and a square to measure the
valve spring squareness.
If the measured value exceeds the specified limit,
the valve spring must be replaced.
Valve spring squareness mm (in)

Limit 2.1 (0.083)
Installation
1. Install the valve spring seat.
2. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a valve
stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
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 7. Install the rocker arm shaft ASM.
Valve stem seal installer: 5-8840-2817-0 Refer to “Rocker Arm Shaft ASM”.
Special Tool
Illustration
Special Tool Rank
5-8840-2818-0
Valve spring replacer
Rank B
WSJJ0063 5884028180
3. Install the valve spring.

4. Install the spring upper seat.
5. Install the split collar.
5-8840-2819-0
• Apply compressed air over the cylinder from the
Pivot ASM
glow plug holes to keep the valve at the home
Rank B
position.
• Use a replacer to compress the valve spring and
install the split collar. 5884028190
Special tool
Valve spring replacer: 5-8840-2818-0
Pivot: 5-8840-2819-0
5-8840-2817-0
Valve stem seal installer
Rank B
5884028170
WSJJ0061
6. Apply engine oil to the valve stem end cap and

install it.
Caution:
Pay full attention so as not to drop the valve stem end
cap in the gear case of the front part of the cylinder
head or the hole into which oil pours back in the front.
Cylinder Head
Components
3 1
4 5
WSJJ0212
Name
1. Glow Plug 4. Timing Chain Tensioner
2. Intake and Exhaust Valves 5. Timing Chain Tension Lever
3. Cylinder Head 6. Timing Chain Guide
Caution: 3. Remove the fan shroud and fan guard.

To avoid electric shock; Refer to the “Water Pump” in the Cooling System
Set the switch to the “OFF” position and disconnect Section.
battery negative cable before checking or repairing the 4. Remove the fan ASM.
fuel injector, wiring or/and connectors. Refer to the “Water Pump” in the Cooling System
Section.
Removal 5. Rotate the crankshaft to make the No.1 cylinder
WSJJ0001 WSJJ0004
Name Name
1. TDC 1. Leak-Off Pipe
6. Remove the battery. 10. Remove the EGR valve, boost pressure sensor,
7. Remove the intake pipe and duct. boost temperature sensor, ECT sensor and CMP
sensor connector.
8. Disconnect the connector of the fuel injector.
11. Remove the harness bracket.
9. Disconnect the leak-off hose and pipe.
1 14. Remove the EGR cooler.
Refer to “EGR Cooler” in the Exhaust System
section.
15. Disconnect the front exhaust pipe.
16. Disconnect the water return pipe on the
turbocharger.
WSJJ0239
Name
1. Leak-Off Hose
WSJJ0219
Name
17. Disconnect the water feed pipe on the
turbocharger.
WSJJ0220
WSJJ0011
Name
1. Oil Return Pipe
Name
1. Water Feed Pipe 20. Disconnect the fuel injection pipe.
18. Disconnect the oil feed pipe on the turbocharger. Important:

Do not reuse the high-pressure pipe in fuel system if it
has been removed.
21. Remove the timing chain cover lower.
Refer to “Fuel Supply Pump” in the Fuel System
section.
22. Remove the fan shroud bracket upper and the fan
shroud stay upper.
1 2
WSJJ0224
Name
1. Oil Feed Pipe
19. Disconnect the oil return pipe on the turbocharger.

1
WSJJ0249
Name
1. Fan Shroud Bracket Upper
2. Fan Shroud Stay Upper
23. Remove the timing chain cover upper.

section.
24. Disconnect the bypass pipe.
2
1
3
WSJJ0065
1 Name
1. Timing Chain Tensioner
WSJJ0191
2. Packing
Name 3. Nut
1. Bypass Pipe
32. Remove the idle gear D.
25. Remove the glow plug connector. • Drop the timing chain to the backside.
26. Remove the glow plug.
WSJJ0066
WSJJ0207 33. Remove the pivot of the timing chain tension lever.
28. Remove the fuel injector.
30. Remove the valve stem end cap.
31. Remove the timing chain tensioner.
WSJJ0067 WSJJ0068
34. Remove the timing chain from the supply pump

sprocket. Name
1. Nut
35. Remove the bolt of the chain guide from the 2. Bolt
cylinder head.
37. Remove the cylinder head bolt.
• Loosen the cylinder head bolts in the order shown
in the illustration.
Caution:
Do not reuse the cylinder head bolt.
WSJJ0188
36. Remove the bolt and nut which hold the cylinder
head to the gear case.
WSJJ0069
Name
1. Cylinder Head Bolt
6. Remove the split collar.
• Use a replacer to compress the valve spring to
remove the split collar.
Special tool
2 6 10 14 18 15 11 7 3 Valve spring replacer: 5-8840-2818-0
Pivot: 5-8840-2819-0
5 9 13 17 16 12 8 4
WSJJ0070
38. Remove the cylinder head ASM.

• Remove the cylinder head gasket.
Caution:
Replace the head gasket with a new one once it was
removed. WSJJ0061
7. Remove the spring upper seat.

Disassembly • Remove the special tool to remove the upper seat.
8. Remove the valve spring.
1. Remove the intake manifold ASM.
Refer to “Intake Manifold”. • Sort the removed valve springs by cylinder
number.
2. Remove the turbocharger.
Refer to “Exhaust Manifold”. 9. Remove the intake and exhaust valves.
3. Remove the exhaust manifold. • Sort the removed valves according to cylinders by
Refer to “Exhaust Manifold”. using tags and others.
4. Disconnect the water outlet pipe.
5. Remove the thermostat.
10. Remove the valve stem oil seal.
• Use pliers to remove the oil seals. 1
WSJJ0039
Name
WSJJ0062
1. Cam End Packing
11. Remove the valve spring seat.
12. Remove the valve guide. 14. Remove the oil seal.
• Use the valve guide remover and installer to pull
out the valve guides from the bottom of the
cylinder head.
Special tool
Valve guide remover and installer:
5-8840-2816-0
WSJJ0072
Inspection
1. Check the cylinder head ASM.
• Remove varnish, soot and others adhered on the
metal surface completely. Use metal brush and
WSJJ0071
others so that the surface where the gasket is
13. Remove the cam end packing. installed is not damaged.
• Check the following causes in the case of leak,
corrosion and air leak on the seal surface of the
cylinder head, or defective gasket.
- Improper installation
- Defective tightening of the cylinder head
- Winding seal surface of the cylinder block
a. Inside the combustion chamber, glow plug hole.
• Check whether there is a crack between the
valve seats and in the cylinder head of the
exhaust port part, and replace the cylinder head
if there is serious damage or crack. Check the
collar if necessary.
E F
C D
WSJJ0074
Cylinder head height (H) (Reference) mm (in)

Standard 143.4 (5.646)
WSJJ0189
b. Flatness of the under surface of the cylinder

head
• Use a straight edge ruler and thickness gauge
to measure the four sides and diagonal lines as
shown in the illustration, and replace if they
exceed the limit.
Distortion of the under surface of the mm (in)

cylinder head
H
Limit 0.20 (0.0079)
Note:
Do not place the cylinder head with its surface that
contacts the cylinder block facing downward.
WSJJ0075
c. Flatness of the installation surfaces of the

exhaust manifold and intake manifold
to measure the four sides (right, left, top, and
bottom) and diagonal lines as shown in the
illustration. If the measurement exceeds the
limit value but is less than the maximum
allowable grinding value, grind the manifold
installation surface of the cylinder head. If the
measurement exceeds the maximum allowable
grinding value, replace it.
WSJJ0073
2. Visual check on the valve stem end cap
Distortion of the installation surface of the mm (in) • Inspect for excessive abrasion and damage on the
manifold surface where the cap and the rocker arm
Standard 0.05 (0.002) or less adjusting bolt contact, and replace as required.
Limit 0.2 (0.0079) 3. Check the valve guide.
Maximum 0.4 (0.0157) Caution:

allowable If there is a scratch or abnormal abrasion on the valve
grinding value stem and the inner diameter part of the valve guide,
replace the valve and valve guide together.
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 guide
together.
The external diameter of the valve stem mm (in)

Standard Limit
Intake valve 6.955 — 6.970 6.935
(0.2738 — 0.2744) (0.2730)
Exhaust valve 6.939 — 6.949 6.920
(0.2732 — 0.2736) (0.2724)
WSJJ0076
d. Flatness of the exhaust manifold

to measure the flatness. If it exceeds the limit,
replace the exhaust manifold.
Distortion of the exhaust manifold mm (in)

Limit 0.2 (0.0079)
• Measure the inner diameter of the valve guide.

• If the clearance between the valve stem outside
diameter and the valve guide inner diameter
exceeds the limit, replace the valve guide and
valve together.
Gap between the valve guide and valve mm (in)

stem
Standard Limit
Intake valve 0.039 — 0.071 0.20
(0.00154 — (0.00787)
WSJJ0245 0.00280)
Gap between the valve guide and valve mm (in) Valve seat
stem • Remove carbon, water stain and others on the
under surface of the cylinder head.
Standard Limit
Install the valve in the cylinder head.
Exhaust valve 0.064 — 0.096 0.25 Measure the depth of the valve from the under
(0.00252 — (0.00984) surface of the cylinder head, using a depth
0.00378) gauge or straight edge ruler.
If the value exceeds the limit, replace the valve
insert or the cylinder head ASM.
Depth of the valve mm (in)

Standard 1.8 (0.07)
Limit 2.5 (0.0984)
WSJJ0077
4. Check the valve.

Thickness of valve
• Measure the thickness of the valve.
• If the measured value exceeds the limit, replace
the valve and valve guide altogether.
WSJJ0078
Thickness of valve mm (in) • Measure the contact width of the valve seat. If
Standard 1.32 (0.052) the seat contact surface has a scratch or is
rough, or if the abrasion of the contact surface
Limit 1.1 (0.045) exceeds the limit, modify or replace it.
Contact width of the valve seat mm (in)

Standard Limit
Intake valve 1.7 (0.067) 2.2 (0.087)
Exhaust valve 2.0 (0.079) 2.5 (0.098)
Repair of the seat surface
• Remove carbon from the surface of the valve
seat.
• Use a seat cutter to minimize the scratch and
other roughness (15/45/75°-blade), thereby
returning the contact width to the standard
value.
WSJJ0079
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°
Caution:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Do not let the valve cutter pilot waver inside the valve
guide.
• Attach compound in the valve insert seat.

• Insert the valve into the valve guide.
• Apply compound to the valve seat surface,
rotate the valve and hit it lightly to grind them,
and confirm that it has even contact all round.
Caution:
Remove compound completely after grinding.
Install the valve seat insert
• Carefully place a washer (the outer diameter is
smaller than the valve seat insert) on the valve
seat insert.
• Use the press to apply pressure gradually on
the washer, thereby pushing the valve seat
insert.
• After replacing the valve seat insert, apply
compound to the valve seat surface, rotate the
valve and hit it lightly to grind it, and confirm
that it has even contact all round.
Caution:
Do not apply too much pressure with the press.
Remove compound completely after grinding.
Replacement of valve seat insert

Remove the valve seat insert.
• Arc-weld the entire inner diameter of the valve
seat insert.
• Cool the valve seat insert for two to three
minutes. It contracts as it cools down, making it
easier to remove the valve seat insert.
• Remove the valve seat insert, using a screw
driver. Be sure not to hurt the cylinder head.
Name
1. Washer
2. Valve Seat
3. Press
Reassembly
1. Install the oil seal.
• Install on the surface of injection pipe insert.
• Hammer it in so that the seal does not incline.
Caution:
Name Be careful not to damage the lip.
1. Arc-Weld
2. Valve Seat Insert
3. Screwdriver
Special tool Special tool
Injection pipe oil seal installer: 5-8840-2820-0 Valve guide remover and installer:
5-8840-2816-0
WSJJ0072
WSJJ0081
Height from the upper surface of the cylinder head

to the edge surface of the valve guide: 12.6 ± 0.1
3
mm (0.50 ± 0.0039 in)
Caution:
1
When replacing the valve guide, it must be replaced
together with the valve.
WSJJ0080
Name
1. Cylinder Head
2. Injection Pipe Oil Seal Installer
3. 2 mm (0.079 in)
2. Install the valve guide.

• Hammer in the valve guide from the upper surface WSJJ0082
of the cylinder head, using the valve guide remover 3. Install the valve spring seat.
and installer. 4. Install the valve stem oil seal.
Note: • Apply engine oil on the outer diameter of the valve
The valve guide cannot be set to the specified height guide, use the valve stem seal installer to install
using the valve guide remover and installer. Hammer in the oil seal.
the valve guide while measuring the height during the
work. Caution:
After installation of the valve stem seal, confirm that the
oil seal is not inclining and the garter spring is in place.
Special tool 9. Install the thermostat.
Valve stem seal installer: 5-8840-2817-0 • Install the thermostat on the position shown in the
illustration.
2 1
WSJJ0063
5. Install the intake and exhaust valves. WSJJ0179
• Apply engine oil on the valve stem part and install

the valve. Name
1. Thermostat
6. Install the valve spring. 2. Jiggle Valve
7. Install the spring upper seat.
8. Install the split collar. 10. Connect the water outlet pipe.
• Use a replacer to compress the valve spring and • Tighten the water outlet pipe to the specified
install the split collar. torque.
Special tool
Valve spring replacer: 5-8840-2818-0 11. Install the exhaust manifold.
Pivot: 5-8840-2819-0 Refer to “Exhaust Manifold”.
12. Install the turbocharger.
Refer to “Exhaust Manifold”.
13. Install the intake manifold.
WSJJ0061
Refer to “Intake Manifold”. Caution:
Note that there are three options for the head gasket
according to the amount of extrusion of piston shown in
Installation the following table.
1. Install the cylinder head gasket. • Measure at the measurement positions 1, 2, 3 and
• Select the cylinder head gasket. 4 for each cylinder, and find the differences
• Clean the head of the piston and the upper surface between 1 and 2, and between 3 and 4.
of the cylinder block. • Calculate the average piston extrusion amount of
• Use a dial gauge to measure the extrusion amount each cylinder.
of the piston at the location shown in the • Calculate the maximum amount based on the
illustration. average amount of each cylinder.
• Measure as close to the cylinder bore as possible. • Select a gasket of an appropriate grade based on
the maximum extrusion amount.
• Select the gear case gasket with the same grade
as the cylinder head gasket.
WSJJ0083
WSJJ0085
Combination of cylinder head gasket mm (in)
2 4
Gasket Thickness
Gasket Grade Mark Piston Projection (Reference)
1 3 0.067-0.117 0.95
A (0.0026-0.0046) (0.0630)
0.117-0.167 1.00
B (0.0046-0.0066) (0.0650)
0.167-0.217 1.05
C (0.0066-0.0085) (0.0669)
WSJJ0084
WSJJ0086
3. Install the cylinder head bolt.
• Use a torque wrench and angle gauge to tighten
the head bolts in the order described in the
illustration.
Caution:
Replace the cylinder head bolt with new one.
Tightening torque:
1st step= 70 N⋅m (7.1 kg⋅m/51 lb ft)
2nd step= 70 N⋅m (7.1 kg⋅m/51 lb ft)
3rd step= 60°
4th step= 60°
Special tool
Angle gauge:
5-8840-0266-0 (J-45059, KM470-B)
WSJJ0087
Note:
The amount of the extrusion for each piston should be
equal or within 0.05 mm (0.002 in). 17 13 9 5 1 4 8 12 16
• Install the cylinder head within five minutes after
applying liquid gasket.
1 14 10 6 2 3 7 11 15
18
WSJJ0089
4. Install the bolt and nut which hold the cylinder

head to the gear case.
• Tighten the bolt and nut in the order shown in the
illustration.
WSJJ0088
Name
1. 2 — 3 mm (0.079 — 0.118 in)
2. 3 — 4 mm (0.118 — 0.157 in)
• Install the cylinder head gasket.

2. Install the cylinder head ASM.
• Install the cylinder head, adjusting the knock pin of
the cylinder block.
Caution:
Be sure not to hurt the head gasket when installing it.
1
6
WSJJ0213 WSJJ0188
5. Connect the bypass pipe. 9. Install the timing chain tension lever.
• Apply soap water to the O-ring. 10. Rotate the crankshaft to make the No.1 cylinder
Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft) meet the compression top dead center (TDC).
1
WSJJ0001
WSJJ0191
Name
Name 1. TDC
1. Bypass Pipe
11. Install the timing chain together with the idle gear
6. Install the valve stem end cap. D.
• Apply engine oil. • Apply engine oil to the threads and the seating
7. Install the rocker arm shaft ASM. surface of the bolt, and to the part where the gear
Refer to “Rocker Arm Shaft ASM”. of the idle gear shaft is to be put together.
8. Install the bolt of the chain guide to the cylinder Tightening torque: 59 N⋅m (6.0 kg⋅m/43 lb ft)
head.
WSJJ0090 WSJJ0067
12. Align the timing marks at two locations as shown in 14. Push down the cam of the timing chain tensioner,
the illustration. and push the plunger in. Hook on the pin to hold
• Align the timing marks of the camshaft sprocket the plunger depressed.
with the dark plate of the timing chain link.
• Align the timing marks of the supply pump sprocket 1
with the yellow plate of the timing chain link. 2
1
5
4
WSJJ0092
3 Name
4 1. Pin
WSJJ0091
2. Plunger
3. Cam
Name
4. Body
1. Timing Mark
5. Hook
2. Dark Plate
3. Timing Mark
15. Install the timing chain tensioner and packing.
4. Yellow Plate
13. Install the timing chain tension lever pivot.
18. Rotate the crank pulley two turns (720°).
• Check that the alignment mark and the timing mark
are aligned as shown in the illustration.
2
1
1 2
3
WSJJ0093
Name
1. Timing Chain Tensioner 3
2. Packing
3. Nut WSJJ0095
Name
16. Push the timing chain lightly.
1. Exhaust Camshaft Gear
• This causes the plunger to be pushed to unhook. 2. Intake Camshaft Gear
3. Idle Gear D
Caution:
Perform the above steps securely, and make sure that
the plunger pushes the timing chain tension lever. 2
3
4
WSJJ0091
WSJJ0094 Name
17. Install the camshaft ASM. 1. Timing Mark
2. Dark Plate
3. Timing Mark
4. Yellow Plate
19. Install the timing chain cover upper.

section.
20. Install the fan shroud bracket upper and fan shroud
stay upper.
Tightening torque: 26. Install the cam end packing.
M8 bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft) • Apply liquid gasket (ThreeBond 1207B or
M10 bolt: 51 N⋅m (5.2 kg⋅m/38 lb ft) equivalent).
Nut: 25 N⋅m (2.5 kg⋅m/18 lb ft)
3
1
2
1
WSJJ0040
WSJJ0249 Name
1. Cam End Packing
Name 2. Liquid Gasket Applied Area.
1. Fan Shroud Bracket Upper 3. 2.0 — 3.0 mm (0.078 — 0.118 in)
21. Install the timing chain cover lower. Refer to “Cylinder Head Cover”.
section. 28. Install the glow plug.
22. Adjust the valve clearance. Tightening torque: 15 — 20 N⋅m (1.5 — 2.0 kg⋅m/11 —
Refer to “Function Check”. 15 lb ft)
23. Install the fuel injector.
24. Install the fuel injection pipe.
Important:
25. Install the baffle plate.
WSJJ0207
29. Install the glow plug connector.

Tightening torque: 1.5 — 2.0 N⋅m (0.15 — 0.20 kg⋅m/
13 — 17 lb in)
1
1
WSJJ0096 WSJJ0224
Name Name
1. Glow Plug Connector 1. Oil Feed Pipe
2. Nut
33. Connect the water feed pipe on the turbocharger.
30. Connect the connectors of the EGR valve, boost • Tighten the joint bolts to the specified torque.
temperature sensor, boost pressure sensor, ECT
sensor, CMP sensor and fuel injector.
31. Connect the oil return pipe on the turbocharger. • Install the pipe bracket and tighten each bolt and
nut to the specified torque.
Tightening torque:
M8 bolt: 24.7 N⋅m (2.5 kg⋅m/18 lb ft) Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)
M6 bolt: 10 N⋅m (1.0 kg⋅m/87 lb in) • Connect the rubber hose between the water return
pipe and the thermostat housing.
WSJJ0220
WSJJ0011
Name
1. Oil Return Pipe Name
1. Water Feed Pipe
32. Connect the oil feed pipe on the turbocharger.
34. Connect the return pipe on the turbocharger.
WSJJ0219 WSJJ0239
Name Name
1. Water Return Pipe 1. Leak-Off Hose
35. Connect the front exhaust pipe.

36. Install the EGR cooler.
Refer to “EGR Cooler” in the Exhaust System
section. 1
37. Install the oil level gauge guide tube.
• Apply a coat of engine oil to the O-ring.
• Tighten the bolt to the specified torque.
Tightening torque:
Bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft)
Nut: 51 N⋅m (5.2 kg⋅m/38 lb ft)
38. Install the fan ASM.
Section.
Section. WSJJ0004
41. Install the harness bracket. Name
1. Leak-Off Pipe
42. Connect the leak-off hose and pipe.
Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft) 43. Connect the intake pipe and duct.
Caution:
Do not open the clip too widely. This may damage the
clip.
N m(kg m/lb ft)

70 ( 7.1 / 51 )
70 ( 7.1 / 51 ) 1.5 2.0 ( 0.15 0.20 / 13 17 lb in )
60
60
25 ( 2.5 / 18 )
15 20 ( 1.5 2.0 / 11 15 )
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
10 ( 1.0 / 87 lb in )
27 ( 2.8 / 20 )
WSJJ0214
Special Tool
Tool Number/Description / Tool Number/Description /
Illustration Illustration
Special Tool Rank Special Tool Rank
5-8840-2816-0
5-8840-2817-0
Valve guide remover and
Valve stem seal installer
installer
Rank B
Rank B
5884028160 5884028170
Illustration
Special Tool Rank
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Rank B
5-8840-2820-0
Injection pipe oil seal
installer
Rank A
5884028200
5-8840-2818-0
Valve spring replacer
Rank B
5884028180
5-8840-2819-0
Pivot ASM
Rank B
5884028190
Piston, Connecting Rod

Components
WSJJ0097
Name
1. Snap Ring 5. Connecting Rod
2. Piston Pin 6. Bearing
3. Piston Ring 7. Connecting Rod Cap
4. Piston
Removal Refer to the “Cylinder Head”.

1. Lower the engine ASM. 6. Remove the gear case ASM.
Refer to “Gear Case ASM”.
Refer to “Cylinder Head Cover”. 7. Remove the oil pan.
Refer to “Crankcase, Oil Pan”.
Refer to “Camshaft ASM”. 8. Remove the connecting rod cap.
4. Remove the rocker arm shaft ASM. Caution:
Refer to “Rocker Arm Shaft ASM”. Sort the removed bearings according to cylinders by
5. Remove the cylinder head. using tags.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Caution:
Sort the piston rings in the order of cylinders when
reusing them so that they will not be confused with the
pistons and piston rings of other cylinders.
9. Remove the piston and connecting rod.

• Remove carbon on the upper side of the cylinder
block with a scraper.
• Pull out the piston and connecting rod towards the
cylinder head.
Caution:
Be sure not to damage the oil jet and cylinder block
when pushing out the connecting rod. 2. Remove the snap ring.
• Remove the snap ring while inserting and scraping
with a fine screwdriver at the position shown in the
illustration.
WSJJ0167
10. Remove the connecting rod bearing.
Caution:
WSJJ0227
Sort the bearings in the order of cylinders when reusing
them so that they will not be confused with the bearing 3. Remove the piston pin.
of other cylinders.
Caution:
Sort the disassembled piston pins, pistons and
connecting rods together in the order of cylinders.
2
3
3
2
WSJJ0098
4. Remove the connecting rod from the piston.

Name
5. Piston 1. 20 mm (0.79 in)
• Clean carbon carefully that is adhered to the head 2. Radial Direction
of the piston and the groove of the piston ring. 3. Thrust Direction
Caution: Piston outside diameter

Do not use wire brush to clean the piston because it • Use a micrometer to measure the outside diameter
scratches the piston. of the piston in the right angle to the piston pin in
Inspect the piston with eyes for cracks, burns and other the specified position.
excessive wear, and replace it if there is any
• Measurement position (from the lower surface of
abnormality.
the piston) 11 mm (0.43 in)
6. Measure the gap between the piston and the inner
diameter of the cylinder block. Piston diameter (supply parts) mm (in)
Cylinder block inner diameter
Grade Standard
• Use a cylinder gauge to measure the cylinder
block inner diameter both in the thrust and radial A 95.330 — 95.339 (3.75314 — 3.75350)
directions in the specified position. B 95.340 — 95.349 (3.75354 — 3.75389)
• Measurement position (from the upper surface of
the cylinder block) C 95.350 — 95.359 (3.75393 — 3.75428)
1. 20 mm (0.79 in)
• Measure the liner inner diameter based on the Gap between the piston and the inner mm (in)
average value of the actual measurement values diameter of the cylinder block
on 2 positions. Standard 0.082 — 0.100 (0.0032 —
0.0039)
Cylinder block inner diameter mm (in)
95.421 — 95.450 (3.75673 — 3.75787) Caution:
If the gap between the cylinder block inner diameter
and the piston exceeds the standard value, replace the
piston or cylinder block.
Measure the joint of the piston ring (remove carbon
on the ring joint).
• Insert the piston ring into the cylinder liner.
• Use the piston to push the ring up to the
measurement position (1) or (2) where the cylinder
bore diameter is the smallest. Keep the ring in a
1 horizontal position.
WSJJ0099
7. Piston replacement
• You do not need to select more than one grade
because there is only one grade for each of the
piston and the cylinder block inner diameter.
• Refer to “Cylinder Block” if you replace the cylinder
block.
Caution: • Use a thickness gauge to measure the gap of the

The head of piston has a marking of grade B or C when ring joint.
it is shipped from the factory.
WSJJ0102
WSJJ0100
Name
1. Front Mark Cut
8. Inspect the piston ring.

Measurement position (1): 10 mm (0.4 in)
WSJJ0103 9. Inspect the piston pin.

Measurement position (2): 120 mm (4.7 in) • Inspect the piston pin with eyes for cracks,
• If the measurement exceeds the limit, replace the scratches and other damages, replace it if
piston ring. necessary.
• Use a micrometer to measure the outer diameter
Piston ring gap mm (in)
of the piston pin. If the measured value exceeds
Standard Limit the limit, replace the piston pin.
Top ring 0.3 — 0.5 1.5 Piston pin outer diameter mm (in)
(0.0118 — 0.0197) (0.059)
Standard 33.995 — 34.000 (1.33838 —
Second ring 0.3 — 0.5 1.5 1.33858)
(0.0118 — 0.0197) (0.059)
Limit 33.970 (1.33740)
Oil ring 0.25 — 0.45 1.5
(0.0098 — 0.0177) (0.059)
Measure the clearance between the piston ring

groove and the piston.
• Remove carbon on the piston ring groove
completely.
• Put the piston ring in the piston ring groove, and
use a thickness gauge to measure the gap
between them.
• If the clearance between the piston ring groove
and the piston exceeds the limit, replace the piston
and the piston ring.
Piston ring and piston ring groove mm (in)

clearance
Piston ring Standard Limit
Top ring —* —*
Second ring 0.05 — 0.09 0.15
(0.0020 — 0.0035) (0.0059)
Oil ring 0.03 — 0.07 0.15
(0.0012 — 0.0028) (0.0059)
* Measurement is impossible.
• Inspect to make sure that there is a resistance to 10. Measure the clearance between the piston and the
the extent which the piston can push the piston pin piston pin.
lightly in normal temperatures. • Apply engine oil on the piston pin. Use your finger
• If it is too loose or rattles when it is put in the to push it in the piston hole and rotate it. If the pin
normal temperatures, replace the piston or piston smoothly rotates without rattling, the clearance is
pin. normal. If there is rattling, measure the clearance.
If the clearance exceeds the limit, replace the
piston and the piston pin.
Piston pin and piston pin hole clearance mm (in)

Standard 0.004 — 0.017 (0.0002 — 0.0007)
Limit 0.04 (0.0016)
11. Measure the connecting rod alignment.

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

(per length of 100 mm {3.94 in})
Standard Limit
Torsion 0.08 (0.003) or less 0.20 (0.008)
• Measure the bushing in the small end of the
connecting rod. If the clearance between the Parallelism 0.05 (0.003) or less 0.15 (0.006)
bushing inner diameter and the pin diameter
exceeds the limit, replace the connecting rod ASM
and the pin.
Piston pin and connecting rod small end mm (in)

bushing clearance
Standard 0.008 — 0.020
(0.0003 — 0.0008)
Limit 0.05 (0.0020)
WSJJ0228
12. Measure the bearing oil clearance. - Remove the cap.

• Measure the oil clearance between the connecting - Measure the largest width of the plastigauge to
rod bearing and the crank pin with the following calculate the oil clearance. If the clearance
method. exceeds the limit, replace the bearing or
- Remove the connecting rod cap. Sort the crankshaft.
removed caps according to the cylinder
number. Crank pin and bearing clearance mm (in)
- Clean the bearing and the shaft pin. Standard 0.029 — 0.083 (0.0011 — 0.0026)
- Check the bearing. If it is damaged or worn Limit 0.10 (0.0039)
seriously, replace the bearing ASM.
• Place the plastigauge on the crankshaft pin. - Remove the plastigauge from the bearing and
• Install the bearing cap and tighten the bolt with the crank pin.
specified torque.
Apply engine oil to the threads and the bearing
surface.
Connecting rod bearing cap bolt N⋅m

torque: (kg⋅m/lb ft)
1st step 29.4 (3.0/22)
2nd step 45°
Caution:
Do not rotate the crankshaft.
WSJJ0240
Reassembly 5. Use the piston ring setting tool to install the piston
ring.
1. Install the piston.
• Install the piston ring in the order shown in the
2. Install the connecting rod.
illustration.
• Install it so that the front mark of the head of the
• Install the piston ring with the “N” mark facing
piston and the connecting rod forging mark
upward.
(projecting) on the connecting rod face the same
direction. • Install the second ring so that the yellow paint on
the outer circumference comes to the right side of
• Install the snap ring on either side.
the end gap.
Special tool
Piston ring setting tool: 1-8522-1029-0
Name
1. Snap Ring WSJJ0104
2. Front Mark
Name
3. Forging Mark (Projecting)
1. Top Ring
2. Second Ring
3. Apply enough engine oil on the piston pin, push it
3. Oil Ring
in the piston and the connecting rod small edge.
4. Coil Expander
4. Assemble the snap ring.
Caution: Caution:
Make sure that the snap ring is installed in the ring Note that the shapes are different for each piston ring.
groove properly. Make sure that the connecting rod
moves smoothly.
WSJJ0105
Make sure that there is no gap in the position shown in Special tool
the illustration when the oil ring coil expander is Piston ring compressor:
installed. 5-8840-9018-0 (J-8037)
3 1
2 4
WSJJ0106
3. Install the connecting rod cap.

Installation • Install the bearing on the connecting rod cap and
apply engine oil.
1. Install the connecting rod bearing.
• Install the cap, matching the numbers (1, 2, 3, 4) of
• Install the bearing on the connecting rod, apply the caps and connecting rods.
engine oil on the bearing.
• Face the front mark on the cap forward, so that the
2. Install pistons and connecting rod ASM. cylinder number indication comes to the left side.
• Apply enough engine oil on the piston ring, ring
groove and piston side surface.
• Position each end gap of piston rings in the
following positions; (1) for top ring, (2) for 2nd ring,
(3) for oil ring, and (4) for coil expander, as shown
• Face the front mark (arrow) on the piston forward,
and use the piston ring compressor to insert the
piston in the cylinder block.
Caution:
• Be sure not to make the connecting rod touch the
oil jet when pushing in the piston.
• Be sure not to hurt the inside of the block when
pushing in the piston.
WSJJ0107
• Apply engine oil to the threads and the seating

surface of the tightening bolt and tighten it to the
specified torque.
Tightening torque:
1st step= 29.4 N⋅m (3.0 kg⋅m/22 lb ft)
2nd step= 45°
Special tool
Angle gauge:
5-8840-0266-0 (J-45059, KM470-B)
Caution:
Make sure that the crankshaft rotates smoothly.
WSJJ0108
4. Install the oil pan.

5. Install the gear case ASM.
6. Install the cylinder head.
Refer to the “Cylinder Head”.
N m(kg m/lb ft)
29.4 ( 3.0 / 22 ) 45
WSJJ0109
Special Tool
Tool Number/Description Tool Number/Description
Illustration Illustration
Special Tool Rank Special Tool Rank
5-8840-0266-0
5-8840-9018-0
J-45059
J-8037
KM470-B
Piston ring compressor
Angle gauge
Rank B
Rank B
1-8522-1029-0
Piston ring setting tool
Rank B
Flywheel
Components
WSJJ0013
Name
1. Flywheel ASM 2. Washer
Removal 2. Remove the washer and flywheel.

1. Remove the starter motor. • Install the crankshaft stopper to the starter
installing portion of the flywheel housing.
• Remove the mounting bolt, and remove the starter
motor and ground cable. Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
WSJJ0032
Special tool 3. Take out the ring gear.
Crankshaft stopper • Put a bar on the ring gear and hit it with a hammer
to remove it.
• Gradually loosen the flywheel installation bolts in WSJJ0182

the order shown in the illustration so that the
flywheel does not rotate.
• After loosening all the bolts, remove the stopper to
Inspection
remove the flywheel. 1. Visual check
• Inspect the flywheel friction surface for cracks and
damages, and replace it if it has abnormality.
• Inspect the tooth part of the ring gear, and replace
the ring gear if it has damage or serious wear.
• Check the flywheel installing bolt, and replace the
bolt if it is damaged.
Installation
1. Install the ring gear.
• After heating the ring gear with a gas burner
equally, install it in the flywheel. Do not let the gas
burner temperature exceeds 200°C (390°F).
Caution:
• Install the ring gear so that the side with a pattern
faces forward.
• Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
complete.
2. Install the flywheel and washer. 3. Install the starter motor and ground cable to the
• Install the flywheel to the crankshaft, and tighten in flywheel housing and tighten the bolt to the
the order shown in the illustration. specified torque.
• Apply engine oil to the threads of the bolt. Tightening torque: 97 N⋅m (9.9 kg⋅m/72 lb ft)
• Install the crankshaft stopper to the starter
Tightening torque:
1st step=59 N⋅m (6.0 kg⋅m/43 lb ft)
2nd step=60° — 90°
Special tool
Crankshaft stopper
Angle gauge:
5-8840-0266-0 (J-45059, KM470-B)
WSJJ0032
N m(kg m/lb ft)
59 ( 6.0 / 43 ) 60 90
WSJJ0110
Special Tool
Illustration
Special Tool Rank
Crankshaft stopper
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Rank B
Gear Case ASM

Components
WSJJ0031
Name
1. Gear Case ASM 2. Gasket
Removal
2. Remove the cylinder head.
3. Remove the generator adjust plate.
4. Remove the water pump.
Refer to the “Water Pump” in the cooling system
section.
5. Remove the fuel supply pump.
section.
6. Remove the crankshaft pulley.
Refer to “Crankshaft Front Oil Seal”.
Refer to the “Timing Gear Train”.
8. Remove the idle gear A, idle gear A flange and idle
gear A shaft.
9. Remove the oil pump.
Refer to the “Oil Pump”. 2. Install the timing gear case.
10. Remove the timing gear case and gasket. • Aligning with the knock pin, install the timing gear
• The bolt (1) shown in the illustration is installed to case and tighten the bolt as shown in the
the inside of the timing gear case, and the bolt (2) illustration.
is installed to the crankcase side. Do not forget to • Tighten the bolt to the specified torque.
remove the bolts. Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)
Caution:
Be careful not to forget to fasten the bolt indicated with
an arrow.
1
1
6 4
3
5
3
3
2
3 3 3 3
3 2
3
5
WSJJ0033
3 3
3
Installation 3 3 3
1. Install the gasket. WSJJ0174

equivalent) on the joint of the cylinder block and Name
the crankcase, and then install the gasket. 1. Timing Gear Case
2. Bolt: L = 16
• After installing the gasket, apply liquid gasket 3. Bolt: L = 20
(ThreeBond 1207B or equivalent) to the gasket 4. Bolt: L = 35
surface as well. 5. Bolt: L = 45
• Install within five minutes after applying liquid 6. Bolt: L = 60
gasket.
3. Install the oil pump.
Refer to the “Oil Pump”.
4. Install the idle gear A, idle gear A flange and idle
gear A shaft.
6. Install the crankshaft pulley.
7. Install the fuel supply pump.
section.
1 8. Install the water pump.
Section.
9. Install the generator adjusting plate.
1 WSJJ0229 • Tighten the bolt to the specified torque.
Name
10. Install the cylinder head. Refer to the “Cylinder Head”.
N m(kg m/lb ft)
25 (2.5 / 18)
WSJJ0175
Crankshaft Front Oil Seal

Components
2
1
WSJJ0012
Name
1. Crankshaft Pulley 2. Crankshaft Front Oil Seal
Removal
1. Remove the fan ASM.
Section.
2. Remove the fan belt.
Refer to the “Water Pump” in the Cooling System 5. Remove the crankshaft front oil seal.
Section. • Remove the oil seal off with a screwdriver or the
3. Remove the starter. like avoiding damage to the oil seal contact surface
• Remove the mounting bolt, and remove the starter on the gear case cover and the shaft.
Installation
1. Install the crankshaft front oil seal.
• Press fit the oil seal using an front oil seal installer.
Special tool
Front oil seal installer kit:
5-8840-2821-0
WSJJ0032
4. Remove the crankshaft pulley.

• Loosen the pulley bolt after blocking the crankshaft
from turning by placing a crankshaft stopper on the
starter mounting position on the flywheel housing.
Caution:
• Make sure that the stopper is properly fitted and
WSJJ0111
• Apply engine oil to the lip and the outer
circumference of the oil seal, and push it in up to
washer.
the measurement shown in the illustration.
Special tool
Crankshaft stopper
WSJJ0112
Measurement (A): 1.5 mm (0.06 in)
• Install the crankshaft pulley while aligning it with
the key on the crankshaft.
Caution:
ones.
WSJJ0113
3. Install the starter motor and ground cable to the

flywheel housing and tighten the bolt to the
specified torque.
4. Install the fan belt.
Section.
5. Install the fan ASM.
Section.
N m(kg m/lb ft)
220 ( 22.4 / 162 )
WSJJ0114
Special Tool
Illustration
Special Tool Rank
Crankshaft stopper
5-8840-2821-0
Front oil seal installer
Rank A
5884028210
Crankshaft Rear Oil Seal

Components
WSJJ0014
Name
1. Crankshaft Rear Oil Seal 3. Flywheel Housing
2. Retainer 4. Flywheel
Removal 4. Remove the slinger.
1. Remove the flywheel. • Use slinger puller to remove the slinger.
Refer to the “Flywheel”.
Caution:
2. Remove the flywheel housing. When replacing the oil seal, it must be replaced
• Loosen the bolt shown by the arrow while holding together with the slinger.
the nut located on the back using a tool.
Special tool
Slinger puller: 5-8840-2360-0
WSJJ0230
Name WSJJ0241
1. Flywheel Housing
3. Remove the retainer. Installation

• After removing the retainer, remove the crankshaft 1. Install the retainer.
rear oil seal from the retainer.
• Apply the liquid gasket (ThreeBond 1207B or
equivalent) and mount within 5 minutes.
WSJJ0231
Name
1. Retainer
WSJJ0139
Name
1. 2.0 — 2.5 mm (0.079 — 0.098 in)
2. 2.0 — 2.5 mm (0.079 — 0.098 in)
2. Use an oil seal installer to install the slinger and oil
seal.
Special tool
Oil seal installer: 5-8840-2359-0
WSJJ0116
• After inserting the oil seal, check that the distance

from the crankshaft tip to the oil seal is within the
specified range.
Caution:
Replace the oil seal together with the slinger.
3. Install the flywheel housing.
• Tighten the bolt (4) while holding the nut located on
the back using a tool.
Tightening torque of the flywheel housing:
N⋅m (kg⋅m/lb ft)
1 = 51 (5.2/38) 2 = 82 (8.4/60) 3 = 97 (9.9/72)
4 = 51 (5.2/38)
4
2
WSJJ0242
4. Install the flywheel.

N m(kg m/lb ft)
51 ( 5.2 / 38 )
82 ( 8.4 / 60 ) 51 ( 5.2 / 38 )
97 ( 9.9 / 72 ) 25 ( 2.5 / 18 )
WSJJ0243
Special Tool
Illustration
Special Tool Rank
5-8840-2360-0
Slinger puller
Rank B
5884023600
5-8840-2359-0
Oil seal installer
Rank A
5884023590
Crankshaft
Components
3
4
WSJJ0015
Name
1. Bearing Cap 5. Gear
2. Lower Bearing 6. Crankshaft
3. Thrust Bearing 7. Upper Bearing
4. Key 8. Rotor
Removal 5. Remove the cylinder head.

6. Remove the fuel supply pump.
section.
3. Remove the camshaft.
7. Remove the common rail.
Refer to “Common Rail” in the Fuel System
4. Remove the rocker arm shaft. section.
8. Remove the crankshaft front oil seal.
9. Remove the crankshaft rear oil seal. 18. Remove the bearing cap.
Refer to the “Crankshaft Rear Oil Seal”. • Gradually loosen the installation bolts of crankshaft
10. Remove the water pump. bearing cap in the order shown in the illustration.
Section.
12. Remove the timing gear train.
13. Remove the oil pump. 3 7 10 6 2
1 2 3 4 5
14. Remove the gear case ASM.
15. Remove the crankshaft gear. 4 8 9 5 1
• Remove the gear using a gear puller.
WSJJ0149
19. Remove the lower crankshaft bearings.

20. Remove the crankshaft ASM.
21. Remove the thrust bearing.
22. Remove the upper crankshaft bearings.
Disassembly
1. Remove the CKP sensor rotor.
WSJJ0117
16. Remove the crankcase and oil pan. 1

Refer to the “Piston, Connecting Rod”.
WSJJ0118
Name
1. CKP Sensor Rotor
2. Bolt
Reassembly
1. Install the CKP sensor rotor.
• Install the rotor with the protruded teeth facing
forward.
• Apply Loctite No. 262 or equivalent to the threads
of the bolt (if new bolt is used, Loctite is not
necessary).
WSJJ0120
2 2. Main bearing clearance

1
• Remove the bearing cap.
Set out disassembled main bearings in the order of
the numbers.
• Remove the crankshaft. Remove the main bearing.
• Clean the crankshaft journal and the upper and
WSJJ0119 lower bearings.
• Check the bearings for damage or excessive wear.
Name
1. CKP Sensor Rotor If you find damage or excessive wear in the check,
2. Bolt replace the bearings in pairs.
• Gently place the crankcase on the cylinder block.
Place the crankshaft horizontally to install.
Inspection
1. Thrust clearance
• Measure the thrust clearance of the crankshaft at
its center journal part.
• If the thrust clearance exceeds the limit, replace
the thrust bearings in a pair.
Axial play of the crankshaft mm (in)

Standard 0.10 (0.004)
Limit 0.30 (0.012)
Caution:
Measure the thrust clearance before dismounting.
Caution: Caution:
Turn the crankshaft about 30° to allow the bearings to Do not rotate the crankshaft after tightening the bearing
settle in. cap.
• Place Plastigauge on the crankshaft journal as • Loosen the bolt, and gently remove the bearing
shown. cap.
• Place each lower bearing at the original position on • Tighten the bearing cap, and measure the widest
the bearing cap. part of the Plastigauge flattened to determine the
clearance.
Journal oil clearance mm (in)

Standard 0.032 — 0.077 (0.0013 —
0.0030)
Limit 0.11 (0.0043)
WSJJ0121
• Install the bearing cap and tighten the bolt with the
specified torque.
• Tighten the crankcase in the order shown in the
illustration using a torque wrench.
• If the journal oil clearance exceeds the limit,

replace the main bearings altogether or the
crankshaft.
8 4 1 5 9 • Remove the plastigauge from the bearing and
1 2 3 4 5
crank pin.
Inspection of crankshaft
7 3 2 6 10 • 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
WSJJ0177 turn the crankshaft to measure the run-out. If the
Tightening torque: 166 N⋅m (16.9 kg⋅m/122 lb ft) crankshaft run-out exceeds the limit, replace the
crankshaft.
Crankshaft run-out mm (in)

Standard 0.05 or less (0.0020 or less)
Limit 0.08 (0.003)
Selection of crankshaft bearing

• 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.
• The number 1, 2 or 3 of the cylinder block journal
part is stamped on the right rear of the cylinder
body.
WSJJ0123
1 2 3 4 5
4. Measure the journal and the crank pin diameters

and uneven wear.
• Measure outer diameters of the journal and the pin
and calculate differences between the maximum
and the minimum values. Take measurements at
four positions for both the journal and the pin.
1 2 1 1 2
WSJJ0125
Name
1. No. 1
2. No. 2
3. No. 3
4. No. 4
5. No. 5
• The number (1 or “-”, 2 or “--”, 3 or “---”) of the

crankshaft journal diameter is stamped on each
crank arm.
Note:
The number of the No. 4 journal diameter is stamped
Crankshaft outside diameter mm (in) on either the front or the rear side of the No. 4 crank
Standard Limit arm.
Journal 69.917 — 69.932 69.91

(2.7526 — 2.7532) (2.7524)
Pin 52.915 — 52.930 52.9
(2.0833 — 2.0839) (2.083)
Caution:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
shall not polish the surface of the crankshaft.
1 2 3 4 5
WSJJ0126
Caution:
Be careful about difference in the shape of the bearings
when installing them.
WSJJ0127
Name
1. Lot No.
2. Size Code
Bearing selection table
Combination of grades Oil clearance mm (in)

Cylinder block Crank journal Bearing
Grade Grade Grade mark
1 1 or “-” 4 0.030 — 0.049
(0.00118 — 0.00193)
1 2 or “--” 0.035 — 0.054
(0.00138 — 0.00213)
1 3 or “---” 5 0.034 — 0.053
(0.00134 — 0.00209)
2 1 or “-” 2 0.033 — 0.052
(0.00130 — 0.00205)
2 2 or “--” 3 0.032 — 0.051
(0.00126 — 0.00201)
2 3 or “---” 4 0.031 — 0.050
(0.00122 — 0.00197)
3 1 or “-” 1 0.031 — 0.049
(0.00122 — 0.00193)
3 2 or “--” 2 0.030 — 0.048
(0.00118 — 0.00189)
3 3 or “---” 0.035 — 0.053
(0.00138 — 0.00209)
Installation
1. Install the crankshaft upper bearing.
• The upper bearing has the oil hole and oil groove,
whereas the lower bearing does not.
• Carefully wipe foreign matter from the upper
bearing.
• When reusing the upper bearing, install on its
original position.
• Install the upper bearing in the cylinder block and
apply oil.
Caution:
When replacing the crankshaft bearings, select grades
referring to the Crankshaft Bearing Grade Selection.
Do not apply oil to the bearing installation surface on
the cylinder block and external surface of the bearing.
WSJJ0128
2. Install the crankshaft ASM. 5. Install the bearing cap.
• Apply engine oil to the crankshaft journal and • Install the bearing cap so that its arrow faces
gently place the crankshaft on the cylinder block. toward the front of the engine.
equivalent) to the installation surfaces of the No. 5
crankshaft bearing cap and the cylinder body as
shown in the illustration.
• Install the bearing cap within five minutes after
applying liquid gasket.
• Tighten the installing bolt to the specified torque
according to the order shown in the illustration.
Note:
Remove oil from the bearing cap installing surface
completely before applying liquid gasket.
Apply liquid gasket so that it does not adhere to the
cylinder bolt hole and bearing.
Caution:
WSJJ0129 Confirm that the crankshaft turns smoothly.
3. Install the thrust bearing.
• Apply engine oil to the thrust bearing, and install it
to the crankshaft at the center journal part.
Caution:
Install the thrust bearing so that the oil groove contacts
the crankshaft.
1 2 3 4 5
WSJJ0132
WSJJ0130
4. Install the lower crankshaft bearing.
WSJJ0131
Refer to the “Crankshaft Rear Oil Seal”.
16. Install the common rail.
section.
8 4 5 9
section.
1
1 2 3 4 5 Refer to the “Cylinder Head”.
7 3 2 6 10 Refer to “Rocker Arm Shaft ASM”.
WSJJ0177
6. Install pistons and connecting rods.

Refer to the “Pistons, Connecting Rod”.
7. Install the crankcase and oil pan.
8. Install the crankshaft gear.
WSJJ0215

11. Install the timing gear train.
13. Install the water pump.
Section.
15. Install the crankshaft rear oil seal.
N m(kg m/lb ft)
166 ( 16.9 / 122 )
12 ( 1.2 / 104 lb in )
WSJJ0133
Cylinder Block
Components
WSJJ0016
Name
1. Cylinder Block
Removal 6. Remove the fuel supply pump.

section.
Refer to “Common rail” in Fuel System section.
8. Remove the oil cooler.
Refer to “Oil Cooler”.
9. Remove the crankshaft front oil seal.
10. Remove the crankshaft rear oil seal.
11. Remove the water pump. 4. Visually inspect the cylinder block.
Refer to the “Water Pump” in the Cooling System • Conduct color check and hydraulic (or pneumatic)
Section. test and if you find crack or other damage, replace
12. Remove the gear case cover. the cylinder block.
13. Remove the timing gear train.
14. Remove the oil pump.
16. Remove the crankcase and oil pan.
18. Remove the crankshaft.
Refer to the “Crankshaft”.
19. Disconnect the piston cooling pipe.
WSJJ0034
5. Wear measurement of cylinder block

• Check the internal surface of the block for scratch
or damage.
• Use a cylinder gauge to measure the block inner
diameter both in the thrust (2-2) and radial (3-3)
directions in the specified position (1).
• Measurement position (from the top surface of the
cylinder block) 20 mm (0.79 in)
Replace the cylinder block or perform boring if the
wear amount exceeds the limit value.
WSJJ0134
Inspection
1
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
2. Carefully remove the liquid gasket on the
3
crankcase mounting surface.
3
3. Clean up the cylinder block. 2
WSJJ0098
Cylinder block bore diameter mm (in)

Standard 95.421 — 95.450
(3.7567 — 3.7579)
Limit 95.48 (3.7590)
6. Cylinder boring • Perform boring and honing of each cylinder as
• Select an oversize piston that fits the maximum required.
cylinder bore size which is previously measured. • Measure the diameter of each cylinder bore again.
• Use a micrometer to measure the outside diameter Differences among the cylinders mm (in)
of the piston at a right angle to the piston pin in the
specified position. 0.02 (0.0008) or less
Measurement position (from the bottom surface of
the piston) 11 mm (0.43 in) 7. Cylinder block upper face warpage
• Calculate the necessary amount of cylinder boring • Measure four sides and two diagonals of the top
for each cylinder. surface of the cylinder block using a straight edge
(1) and a thickness gauge (2).
• 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)
1
Limit 0.20 (0.079)
WSJJ0099
Name 2
1. 11 mm (0.43 in)
Formula
Boring inner diameter = D + C - H ± E
D = Piston outside diameter
(Measurement of oversize piston)
C = Clearance between piston and cylinder bore
0.082 — 0.100 mm (0.0032 — 0.0039 in) WSJJ0135
H = Honing allowable amount

Cylinder block height mm (in)
0.03 mm or less (0.0012 in or less)
E = Boring machine error Standard 259.945 — 260.055
(10.2340 — 10.2384)
Piston size mm (in)
Standard 95.330 — 95.359
(3.7531 — 3.7543)
Oversize (0.25) 95.580 — 95.609
(3.7629 — 3.7641)
(0.50) 95.830 — 95.859
(3.7728 — 3.7739)
(0.75) 96.080 — 96.109
(3.7826 — 3.7838)
7. Install the timing gear train.
H
9. Install the water pump.
Section.
10. Install the crankshaft rear oil seal.
12. Install the oil cooler.
WSJJ0136 Refer to “Oil Cooler”.
Installation section.
1. Install the piston cooling pipe. 14. Install the fuel supply pump.
• Align the knock pin of the piston cooling pipe with Refer to “Fuel Supply Pump” in the Fuel System
the pin hole of the cylinder block and tighten with section.
the relief valve and bolt. 15. Install the cylinder head.
Tightening torque: Refer to the “Cylinder Head”.
Relief valve: 30 N⋅m (3.1 kg⋅m/22 lb ft) 16. Install the rocker arm shaft ASM.
M8 bolt: 25 N⋅m (2.5 kg⋅m/18 lb ft) Refer to “Rocker Arm Shaft ASM”.
M6 bolt: 8 N⋅m (0.8 kg⋅m/69 lb in) 17. Install the camshaft ASM.
Caution:
Be careful not to deform or damage the piston cooling
pipe.
WSJJ0134
2. Install the crankshaft.

Refer to the “Crankshaft”.
3. Install pistons and connecting rods.
4. Install the crankcase and oil pan.
Lubrication System
Precautions on Service Work Explanations on functions and operation
• During each disassembly, remove the old gasket The lubrication system uses the filter element
adhering to each part and mating part completely combined with a full flow bypass, water-cooled oil
using a scraper at the location, where the fluid cooler, and oil jet for piston cooling.
gasket is to be used, clean the traces of oil,
moisture and dirt completely using waste cotton,
and apply the specified new fluid gasket at each
location.
• Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
coating due to clogging of the oil gallery and oil jet,
and oil and water leakage may occur if the coating
is insufficient.
• Always, the start and end of the application should
be overlapped.
Lubricating system diagram
4. Oil Press. Warning

SW Lamp
Oil Gallery
Oil Filter & Cooler Assembly
5. Regulating Crankshaft Turbo-

Oil Filter 3. Relief Valve Bearing charger
Valve
Idler Gear Camshaft Vacuum

Shaft Bearing Pump
Oil Cooler
Piston Connecting
2. Relief Cooling Jet Rod Bearing
Valve
Timing Chain
Oil Jet
Timing Gear
Oil Pump
Rocker Arm
1. Relief
Valve Oil
Strainer
Oil Pan
WSJJ0137
Name
1. Oil Pump Relief Valve Opening Pressure: 4. Oil Pressure Switch Operating Pressure:
490 — 686 kPa (71 — 100 psi) 29.4 — 49.0 kPa (4.3 — 7.1 psi)
2. Oil Cooler Relief Valve Opening Pressure: 5. Regulating Valve:
176 — 216 kPa (26 — 31 psi) 176 — 216 kPa (26 — 31 psi)
3. Oil Filter Relief Valve Opening Pressure:
80 — 120 kPa (11 — 17 psi)
Functional Check 7. Stop the engine.
Oil pressure check 8. Remove the oil pressure gauge.
1. Check whether the engine oil is contaminated with 9. Install the oil pressure switch.
dirt, light oil, or water. If contaminated with dirt, 10. Start the engine and check for oil leakage.
light oil, or water (after examining the cause and
taking the appropriate measures for light oil or Engine oil
water contamination), replace the oil. • Ensure the engine is at a level ground. Before
2. Check the engine oil level. The oil level should be starting the engine or when 5 minutes or more
between the two holes of the level gauge. If the oil have elapsed after stopping the engine, check the
level is insufficient, replenish it. engine oil volume using the level gauge. The
3. Remove the oil pressure switch from the nipple. volume is appropriate if the engine oil is between
the upper and lower limits of the level gauge.
4. Install the oil pressure gauge on the nipple.
Replenish the engine oil, if level is below the lower
limit. Also, check for contamination of the engine
Special tool
oil.
Oil pressure gauge: J43620-20
Hose: J43630
Connector: J43630-14
Oil pressure testing adapter:
EN-46333
1 5 WSJJ0221
ADD FULL
2 1
WSJJ0183
Name
1. Oil Pressure Testing Adapter
2. Connector
3. Hose WSJJ0216
4. Oil Pressure Gauge

5. Nipple Name
1. Upper Limit
5. Warm-up the engine. 2. Lower Limit
6. Measure the oil pressure, to check whether it is
more than 343 kPa (50 psi) at 2000 rpm.
Engine oil leakage
• In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
Special Tool
Illustration
Special Tool Rank
J-43620-20
Oil pressure gauge
Rank B
J-43630
Hose
Rank B
J-43630-14
Connector
Rank A
J-46333
Oil pressure testing
adapter
Rank A
Oil Filter ASM

Components
WSJJ0232
Name
1. Oil Filter
Removal
1. Put a tray under the oil filter.
2. Remove the oil drain plug (1).
3. Loosen the bolt (2), and remove the oil filter ASM.
4. Remove the element (4) from the filter case (3).
2 4
WSJJ0258
Installation
1. Install the element to the filter case.
2. Install the oil filter ASM.
3. Install the oil drain plug.
Oil Port Cover ASM

Components
WSJJ0017
Name
1. Oil Port Cover
Removal
1. Put a tray under the oil port cover.
2. Remove the oil port cover.
3. Remove the O-ring.
2
Installation
1
1. Install the oil port cover and O-ring.
• Apply a coat of engine oil to the O-ring.
• Apply engine oil to the O-ring of the bolt, and
tighten to the specified torque.
WSJJ0190
Name
1. Oil Port Cover
2. O-Ring
Oil Cooler
Components
WSJJ0018
Name
1. Oil Cooler
Removal
2. Remove the exhaust manifold.
3. Remove the generator.
4. Remove the generator adjust plate.
5. Remove the engine foot RH.
Refer to “Engine Foot”.
6. Remove the water bypass pipe.
WSJJ0191
Name
1. Water Bypass Pipe
7. Remove the water intake pipe.

1
1
1
WSJJ0233 WSJJ0194
Name Name
1. Water Intake Pipe 1. Nut
2. Engine Foot RH
2. Remove the element.
8. Remove the oil cooler ASM. 3. Remove the packing.
WSJJ0192 WSJJ0193
Name
1. Element
Disassembly 2. Packing
1. Remove the element mounting nut.
Reassembly Installation
1. Install the packing to the oil cooler case. 1. Install the oil cooler ASM.
2. Install the element. • Apply liquid gasket (ThreeBond 1207B or
3. Tighten the element fixing bolts using the specified equivalent) to the flange surface groove (cylinder
torque. block). Bead diameter must be between 2 — 3 mm
(0.08 — 0.12 in).
Refer to the illustration for the offset position (less
than 1 mm (0.04 in)).
• Install the O-rings to the oil passage inlet and
outlet. In doing this, you may attach the O-ring to
1
the oil cooler with grease. Do not allow the liquid
gasket to contact the O-ring.
(0.08 0.12)
2 3 1(0.04)
(0.08 0.12)
2 3
WSJJ0193
Name
1. Element 2
2. Packing 1
WSJJ0287
Name
1. O-Ring
2. Liquid Gasket
- Align the oil cooler holes with the cylinder block

studs.
- Install the oil cooler to the cylinder block.
- Tighten the bolts to the specified torque in the
order shown in the illustration.
• Liquid gasket quickly hardens.
Finish installation within 5 minutes after
applying the liquid gasket.
1 1 1 1 1 1
1 4
2 2 2
1 1 1 1 1
3
1
WSJJ0195 WSJJ0233
Name Name
1. Bolt: L = 35 1. Water Intake Pipe
2. Bolt: L = 70 2. Engine Foot RH
3. Bolt: L = 90
4. Nut 3. Connect the water bypass pipe.
• Apply soap water to the O-ring and install it to the
water bypass pipe.
• Tighten to the specified torque.
13 9 5 1 3
7 11
19
17
20
15
16 14
10 2 4
6 8 12 18
WSJJ0196
2. Connect the water intake pipe.

• Apply soap water to the O-ring and install it to the
water intake pipe. 1
• Install the water intake pipe to the oil cooler. WSJJ0191
• Tighten the bolt to the specified torque. 4. Install the engine foot RH.
Refer to “Engine Foot”.
5. Install the generator adjusting plate.
6. Install the generator.
7. Install the exhaust manifold.
Oil Relief Valve
Components
3
WSJJ0305
Name
1. Oil Cooler 3. Oil Relief Valve (Oil Filter Side)
2. Oil Relief Valve (Oil Cooler Side)
Removal
1. Remove the oil cooler.
2. Remove the oil relief valve on the oil cooler side.
• Loosen the plug and remove so as not to let the
spring stick out.
• Remove the spring, valve and valve sheet.
Installation
1. Install the oil relief valve on the oil filter side.
2
• Insert the spring and valve.
3
1 4 • Install the valve seat and fasten until it contacts.
Make sure that the snap ring is installed in the ring
groove properly.
Note:
There is no specified torque for fastening the valve
seat. Adequate care should be taken as over-tightening
may lead to damage.
• Install the snap ring.
WSJJ0303
Name
1. Plug
2. Spring
3. Valve (The Ball) 4
4. Valve Seat
3. Remove the oil relief valve on the oil filter side. 3

• Remove the snap ring.
• Loosen the valve seat and remove so as not to let 2
the valve and spring stick out. 1
• Remove the valve and spring.
WSJJ0304
Name
1. Snap Ring
2. Valve Seat
3. Valve (The Ball)
4. Spring
2. Install the oil relief valve on the oil cooler side.

• Insert the valve seat, valve and spring.
4
• Install the plug and tighten using the specified
torque.
3
2
1
WSJJ0304
Name
1. Snap Ring
2. Valve Seat
3. Valve (The Ball)
4. Spring
2
3
1 4
WSJJ0303
Name
1. Plug
2. Spring
3. Valve (The Ball)
4. Valve Seat
3. Install the oil cooler.

Crankcase, Oil Pan

Components
WSJJ0019
Name
1. Oil Pan 3. Crankcase
2. Oil Strainer
Removal
2. Drain engine oil.
• Loosen the oil drain plug. 5. Remove the flywheel.
6. Remove the flywheel housing.
9. Remove the retainer.
10. Remove the slinger.
11. Remove the crankcase.
2
1
WSJJ0234
WSJJ0235
Name
1. Crankcase
2. O-Ring
WSJJ0009
4. Remove the oil pan. Disassembly

1. Remove the oil strainer.
WSJJ0197
WSJJ0198 WSJJ0138
Name Name
1. Oil Strainer 1. 2.0 — 3.0 mm (0.079 — 0.118 in)
2. Bolt 2. 4.0 — 5.0 mm (0.157 — 0.179 in)
3. Packing
4. Crankcase 2. Install the oil pan and packing.
Reassembly
1. Assemble the packing into the oil strainer, and
install it to the crankcase.
• Apply engine oil to the packing.
Installation
1. Install the crankcase.
equivalent) to the cylinder block.
• Be careful that the liquid gasket does not run over
the oil passage shown by the arrow mark.
• Apply the liquid gasket and install the crankcase
within 5 minutes.
Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft) WSJJ0197
3. Install the oil drain plug.

4. Install the retainer.
5. Install the slinger and oil seal.
8. Install the flywheel housing.
9. Install the flywheel.
10. Install the oil level gauge guide tube.
• Apply engine oil over the O-ring nice and thin and
install it.
Tightening torque:
Nut: 51 N⋅m (5.2 kg⋅m/38 lb ft)
WSJJ0009

12. Add engine oil.
N m(kg m/lb ft)
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
WSJJ0199
Oil Pump
Components
WSJJ0020
Name
1. Oil Pump ASM
Removal 3. Disconnect the radiator upper hose.

1. Drain engine oil. 4. Remove the fan shroud and fan guard.
• Loosen the oil drain plug.
Section.
5. Remove the fan ASM, fan belt and water pump
pulley.
Section.
6. Remove the power steering pump hole cover.
WSJJ0234

WSJJ0226 WSJJ0225
Name Name
1. Power Steering Pump Hole Cover 1. Vacuum Pump Hole Cover
7. Remove the fan shroud bracket LH and fan shroud 9. Remove the starter motor.
stay LH. • Remove the mounting bolt, and remove the starter
WSJJ0257
WSJJ0032
Name
1. Fan Shroud Bracket LH 10. Remove the crank pulley.
2. Fan Shroud Stay LH • Install the crankshaft stopper to the starter
8. Remove the vacuum pump hole cover.
Caution:
• Make sure that the stopper is properly fitted and
washer.
Special tool
Crankshaft stopper
Disassembly
1. Remove the spring pin.
2. Remove the spring seat.
3. Remove the spring.
4. Remove the valve.
2 3 4
WSJJ0141
Reassembly
1. Install the valve.
2. Install the spring.
3. Install the spring seat.
4. Install the spring pin.
Inspection
1. Measure the clearance between the driven gear
shaft and bushing, and between the drive gear
WSJJ0169
shaft/driven gear shaft and pump case hole.
12. Remove the oil pump ASM. • Measure the outside diameters of the drive gear
shaft and driven gear shaft using a micrometer.
Outside diameter of the drive gear shaft/ mm (in)

driven gear shaft
Standard 15.989 — 16.000
(0.62949 — 0.62992)
Limit 15.900 (0.62598)
WSJJ0140
• Measure the inside diameters of the bushing of the
oil pump body and the pump case hole using the
dial gauge.
• If the clearance between the driven gear shaft and
bushing, or between the drive gear shaft/driven
gear shaft and pump case hole exceeds the limit,
replace the oil pump ASM.
Clearance between the driven gear shaft mm (in)

and bushing, and between the drive gear
shaft/driven gear shaft and pump case
hole
Standard 0.04 — 0.07 (0.0016 — 0.0028)
Limit 0.20 (0.0079)
WSJJ0143
2. Measure the clearance between the oil pump gear

side surface and the oil pump housing gear side
surface.
• Measure the width of the driven gear/drive gear.
WSJJ0142
Width of driven gear/drive gear mm (in)
Standard 14.5 (0.5709)
WSJJ0144
• Measure the depth between the gear case housing
surface and the oil pump housing gear case side.
Depth between the gear case housing mm (in)

surface and the oil pump housing gear
case side
Standard 14.500 — 14.527(0.5709 — 0.5719)
WSJJ0140
Name
1. Oil Pump
• Confirm that the pump gear turns smoothly.

WSJJ0145
• Apply the liquid gasket and install the gear case
Clearance between the oil pump gear side mm (in) cover within 5 minutes.
surface and the oil pump housing gear • Install the packing in the groove of the gear case
side surface cover.
Standard 0.063 — 0.027(0.0025 — 0.0011) • Tighten the installing bolt to the specified torque.
Limit 0.20(0.0079) Tightening torque: 3.5 N⋅m (0.4 kg⋅m/31 lb in)
1
Installation
1. Install the oil pump ASM.
Apply engine oil to the pump case in which oil
pump is installed.
WSJJ0048
Name
WSJJ0049 WSJJ0225

Name
• Apply liquid gasket (ThreeBond 1207B or 1. Vacuum Pump Hole Cover
• Install the crankshaft pulley while aligning it with 6. Install the fan shroud bracket LH and fan shroud
the key on the crankshaft. stay LH.
• After temporarily tightening the nut as shown (1) in
Caution:
the illustration, temporarily tighten the bolt (2).
ones. • After fully tightening the nut as shown (1) in the
illustration, fully tighten the bolt (2).
Tightening torque: 294 N⋅m (30.0kg⋅m/217 lb ft)
Tightening torque:
M10 bolt: 51 N⋅m (5.2 kg⋅m/38 lb ft)
Nut: 25 N⋅m (2.5 kg⋅m/18 lb ft)
WSJJ0113 1
4. Install the starter motor and ground cable to the
flywheel housing and tighten the bolt to the
specified torque.
WSJJ0251
7. Install the power steering hole cover.
5. Install the vacuum pump hole cover. • Apply a coat of engine oil to the O-ring.
• Apply engine oil to the packing. • Tighten the mounting nut to the specified torque.
• Tighten the installing nut to the specified torque.
WSJJ0226
Name
1. Power Steering Pump Hole Cover
8. Install the fan, fan belt and water pump pulley.

Section.
Section.
12. Install the oil drain plug and add engine oil.
WSJJ0234
Oil Pressure Switch

Components
1 2
WSJJ0021
Name
1. Oil Pressure Switch 2. Nipple
Removal Inspection
1. Remove the oil pressure switch. Check for continuity between the switch terminal and
2. Remove the nipple. the body grounding in the no-load condition.
If there is no continuity, replace with normal parts.
Circuit check
1. Turn the key 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.
Installation
1. Install the nipple.
2. Install the oil pressure switch.
Cooling System
Engine
Cooling System
Contents
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Precautions on Service Work . . . . . . . . . . . . . . . 1B-2
A List of Defective Phenomena . . . . . . . . . . . . . 1B-7
Main Data and Specifications. . . . . . . . . . . . . . . 1B-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-16
Fan Clutch, Cooling Fan . . . . . . . . . . . . . . . . . . . 1B-17
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
1B-2 Cooling System
Cooling System
Precautions on Service Work
WARNING:
Do not remove the radiator cap when the cooling water
is at high temperature. Steam or boiling water will gush
out and you may be burnt. To open the radiator cap,
cover the cap with a thick cloth when the cooling water
is cool, release the pressure by slowly turning the cap,
and then remove the cap.
Explanations on functions and operation

Cooling water system
The engine cooling system consists of the radiator,
water pump, cooling fan and thermostat.
The water pump and thermostat circulates the coolant
to rapidly raise the engine coolant temperature for
smooth operation of the engine. In doing so, the
coolant returns to the cylinder block through the bypass
pipe.
The coolant is not circulated through the radiator in the
beginning; however, when it reaches the specified
temperature, the thermostat starts to open, allowing the
coolant flow in the radiator to increase gradually.
When the coolant reaches the specified temperature,
the thermostat fully opens allowing all coolant to flow
through the radiator, thus to cool down the engine
efficiently.
Cooling System 1B-3
4
10
1
11
WSJJ0146
Name
1. Cylinder Block 7. Turbocharger
2. Water Pump 8. EGR Cooler
3. Cooling Fan 9. Cylinder Head
4. Radiator 10. Oil Cooler
5. Reserve Tank 11. Heater
6. Thermostat
1B-4 Cooling System
Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.
The water pump is a non-disassembled part.
2
1 3
WSJJ0248
Name
1. Fan Center 3. Impeller
2. Bearing 4. Seal Unit
Cooling System 1B-5
Thermostat
The thermostat is a wax pellet type. It is a bottom
bypass type, and starts to open at the temperature of
82 °C (180 °F). It is mounted in the thermostat-housing
unit.
3
1
WSJJ0147
Name
1. Valve 3. Jiggle Valve
2. Piston
Coolant • Use only genuine Isuzu engine coolant.

1. About the engine coolant concentration • Use engine coolant with a mix ratio in the range
• Take the concentration corresponding to the of 30 to 60% because over heating is likely to
minimum temperature because the freezing occur if the ratio is greater than 60% and
temperature varies according to the corrosion prevention is inadequate if the ratio is
concentration of the engine coolant. less than 30%.
2. Engine coolant concentration measurement

1B-6 Cooling System
Methods for measuring specific gravity • Fix the temperature of the cooling water being
• Measure the specific gravity and the temperature measured in the range of 0 to 50 °C (32 to 122 °F).
of the cooling water using an anti-freeze specific • Measure the temperature and specific gravity and
gravity meter and thermometer. determine the concentration from the table given
• Take precautionary measures as the boiled cooling below.
water may gush out at high temperatures if the cap
is removed.
• Use a deep container to suit the height of the

specific gravity meter.
Name
1. Anti-Freeze Specific Gravity Meter
2. Radiator
Coolant scooping method

• Measure the concentration using the coolant
scoop.
Cooling System 1B-7
A List of Defective Phenomena
• Engine overheats
• Engine overcools
Engine overheats
Condition Possible Cause Correction

Engine overheats Cooling water volume is deficit. Add.
Thermometer unit is defective. Replace.
Thermostat is defective. Replace.
Radiator pump is defective. Replace.
Radiator is clogging. Clean or replace.
Radiator cap is defective. Replace.
Engine oil volume is deficient or Add or change engine oil.
incorrect engine oil is used.
Cylinder head gasket is defective. Replace.
The fan belt is loose. Adjust.
Exhaust system is clogging. Clean or replace.
The fuel injection quantity is in Diagnose the engine control
surplus. system.
Fuel injection timing is incorrect. Diagnose the engine control
system.
Starting pressure of fuel injection is Diagnose the engine control
low. system.
Engine overcools

Engine overcools Thermostat is defective. Replace.
Water pump Centrifugal impeller type

Pulley ratio 1.03
Thermostat Wax pellet system
Valve opening temperature °C (°F) With jiggle valve 85 (185)
Temperature when fully open °C (°F) With jiggle valve 100 (212)
Valve lift amount at full open mm (in) 10 (0.39)
1B-8 Cooling System
Water Pump
Components
4 3 2
WSJJ0255
Name
1. Fan 3. Water Pump Pulley
2. Spacer 4. Water Pump ASM
Removal
WSJJ0263
4. Remove the fan ASM, spacer and water pump

pulley.
Cooling System 1B-9
1
3 2
4
1
WSJJ0264 WSJJ0256
Name Name
1. Fan 1. Water Pump
2. Spacer
3. Water Pump Pulley 7. Remove the gasket.
4. Bolt
5. Loosen the tension adjusting bolt (1) of the Inspection

generator and remove the fan belt. 1. Appearance check
• Check for cracks or damage in the pump body.
• Check for cracks and corrosion in the impeller.
• Check for water leakage from the seal unit.
• If you find abnormalities, replace with the water
pump ASM.
2 2. Bearing nut check
• Check the play in the thrust direction.
Standard: 0.2 mm or less (0.0078 in or less)
1 • Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
• If you find abnormalities, replace with the water
pump ASM.
4 3
WSJJ0035
Name
1. Tension Adjusting Bolt
2. Lock Nut
3. Bolt
4. Nut
6. Remove the water pump ASM.

1B-10 Cooling System
M
4 3
WSJJ0267 WSJJ0035
Installation Name
1. Install the gasket. 1. Tension Adjusting Bolt
2. Install the water pump ASM. 2. Lock Nut
3. Bolt
• Tighten the bolt and nut to the specified torque.
4. Nut
3. Temporarily tighten the bolt until the water pump 6. After fan belt adjustment, tighten the temporarily
pulley is properly seated in the water pump ASM. fitted water pump pulley to the specified torque.
4. Mount the fan belt, and tighten the tension Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)
adjusting bolt of the generator to adjust the 7. Install the fan ASM and spacer.
tension.
Tightening torque:
• Refer to the “Drive Belt”.
M8 : 25 N⋅m (2.5 kg⋅m/18 lb ft)
5. After fan belt adjustments, tighten the generator M10: 52 N⋅m (5.3 kg⋅m/38 lb ft)
using the specified torque.
Tightening torque:
Lock nut: 25 N⋅m (2.5 kg⋅m/18 lb ft) 1
3 2
WSJJ0264
Name
1. Fan ASM
2. Spacer
3. Water Pump Pulley
4. Bolt
Cooling System 1B-11
WSJJ0263

10. Pour coolant.
N m(kg m/lb ft)
25 ( 2.5 / 18 )
M8 : 25 ( 2.5 / 18 )
M10 : 52 ( 5.3 / 38 )
10 ( 1.0 / 87 lb ft )
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
51 ( 5.2 / 38 )
WSJJ0269
Thermostat
Components
WSJJ0023
Name
1. Water Outlet Pipe 2. Thermostat
Removal
1. Drain the coolant. Prepare the container for
discharging and use it for replenishment when
mounting the thermostat. Set the discharge of
cooling water such that the water does not flow out
of the thermostat housing.
3. Remove the engine harness clip.
4. Disconnect the water outlet pipe.
• Disconnect the turbocharger water feed hose
from the water outlet pipe.
5. Remove the thermostat.
• Be careful not to damage the thermostat. 2 1
WSJJ0179
Name
1. Thermostat
2. Jiggle Valve
Inspection Installation
• Place the thermostat in water and increase the 1. Install the thermostat on the position shown in the
temperature while stirring it sufficiently. illustration.
• Measure the temperature when the valve is just • Install the thermostat with its jiggle valve (2)
opened and when it is fully open. facing the front of the engine.
Thermostat valve-opening temperature °C (°F)

85(185)
Thermostat full-open temperature °C (°F)

100(212)
Valve lift amount at full open mm (in)

10(0.39)
2 1
WSJJ0179
2
Name
1. Thermostat
2. Jiggle Valve
2. Connect the water outlet pipe.

3
• Connect the turbocharger water feed hose to
the water outlet pipe.
3. Install the engine harness clip.
WSJJ0148
5. Replenish the cooling water stored during the
Name discharge, and check the volume of the cooling
1. Thermometer water.
2. Stirrer
3. A Piece of Wood
Drive Belt
Components
6
7
1
3
2
WSJJ0024
Name
1. Crankshaft Pulley 5. Tension Adjusting Bolt
2. Generator Drive Belt 6. Lock Nut
3. Bolt 7. Generator Adjusting Plate
4. Generator 8. Water Pump Pulley
Inspection Drive belts adjustment

Check for the presence of wear or damage in the Adjustment procedure
drive belt and renew the parts if necessary. Adjust simultaneously the generator drive belt for
Check the tension of the belt and adjust if necessary. adjustment of belt.
Inspection procedure 1. Loosen the adjusting plate lock nuts and the
Apply a pressure of 98 N (22 lb) at the center of the mounting bolts of generator on the underside of
long span of each belt and check the deflection of the the generator.
belt. • Loosen the installing bolt under the generator
while holding the nut on the back using a tool.
Deflection of generator drive belt
2. Rotate the adjusting bolts of generator and adjust
When the belt is new the belt (remove and fit).
5 — 6 mm (0.20 — 0.24 in) 3. After adjustments, tighten the adjusting plate lock
When the belt is reused nuts and the mounting bolts of generator on the
7 — 8 mm (0.28 — 0.32 in) underside of the generator using the specified
torque.
• Loosen the installing bolt under the generator
while holding the nut on the back using a tool.
Tightening torque: 5
Nut: 25 N⋅m (2.5 kg⋅m/18 lb ft) 7
Bolt: 51 N⋅m (5.2 kg⋅m/38 lb ft) 4
2 1
WSJJ0180
Name
1. Crankshaft Pulley
2. Bolt
3. Generator
4. Tension Adjusting Bolt
5. Lock Nut
6. Water Pump Pulley
7. Generator Drive Belt
N m(kg m/lb ft)
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
51 ( 5.2 / 38 )
WSJJ0200
Fan Clutch, Cooling Fan
Inspection 2. Inspection (single unit)

If wear, damage or any fault is found during the 1) Warm up the bimetal area of the fan clutch
inspection, replace or repair as required. using a heat gun until the temperature reading
on the thermistor reaches approx. 85°C. Then
Visually check for damage, silicon grease leakage or check if considerable force (clutch torque) is
other faults. required to rotate the fan clutch. At this time, if
the fan clutch rotates easily, this indicates that
1. Inspection (on-vehicle)
the silicon grease is leaked inside. Replace
1) Before starting the engine, rotate the fan the fan clutch with new one.
clutch when it is cold by hand to check if it
rotates easily.
2) Start the engine and warm it up until the
temperature of the fan clutch reaches approx.
85°C. Then stop the engine, and rotate the fan Heat gun
clutch by hand to check if considerable force
(clutch torque) is required to rotate. However,
if the fan clutch rotates easily, this indicates
that the silicon grease is leaked inside.
Replace the fan clutch with new one.
Thermistor WSJJ0279
WSJJ0278
Fuel System
Engine
Fuel System
Contents
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2
Precautions on Service Work . . . . . . . . . . . . . . .1C-2
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Fuel Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . . .1C-11
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-11
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-14
Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-17
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-18
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-19
Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .1C-22
Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-26
1C-2 Fuel System
Fuel System
Precautions on Service Work
Parts of the fuel system such as the internal part of the
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter
and the entry of foreign matter could cause damage to
the fuel passage. Take extreme care not to allow
foreign matter to enter.
If water removal agent is used in the fuel then it will
absorb moisture in the light oil and may cause rust.
Therefore, do not use water removal agent in the fuel
tank.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• Always replace the high-pressure pipe in fuel
system with new one if it has been removed.
Reuse of it causes damage to the seal surface,
resulting in fuel leakage.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.), do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with
new ones.
Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and common rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage after
starting the engine.
Fuel System 1C-3
Explanations on functions and operation
Fuel system diagram
10
11 12
7
5 4 3
WSJJ0025
Name
1. Fuel Tank 7. Fuel Supply Pump
2. Fuel Feed Hose 8. Common Rail
3. Pre-Fuel Filter 9. Fuel Injector
4. Fuel Feed Pump 10. Fuel Leak-Off Pipe
5. Fuel Filter 11. Fuel Return Hose
6. Relief Valve 12. Fuel Cooler
1C-4 Fuel System
Removal of Foreign Material between Main Filter

and Supply Pump
IMPORTANT: When the bolt at fuel outlet side in

main filter is loosened or the hose is
removed, remove foreign material
between main filter and supply
pump.
When the main filter or the hose between main filter

and supply pump is replaced, remove foreign material
between main filter and supply pump.
1. Install the base to the fuel outlet in main filter.

: 19 mm
Main Filter
: 44±5 N⋅m (4.5±0.5 kgf⋅m, 32±3.69 lbf⋅ft) W1GR-01-01-006
Bolt
2. Install the hose to the base and secure with the Fuel Base
clamp. Outlet Clamp
3. Remove the hose at the fuel inlet side in supply

pump.
Hose
To Supply
Pump
W1GR-01-01-001
Supply Pump
Fuel Inlet
T1T1-01-02-004
Fuel System 1C-5
4. Turn the key switch ON and operate the fuel

solenoid pump. Put fuel from the hose into the
Hose
container.
Incorrect Correct
CAUTION: Use the container which can

measure beyond 10 liters.
Make the hose extend straight in order not to
accumulate foreign material inside. W1GR-01-01-004
Keep away the hose end from the container
or fuel in the container in order not to enter Hose
foreign material.
5. When fuel in the container is beyond 4 liters, turn

Container
the key switch OFF and stop the fuel solenoid
pump.
W1GR-01-01-005
6. Install the hose to the fuel inlet in supply pump and

secure with the clamp.
7. Release any pressure in the fuel system. (Refer to

Bleeding Air in Fuel System on the Operator’s
Manual.)
8. Start the engine. Check for any leaks in fuel

system.
Supply Pump
Fuel Inlet T1T1-01-02-004
1C-6 Fuel System
Caution:
• Be careful foreign material does not into the fuel
system, because the precise fuel system is used.
Common rail
2
1
WSJJ0026
Name
1. Pressure Limiter 2. Pressure Sensor
Fuel System 1C-7
Fuel supply pump
WSJJ0027
Name
1. Fuel Temperature Sensor 4. Camshaft Key
2. Suction Control Valve 5. Camshaft Nut
3. High Pressure Pipe
1C-8 Fuel System
Fuel injector Fuel filter
2 3
1
4
7
WSJJ0150
Name Name
1. Terminals 1. Priming Pump
2. ID Code 2. Air Bleed
3. Leak-Off Pipe 3. Case
4. QR Code 4. Drain Plug
5. Parts Number
6. Part to Connect Injection Pipe
7. O-Ring Function check
Air bleeding
1. Before starting the engine
a. Place a tray under the fuel filter (under the air
bleed plug).
b. Turn the key switch to ON, and activate the
electromagnetic pump.
c. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
overflows near the plug.
d. Tighten the plug, and operate the priming pump
more than 10 times until it is filled with fuel.
After waiting for approximately a minute, loosen
the plug and bleed out the air in the fuel filter.
(This work must be repeated a minimum of
three times until no more air comes out from the
plug.)
e. Tighten the plug firmly and wipe the spilled fuel
on the surrounding area. Operate the priming
pump (10 to 15 times) till it is filled with fuel and
then send fuel to the engine.
Fuel System 1C-9
2. After starting the engine
a. Start the engine without operating the engine
speed on the machine side.
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly raise the engine speed and maintain it
for 3 minutes.
d. Set to “maximum speed” on the machine side in
order to increase the speed to the maximum.
(Repeat this operation several times)
e. Return to the idling.
Caution:
If the air bleeding work is insufficient then it could lead
to faults in the engine. Therefore, the procedures after
starting the engine should always be implemented.
Water drain
It is designed that the float inside of the water
sedimenter floats when water accumulates.
When the float level goes up to the aluminum body
section, be sure to drain the water.
Water draining procedure

Loosen the air bleeder plug at the top of the water
sedimenter. Then loosen the drain plug to drain the
water inside of it. After draining, tighten each plug
securely. Then bleed air from the fuel.
Name
1. Fuel Pressure/Vacuum Gauge ASM
Fuel system vacuum check
2. Fuel Pipe (Discharge Side)
Use this procedure to measure the vacuum (negative 3. Fuel Pressure/Vacuum Gauge Adapter
pressure) discharge side the fuel system.
4. Loosen the air bleed plug on the supply pump.
Important:
5. Use your hand to operate the fuel filter priming
The fuel pressure/vacuum gauge ASM (gauge (1)) and
pump. Operate the pump until all the air has been
the fuel pressure/vacuum gauge adapter (adapter (5))
bled from the system.
must be cleaned before connecting to the fuel line.
Otherwise, foreign material adherent to the tools may 6. Start the engine and allow it to idle.
damage the fuel supply pump. 7. Note the gauge (1) reading. If the reading is
normal, go to Step 8. If the fuel vacuum is greater
1. Disconnect the fuel hose from the fuel filter than the specified value, there is a problem in the
housing. (fuel supply pump side). fuel system. Perform the procedures outlined
below.
2. Install the adapter.
Standard fuel vacuum Less than 17 kPa (170 mbar)
Special tool
Fuel pressure/vacuum gauge adapter: EN-47667
3. Connect the gauge (1) with hose to the adapter
(3).
Special tool
Fuel pressure/vacuum gauge ASM: J-44638
1C-10 Fuel System
• Replace the cartridge fuel filter element.
• Check the fuel delivery pipe. If it is clogged, it must
be replaced.
• Remove the fuel pipe at the fuel filter inlet. Use
high-pressure air forced through the fuel pipe to
clean the fuel system.
Caution:
• Remove the fuel filler cap before applying high-
pressure air.
• Do not perform this procedure if the fuel tank is
nearly full (fuel approaching or flowing into the fuel
filler neck). The forced air will spray fuel from the
fuel filler neck.
8. Remove the gauge (1) and hose from the adapter
(3).
9. Remove the adapter (3).
10. Connect the fuel hose.
11. Use your hand to operate the fuel filter priming
pump. Operate the pump until all the air has been
bled from the system.
12. Start the engine and allow it to idle.
13. Inspect the fuel system for fuel leakage.
Special Tool
Illustration
Special Tool Rank
EN-47667
Fuel pressure/vacuum
gauge adapter
Rank B
J-44638
Fuel pressure/vacuum
gauge ASM
Rank B
Fuel System 1C-11
Fuel Filter ASM

Components
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Removal
1. Remove the feed hose and the return hose from
the fuel filter and plug the hoses so that the fuel
does not flow out.
2. Remove the bolts for mounting the fuel filter.
3. Remove the fuel filter ASM.
Installation
1. Install the fuel filter ASM.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Bleed the air.
• Refer to “Fuel System”.
1C-12 Fuel System
Fuel Filter Element

Removal Installation
1. Remove the case using the filter wrench. 1. Assemble the fuel filter element.
2. To simplify air bleeding, fill light oil in the case.
Special tool
3. Tighten the case by hand. During this process take
Fuel main filter wrench:
adequate care that the light oil that is inside does
8-9801-3170-0
not flow out.
2. Remove the fuel filter element.
4. Use the filter wrench and tighten rotating by 1/3 to
2/3.
Special tool
Fuel main filter wrench:
8-9801-3170-0
Special Tool
Illustration
Special Tool Rank
8-9801-3170-0
Fuel main filter wrench
Rank A
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Fuel System 1C-13
Fuel Injector
Components
3
4
5
2
1
WSJJ0270
Name
1. Fuel Injection Pipe Clip 4. Nozzle Bracket
2. Fuel Injection Pipe 5. Nozzle Bracket Bolt
3. Fuel Injector
The fuel system consists of many tiny holes and Caution:

spaces that allow the movement of fuel from one place To avoid electric shock;
to another. These holes and spaces are milled to Set the switch to the “OFF” position and disconnect
extremely high precision. This is especially true of the battery negative cable before checking or repairing the
fuel injectors. fuel injector, wiring or/and connectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
removal and installation procedure.
1C-14 Fuel System
Removal • If replacing one or more fuel injectors:
Black out the replaced cylinder of injector ID code
on the injector ID code label with a marking pen or
Refer to “Cylinder Head Cover” in Engine
equivalent.
Mechanical section.
2. Remove the fuel injection pipe clips and the
injection pipes.
5F 16 1A
25 1A 24
17 17 00
14 00 52
1
1
2
WSJJ0153
Name
WSJJ0253 1. Injector ID Code
2. Fuel Injector
Name
1. Fuel Injection Pipe
2. Pipe Clip
Installation
3. Loosen the nozzle bracket fixing bolts and remove Important:
the fuel injectors. Install each of the fuel injectors on its original position.
(the cylinder from which it was removed)
Caution:
Do not remove the fuel injector sleeve. 1. Install a new gasket and O-ring to each fuel
injector. Refer to the illustration.
4. Mark each fuel injector with the number of the
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.
Recording “Injector ID Code” on the connector of

the replaced fuel injector housing;
Record ID code information of all the replaced fuel
injectors.
Note:
If replacing the fuel injector, perform the following
procedures.
• If replacing all fuel injectors:
Remove the injector ID code label on the cylinder
head cover.
Fuel System 1C-15
Important: 6. Apply a thin coat of engine oil to the outside of the
Do not reuse the clip. fuel injector side sleeve nuts, and the O-ring.
7. Install each fuel injection pipe to the position
3
2 8. Temporarily fix the fuel injection pipe clip.
9. Use a wrench to tighten carefully until the fuel
injection pipe contacts the fuel injector and
common rail.
1 • When temporarily tightening, tighten at the
common rail side, then tighten at the fuel injector
side.
WSJJ0151
Name
1. Fuel Injector
1
2. Leak-Off Pipe 2
3. Clip
4. O-Ring
5. Gasket
2. Install the nozzle bracket to the fuel injector. Refer

to the illustration. WSJJ0253
Name
1. Fuel Injection Pipe
1
2
2. Pipe Clip
3 10. Fully tighten the nozzle bracket bolts to the

specified torque.
11. Tighten the injection pipes to the specified torque.
• When fully tightening, tighten at the fuel injector
side, then tighten at the common rail side.
12. Tighten the fuel injection pipe clips to the specified
torque.
Tightening torque: 7.8 N⋅m (0.8 kg⋅m/69 lb in)
Refer to “Cylinder Head Cover” in Engine
WSJJ0152 Mechanical section.
Name
1. Fuel Injector
2. Bolt
3. Nozzle Bracket
3. Apply engine oil to the threads of each bracket

bolt, the seating surface of it, and between the
washer and bracket.
4. Install each nozzle bracket to the cylinder head.
5. Temporarily tighten each bracket bolt.
1C-16 Fuel System
Before programming the fuel injector ID code
Important:
Do not program the fuel injector ID code data unless
you are directed by a service instruction or by a service
bulletin issued by the manufacturer. Programming the
fuel injector at any other time does not always meet a
customer’s demand.
Ensure the following conditions are met before
programming the ECM.
• System voltage for the machine
- There is no charging system concern. All
charging system concerns must be repaired
before programming the ECM.
- Battery voltage is 12 V or 24 V (varies
depending on the machine). The battery must
be charged before programming the ECM if the
battery voltage is low.
- A battery charger is not connected to the
machine's battery. Incorrect system voltage or
voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
- Turn off the system and electrical component
that may put a load on the machine’s battery.
• The key switch is in the proper position. Do not
change the position of the key switch during the
programming procedure, unless instructed to do
so.
• All tool connections are secure.
- RS-232
- The connection at the data link connector
(DLC) is secure.
- Power supply circuit
• Do not disturb the tool harness while
programming. If an interruption occurs during the
programming procedure, programming failure or
ECM damage may occur.
• Surrounding environment
- Surrounding temperature is between 0 and
50°C (32 and 122°F) during the programming
procedure. Excessively low or high temperature
may cause the programming failure or ECM
damage.
- Electromagnetic interference (EMI) on the tool
harness and ECM may cause the programming
failure or ECM damage.
Injector ID code programming procedure
Perform the injector ID code programming according to
“Injector Replacement” in EMPS or EMPS III Operating
Instructions manual.
Fuel System 1C-17
N m(kg m/lb ft)
26 ( 2.7 / 19 )
7.8 ( 0.8 / 69 lb ft )
29.5 ( 3.0 / 22 )
WSJJ0271
1C-18 Fuel System
Common Rail
Components
1
4
WSJJ0273
Name
1. Common Rail 3. Fuel Feed Pipe
2. Common Rail Bracket 4. Leak-Off Pipe
Parts of the fuel system such as the internal part of the Removal
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter • Refer to “Starter” in Engine Electrical section.
and the entry of foreign matter could cause damage to 2. Remove the fuel feed pipe from the fuel supply
the fuel passage. Take extreme care not to allow pump.
foreign matter to enter.
Fuel System 1C-19
Note: Important:
Cover the areas exposed during part removal to Do not reuse the high-pressure pipe in fuel system if it
prevent the entry of foreign material into the fuel has been removed.
system. Refer to “Fuel Injector”.
7. Remove the common rail and the common rail
bracket.
1
Caution:
• Do not grasp the pressure sensor, during the
common rail removal procedure.
• Take care not to damage the connector unit of the
pressure sensor.
WSJJ0154 2
Name
1. Fuel Feed Pipe
3. Disconnect the fuel return hose.

4. Disconnect the leak-off pipe and hose.
Note:
Cover the areas exposed during part removal to WSJJ0156
prevent the entry of foreign material into the fuel

Name
system.
1. Common Rail Bracket
2. Common Rail
1
Installation
1. Install the common rail and common rail bracket,
then tighten them in the order shown in the
illustration.
WSJJ0155
Name
1. Leak-Off Pipe and Hose
5. Disconnect the common rail pressure sensor

connector.
6. Disconnect the fuel injection pipe.
1C-20 Fuel System
Caution: 5. Connect the fuel hose.
• Do not grasp the pressure sensor during the 6. Connect the fuel feed pipe to the fuel supply pump,
common rail installation procedure. and tighten to the specified torque.
• Take care not to damage the connector unit of the Tightening torque: 44.1 N⋅m (4.5 kg⋅m/33 lb ft)
pressure sensor.
1 3
4 2
WSJJ0036 WSJJ0154
2. Install the fuel injection pipe.

Name
Important: 1. Fuel Feed Pipe
one if it has been removed. 7. Install the starter motor.
Refer to “Fuel Injector”. Refer to “Starter” in Engine Electrical section.
3. Connect the common rail pressure sensor

connector.
4. Tighten the leak-off pipe and hose using the
eyebolt to the specified torque.
Tightening torque: 7.9 — 12.7 N⋅m (0.8 — 1.3 kg⋅m/81
— 112 lb ft)
WSJJ0155
Name
1. Leak-Off Pipe and Hose
Fuel System 1C-21
N m(kg m/lb ft)
44.1 ( 4.5 / 33 )
7.9 12.7 ( 0.8 1.3 / 81 112 lb in )
29.5 ( 3.0 / 22 )
WSJJ0157
1C-22 Fuel System
Fuel Supply Pump

Components
WSJJ0272
Name
1. Fuel Supply Pump
The fuel system consists of many tiny holes and

spaces that allow the movement of fuel from one place
to another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injectors.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injectors during the
removal and installation procedure.
Fuel System 1C-23
Removal
2. Disconnect the radiator upper hose. 1
Refer to the “Water Pump” in the Cooling System 3
Section.
4. Remove the fan ASM.
Section.
2
5. Remove the battery.
Refer to “Common rail”. 2
Refer to “Cylinder Head Cover” in Engine 2
Mechanical section. 3
8. Disconnect the connectors of the fuel temperature
WSJJ0166
sensor, suction control valve and CMP sensor.
9. Remove the fan shroud bracket upper and the fan Name
shroud stay upper. 1. Timing Chain Cover Lower
10. Remove the timing chain cover upper. 2. Bolt
3. Nut
12. Align the timing marks at three locations as shown

1
2
WSJJ0266
Name
1. Timing Chain Cover Upper
2. Fan Shroud Stay Upper WSJJ0001
Name
11. Remove the timing chain cover lower. 1. TDC
1C-24 Fuel System
2 1
WSJJ0059 WSJJ0158
Name Name
1. Camshaft Alignment Marks 1. Nut
15. Remove the timing chain tensioner.
Refer to “Starter” in Engine Electrical section.
14. Loosen the nut.
• Loosen the nut after blocking the crankshaft from
turning by placing a crankshaft stopper on the
starter mounting position on the flywheel housing.
Caution:
Make sure that the stopper is properly fitted and
Special tool
Crankshaft stopper
2
1
3
WSJJ0065
Name
1. Timing Chain Tensioner
2. Packing
3. Nut
16. Remove the timing chain tension lever pivot.

17. Remove the nut and sprocket.
Fuel System 1C-25
WSJJ0201
Name
1. Tension Lever Pivot
2. Sprocket
3. Nut
18. Move the timing chain upward.
WSJJ0160
20. Use a gear puller to remove the fuel supply pump

gear.
WSJJ0159
19. Put alignment marks between the idle gear A and

fuel supply pump gear.
WSJJ0161
21. Disconnect the fuel feed hose.

22. Remove the fuel supply pump and supply pump
bracket.
1C-26 Fuel System
Installation
1. Install the O-ring to the fuel supply pump.
1
• Apply soap water to the O-ring and install it.
Caution:
Take care not to twist the O-ring.
3. Install the supply pump bracket.
• Temporarily tighten the bolts and nuts on the gear
case side.
• Temporarily tighten the bolts on the cylinder body
2
side.
• Tighten the bolt and nut on the gear case side to
the specified torque.
• Tighten the bolt on the cylinder body side to the
specified torque.
WSJJ0203
Name
1. Fuel Supply Pump
2. Fuel Supply Pump Bracket
1
Caution:
• Do not hold the high pressure pipe, during the
supply pump removal procedure.
• Do not grasp the high pressure pipe, when moving
the supply pump form one location to another.
WSJJ0203
Name
2
1. Fuel Supply Pump
2. Fuel Supply Pump Bracket
3 4. Connect the fuel feed hose.

5. Install the supply pump gear.
• Confirm that the supply pump camshaft key faces
the direction shown in the illustration, and is
horizontal.
WSJJ0202
• Install the supply pump gear and make sure that
the alignment marks are aligned.
Name
• Make sure that the supply pump gear is properly
1. Fuel Supply Pump
fitted and engaged with the main gear of the idle
2. O-Ring
gear A. If the supply pump gear is properly fitted
3. High Pressure Pipe
and engaged with the sub gear of the idle gear A,
push the supply pump gear until it fits and engages
with the main gear.
Fuel System 1C-27
6. Install the timing chain in each sprocket then install
the supply pump sprocket in pump shaft.
• Align the timing marks of the camshaft sprocket
with the dark plate of the timing chain link.
• Align the timing marks of the supply pump sprocket
with the yellow plate of the timing chain link.
• Install the supply pump sprocket to pump shaft
aligning with the knock pins on the supply pump
gear.
• Tighten the supply pump shaft nuts by hand.
1
WSJJ0162
1
3
4
WSJJ0091
Name
1. Timing Mark
2. Dark Plate
3. Timing Mark
4. Yellow Plate
2
WSJJ0306 7. Install the timing chain tension lever pivot.

• Tighten the pivot bolts by hand.
Name
• Check if the tension lever moves smoothly.
1. Alignment Mark for Supply Pump Gear
2. Alignment Mark for Idle Gear A
3. Idle Gear A Main Gear
4. Idle Gear A Sub Gear
WSJJ0067
1C-28 Fuel System
8. Push down the cam of the timing chain tensioner, • This causes the plunger to be pushed to unhook.
and push the plunger in. Hook on the pin to hold
the plunger depressed.
1
2
5
4
WSJJ0094
WSJJ0092 Caution:
Perform the above steps securely, and make sure that
Name the plunger pushes the timing chain tension lever.
1. Pin 11. Tighten the supply pump shaft nut to the specified
2. Plunger torque.
3. Cam
4. Body Tightening torque: 130 N⋅m (13.3 kg⋅m/96 lb ft)
5. Hook
9. Install the timing chain tensioner.

Tighten the nut to the specified torque.
WSJJ0158
2 Name
1. Supply Pump Shaft Nut
1
3 12. Tighten the timing chain tension lever pivot bolt to

WSJJ0093 the specified torque.
Name
1. Timing Chain Tensioner 13. Rotate the crank pulley two turns (720°).
2. Packing 14. Check that alignment marks of the intake camshaft
3. Nut and exhaust camshaft are aligned with that of the
bearing cap.
10. Push the timing chain lightly.
Fuel System 1C-29
1
19. Install the fan shroud bracket upper and fan shroud
stay upper.
Tightening torque:
M10 bolt: 5.2 N⋅m (5.2 kg⋅m/38 lb ft)
Nut: 25 N⋅m (2.5 kg⋅m/18 lb ft)
2
1
WSJJ0059 2
Name
1. Camshaft Alignment Marks
15. Install the starter motor.

Refer to “Starter” in Engine Electrical section.
Refer to “Cylinder Head” in Engine Mechanical
section. 3
17. Apply liquid gasket (ThreeBond 1207B or
equivalent) to the timing chain upper as shown in WSJJ0266
the illustration.
• Install within five minutes after applying liquid Name
gasket. 1. Timing Chain Cover Upper
20. Connect the connector of the CMP sensor.

1 2 21. Apply liquid gasket (ThreeBond 1207B or
equivalent) to the timing chain cover lower as
WSJJ0163
Name
1. Timing Chain Cover Upper
3. 2.0 — 2.5 mm (0.079 — 0.098 in)
18. Install the timing chain cover upper.

1C-30 Fuel System
• Install within five minutes after applying liquid 25. Install the battery.
gasket. 26. Install the fan ASM.
Section.
1
Section.
30. Start and idle the engine.
Important:
In order to make the fuel supply pump characteristic
learn into the ECM, let the engine idle until warm-up. If
the fuel system DTC is stored in the meantime, once
3
clear the DTC and warm-up the engine again.
2 3
WSJJ0165
Name
1. Timing Chain Cover Lower
3. 2.0 — 2.5mm (0.079 — 0.098 in)
22. Install the timing chain cover lower.

2
3
WSJJ0166
Name
1. Timing Chain Cover Lower
2. Bolt
3. Nut
23. Connect the fuel temperature sensor and the

suction control valve connector.
Refer to “Common rail”.
Fuel System 1C-31
N m(kg m/lb ft)
25 ( 2.5 / 18 )
27 ( 2.8 / 20 ) 25 ( 2.5 / 18 )
10 ( 1.0 / 87 lb in )
51 ( 5.2 / 38 )
25 ( 2.5 / 18 )
130 ( 13.3 / 96 )
10 ( 1.0 / 87 lb in )
10 ( 1.0 / 87 lb in )
25 ( 2.5 / 18 )
WSJJ0204
Engine Electrical
Engine
Engine Electrical
Contents
Service Precautions . . . . . . . . . . . . . . . . . . . . . . .1D-2
General Procedure. . . . . . . . . . . . . . . . . . . . . . .1D-2
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .1D-3
General Description . . . . . . . . . . . . . . . . . . . . . .1D-3
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-6
Torque Specifications . . . . . . . . . . . . . . . . . . . . .1D-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-7
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .1D-14
General Description . . . . . . . . . . . . . . . . . . . . .1D-14
Service on the Machine: Starting System . . . .1D-15
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-17
Torque Specifications . . . . . . . . . . . . . . . . . . . .1D-17
Main Data and Specifications. . . . . . . . . . . . . .1D-18
Preheating System . . . . . . . . . . . . . . . . . . . . . . .1D-22
Glow Plug Replacement. . . . . . . . . . . . . . . . . .1D-22
Precautions on Service Work . . . . . . . . . . . . . .1D-22
A List of Defective Phenomena . . . . . . . . . . . .1D-22
Main Data and Specifications. . . . . . . . . . . . . .1D-23
1D-2 Engine Electrical
Service Precautions
General Procedure
When fasteners are removed, always reinstall them at
the same location from which they were removed. If a
fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal
size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking
compound are not indicated in the illustration. The
correct torque value must be used when installing
fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
Engine Electrical 1D-3
Charging System
General Description
The main charging system components are the
batteries, the generator and the battery discharge
indicator light circuit. The generator is a self-rectifying
type with a built-in regulator.
4 5
7
8
2 1
WSJJ0028
Name
1. Lower Mounting Bolt 6. Sliding Piece
2. Nut 7. Adjusting Nut
3. Generator 8. Washer
4. Generator Adjusting Plate 9. Tension Adjusting Bolt
5. Bolt
Maintenance Electrical Tests
The most common indication of charging system Before performing the following generator electrical
troubles is an undercharged or overcharged battery. tests on the vehicle, be certain that the system wiring is
Since the battery itself may be defective, check the not defective and generator belts are not slipping. Also,
battery first. Check if the battery is discharged because the battery must be fully charged for a valid test of the
of short circuit, or electrical components left turned on charging system.
for extended periods. Notice:
Keep the generator and all other electrical system To avoid damage to the vehicle electrical system,
terminals clean and tight. A loose or badly corroded always observe the following precautions:
terminal connection will create excessive resistance in • Do not polarize the generator.
the circuit and result in hard starting, dim lights, etc.
• Do not short across or ground any of the terminals
Inspect the generator system at regular intervals and
in the charging circuit except as specifically
correct any potential causes of trouble before machine
instructed herein.
performance is affected.
• NEVER operate the generator with the output
Diagnosis of Charging System terminal open-circuited.
Trouble in the charging system will be evidenced as • Be sure the generator and battery have the same
one or more of the following three conditions: ground polarity.
1. The battery discharge warning light will stay on. • When connecting a charger or other battery to the
2. An undercharged battery as evidenced by slow machine’s battery, connect negative to negative
cranking. and positive to positive.
3. An overcharge, or overvoltage, condition. 1. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “E” to
Undercharged Battery ground. The voltmeter should show 0 volts.
2. With the engine control switch “ON” and engine not
running, connect a voltmeter from terminal “B” to
Inspection ground. The voltmeter should read at least 24
1. Accessories were not left turned on for extended volts.
periods. 3. With the engine control switch “ON” and the engine
2. Drive belt for proper tension. not running, connect a voltmeter from white wire
3. The ECM main relay has been stuck ON with the side of the connector to ground. The voltmeter
key switch in OFF position. (Battery voltage is should show 24 volts.
consumed.) 4. With the engine control switch “ON” and the engine
4. Wiring and connections for corrosion or looseness. not running, the “charge” light should be on. This
shows that the other circuit in the connection is
Overcharge (or Overvoltage) condition
working.
A charging rate in excess of 29.5-volts for a prolonged
5. With the engine running and the headlight high
period may cause early electrical system failure.
beams (if equipped) turned on, read the voltage at
Blown fuses, light bulbs burned out, and even battery
the “B” post on the generator. The voltmeter should
failure may result. If this condition exists, test the
read at least 24 volts.
generator as described under “Generator Output Test”
later in this section. 6. If steps 1 through 4 are not OK, check connectors
in the harness for looseness or corrosion and
Noisy Generator retest.
7. If step 5 voltage is low, substitute a known good
regulator and test again. If the voltage is still low,
Inspection bench test the generator.
1. Drive pulley for looseness.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
Generator noise may also be caused by worn or
damaged diodes and/or starter.
Generator
WSJJ0293
Removal
• Battery negative cable.
1. Electrical wiring at the generator.
2. Loosen the adjusting nut.
3. Loosen the ACG adjusting bolt.
4. Loosen the lower mounting bolt.
• Loosen the lower mounting bolt while holding the 2. ACG adjusting bolt
nut located on the back using a tool. 3. Adjusting nut
5. Drive belt
Tightening torque:
6. Generator
Adjusting nut 25 N⋅m (2.5 kg⋅m/18 lb ft)
4. Electrical wiring at the generator.
Installation
• Battery negative cable.
1. Generator
• Tighten the lower mounting bolt while holding the
nut located on the back using a tool.
Tightening torque:
Lower mounting bolt 51N⋅m (5.2 kg⋅m/38 lb ft)
N m(kg m/lb ft)
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
51 ( 5.2 / 38 )
WSJJ0205
Specifications Connector terminal
Isuzu Part No. 8980182040 Wire

Terminal symbol Lead wire color
specifications
Nominal output (V-A) 24-50
R R AEX 0.75f
Rated speed (rpm) 5000
L L AEX 0.75f
Regulator-type IC type
Regulated voltage (V) 28.5±1
Weight (kg) 9.5
1 2
WSHK0101
Name
1. R Terminal
2. L Terminal
Internal connections
SG L
IC
REGULATOR
WSHK0102
Disassembly of generator
5
6
7
8 3 12
11
10
9 13
18
15
14
19
23
21
20
2
1
17
16
22
WSJJ0294
Disassembly Procedure
1. Screw 13. Collar
2. Cover 14. Ball Bearing
3. Through Bolt 15. Rotor Assembly
4. Rotor, Front Bracket Assembly 16. Screw
5. Nut, Washer 17. Field Coil Assembly
6. Pulley 18. Stator Assembly
7. Fan 19. Holder
8. Collar 20. Regulator Assembly
9. Screw 21. Bolt (B Terminal)
10. Retainer 22. Condenser
11. Ball Bearing 23. Rectifier Assembly
12. Front Bracket Assembly is the reverse order of disassembly.
Inspection and repair of generator 3. Diode for initiating excitation, Resistor
Check for continuity between connector terminals
1. Diode
R and L with a tester (at Ω x 100 range). Normal
Check for continuity of forward and inverse
diodes and resistors show low resistance in
directions with a tester. Normal diodes show low
forward direction and high resistance in inverse
resistance in forward direction and high resistance
one.
in inverse one.
Judge that they are faulty other than those above.
WSHK0106
WSHK0104
4. Field coil
2. Condenser
Charge the condenser with a tester (at Ω x 1000 • To judge the insulating condition of field coil,
range), and connect a tester lead inversely. Judge measure between the protrusion portions and core
it as normal if the needle on a meter deflects a little of the coil with a tester (at Ω x 1000 range). Judge
and returns to the original position. as faulty if it has continuity.
WSHK0107
WSHK0105
• Measure between the protrusion portions of field • Judge as normal if there is continuity between N
coil with a tester, and judge as normal if the lead of stator coil and three leads.
resistance is about 6.7Ω (20°C {68°F}).
WSHK0110
WSHK0108 6. Bearing
5. Stator coil • Check if the bearing rotates smoothly or has no
• To judge the insulating condition of stator coil, noise.
measure between the stator coil and core with a If the result of the inspection is unsatisfactory,
tester (at Ω x 1000 range). Judge as faulty if it has replace the bearing.
continuity.
WSHK0111
WSHK0109
Performance test
In the performance test of generator, connect as
follows and measure the regulated voltage and output
current.
Actual wiring diagram for performance test of IC regulator built-in generator
2 3 SW 1 SW 2
V 1
6 7
WSJJ0295
Disassembly Procedure
1. Voltmeter 5. Clamp Tester Ammeter
2. R Terminal 6. Battery 24 V
3. L Terminal 7. Variable Resistor
4. Charging Lamp 24 V-3 W
Regulated voltage measurement of regulator Measurement of the output current

Close SW1 switch, and warm-up five to ten minutes at Close SW1 and SW2 switches, and raise the generator
approx. 1500 rpm in generator until an ammeter shows speed to 5000 rpm. While keeping the voltmeter
6 A or less. showing 27 V, measure the maximum value of output
After confirming that an ammeter shows between 2 and current with a variable resistor.
6 A, set the generator between approx. 3000 to 4000 In this time, judge as normal if the output current is 50
rpm. If an voltmeter shows between 27.5 and 29.5 V, A or more.
the regulated voltage of regulator is normal.
If the ammeter shows 6A or more, charge the battery Caution:
for a while or replace it with full-charged battery. • Do not cut off battery circuit during generator
Replace the regulator if the voltmeter shows out of rotating.
range between 27.5 and 29.5 V. • Do not connect to L terminal if the charging lamp
(24 V-3 W) is not used.
Specified value of regulated voltage
Never connect L terminal and B circuit directly.
27.5 — 29.5 V (+25°C {77°F}) Diode for excitation may be broken.
Handling of generator
Be careful with the following when handling a
generator.
• Connecting the polarities of battery inversely
causes generator diode to be broken.
• While the engine runs, NEVER disconnect the
wiring of battery terminal and charging circuit.
• Wiring connection to terminal must be performed
properly according to terminal symbol.
• Do not perform megger test on semiconductor
device.
• Be sure to disconnect the battery terminal (−)
before inspection on equipment.
• Do not open/close the battery relay switch while
the engine runs.
• Disconnect the battery terminal when charging
from external source such as quick charge.
• Do not pour steam cleaner or water directly on it.
• After connecting to B terminal and E terminal,
tighten them to the following torque.
B terminal 4.9 N⋅m {50 kgf⋅cm/43 lb in}
E terminal 4.9 N⋅m {50 kgf⋅cm/43 lb in}
• Refer to “Belt Adjustment" for tension adjustment
of V-belt.
Trouble and action
Action to
Trouble symptom Trouble location Trouble cause
be taken
Charging is Wiring and Open or short circuit, disconnection
Repair
impossible. ammeter
Generator Open circuit, short to ground, short circuit in each coil Replace
Broken diode Replace
Regulator Defective regulator Replace
Poor contact in terminal of regulator Repair
Insufficient Wiring Open or short circuit, looseness in connection Repair
charging
Generator Looseness of generator driven belt Repair
Layer or short circuit in field coil Replace
Layer or short circuit in stator coil Replace
Defective diode Replace
Poor contact in each terminal Repair
Excessive Regulator Defective regulator
Replace
charging
Unstable charging Wiring Intermittent contact or nearly disconnected connection in
Repair
current wiring
Generator Looseness of generator driven belt Repair
Short circuit or nearly disconnected connection in field coil Repair
Short circuit or nearly disconnected connection in stator
Repair
coil
Poor contact in each terminal Repair
Noisy generator Generator Improper installation of generator Repair
Defective bearing Replace
Contact of rotor core and stator core Repair
Defective diode Replace
Short circuit in stator coil Replace
Starting System
General Description
Starter and Glow Plug Relays

The starter is a 4kw, reduction drive model.
The gear housing and armature end bearing housings
are aluminum. The brush ASM has replaceable
brushes. The commutator bars are mica insulated and
are undercut.
The starter circuit starts at the batteries. The battery
cable goes to the large terminal on the starter.
From that terminal wires lead to the engine control
switch and the starter relay.
2 3
WSJJ0029
Name
1. Starter 3. Ground Cable
2. Bolt
Maintenance Tighten the starter to engine mounting bolts and the

Keep the starter's exterior clean. Remove corrosion electrical cable retaining nuts.
from the terminals, leads, and connectors.
Diagnosis of Starting System Service on the Machine: Starting System
No Cranking, No Sound Maintenance
• Discharged batteries. Check for the cause of the Keep starter terminals and all other terminals in the
discharged batteries. electrical system clean tight. A loose or corroded
• Sulfated battery terminals. Clean all the battery connection or terminal will cause excessive resistance
terminals and cable ends. in the system that will result in hard starting. At regular
• A starter that draws too much current. intervals, inspect the starting system to locate and
correct potential causes of trouble before the system
• Starter relay won't work. Attempt to start and listen
performance is affected. Starting motors do not require
for a “click” at the starter relay. If there is no “click,”
lubrication.
check the starter relay control terminals with a test
light. If the test light shows that power is getting to
the starter relay, check the ground circuit with the
test light. If the ground circuit is OK, replace the
starter relay.
• Engine control switch start circuit won't close.
With the engine control switch turned to start,
check the starter relay with a test light. If the test
light doesn't come on, check the starter circuit at
the engine control switch with the test light. If the
test light comes on, check the harness for an open
and repair. If the test light does not come on,
replace the engine control switch.
• Starter relay power circuit isn't closing. Attempt to
start. Starter relay clicks. Check the secondary
terminals with a test light. If the test light lights on
the battery side only, replace the starter relay. If the
test light lights on both terminals, check for an
open at the starter.
• Starter clicks when start is attempted. Check all
power connections for corrosion. Clean
connections if corrosion is present. Terminal on
starter should have at least 18 volts on it when
cranking the engine. If voltage is OK, replace the
starter.
Slow Cranking, Magnetic Switch Clicks or Chatters

• Discharged batteries. Check for cause of
discharged batteries.
• Check the battery terminal for corrosion. Hint: Test
for warm terminals. Clean all the battery terminals
and connectors.
• Loose or dirty connections. Measure the cranking
voltage at the battery terminals. If the voltage is
less than 18 volts, load test the battery. If the
battery is bad, replace the battery. If the battery is
good, repair the starter.
If the voltage is 18 volts or more, measure the voltage
from the battery negative terminal to the engine block.
If the voltage is 0.5 volt or more, repair the ground
cable and connections.
If the voltage is less than 0.5 volt, measure the voltage
at the battery cable terminal on the starter. If the
voltage is 18 volts or more, repair the starter. If the
voltage is less than 18 volts, clean and tighten the
positive cable connections. If the voltage is still less
than 18 volts, replace the positive cable.
Starter
The starter is a non-disassembled part as dip painting is applied to improve waterproof effect.
WSJJ0288
B
M
WSJJ0289 WSJJ0290
Removal
1. Battery negative cable from the battery.
2. Cables and electrical leads from the starter.
3. Two mounting bolts.
4. Starter.
Installation 3. Cables and electrical leads to the starter.
1. Starter 4. Battery negative cable to the battery.
2. Two mounting bolts.
Tightening torque:
Mounting bolt 97 N⋅m (9.9 kg⋅m/72 lb ft)
N m(kg m/lb ft)
97 ( 9.9 / 72 )
WSJJ0206
Model (Manufacturer) Hitachi, Ltd.

Rating Voltage V 24
Power output kw 4.0
Time Sec. 30
Number of pinion teeth 11
Revolution direction (viewed toward pinion side) Clockwise
Weight (approx.) N {kg} 61.8 {6.3}
No load Current/Voltage A/V 120 or less/23
characteristic
Speed rpm 3500 or more
Load characteristic Current/Voltage A/V 250 or less/18.6
Torque N⋅m {kgf⋅m} 13.2 {1.3} or more
Speed rpm 1590 or more
Locking Current/Voltage A/V 1100 or less/10
characteristic
Torque N⋅m {kgf⋅m} 47 {4.8} or more
Connections (Hitachi, Ltd.)
S.S
S
P
B
C1 C2
M
Fc
Ar
3 4 1
WSJJ0292
Name
1. Starter Relay 3. Motor
2. Battery 4. Magnetic Switch
S.S Starter switch

Ar Armature
Fc Field coil
C1 Pressure coil
C2 Holding coil
P Contactor
Inspection and repair of starter Handling of starter
1. Magnetic switch 1. Precautions on handling
Never perform operational check on magnetic • Improper gap between pinion and ring gear causes
switch as single unit. faulty mesh. (Gap 2 — 5 mm {0.079 — 0.197 in})
Inspection of coil • Also, the front bracket is installed on the engine
• Check each continuity between S terminal and M side securely.
terminal, S terminal and case, M terminal and case • Be sure to turn off the battery switch before
of magnetic switch. If no continuity is present in removal/installation of stater.
either one of them, replace the starter since the • Tightening/inserting wiring must be performed
coil is open. properly. Improper work causes starting trouble
due to high contact resistance.
2. Precautions on starting
B S • Be careful with charging status of battery.
Insufficiently-charged battery causes starting
M
trouble.
• After checking engine starting, turn off the stater
switch immediately.
• One continuous use should be less than 10
seconds. If re-starting is needed, wait until the
pinion stops completely.
• If the starter does not stop rotating when the starter
switch is turned off, turn off the battery switch
immediately. In this case, check the wiring, switch,
etc.
WSJJ0291
Contact Point Check

Measure the load current on starter. Replace it if
voltage drop between terminals B and M is 0.3 V or
more per 100 A.
Caution:
Use a digital voltmeter to measure voltage drop. Using
an analog voltmeter may damage itself.
WSHK0117
Trouble countermeasure
Trouble symptom Trouble cause

Starter does not operate when 1. Full discharge of battery
starter switch is turned on. 2. Open circuit, poor contact
3. Poor contact in starter switch or improper tightening of terminal
4. Poor contact in starter relay or plug terminal
5. Short or open circuit in magnetic switch coil
Pinion moves forward but it does not 1. Insufficient capacity of battery
engage with ring gear. 2. Improper gap of pinion and ring gear
3. Wear of pinion or ring gear tooth edge
4. Dust on pinion shaft
5. Insufficient auxiliary rotation of armature due to insufficient thrust gap
of motor
Pinion engages and rotates motor 1. Slippage of clutch
but it does not run engine. 2. Breakage of reduction gear
Pinion engages but it does not run 1. Insufficient capacity of battery
engine. 2. Too high rotational resistance of engine
3. Improper tightening of wiring circuit terminal
4. Short circuit of armature or field coil
5. Contamination of commutator
6. Fatigue or wear of brush spring
7. Locking of bearing
8. Poor contact in magnetic switch
When turning starter switch off after 1. Retuning failure of starter switch contact
engine starts, starter does not stop. 2. Retuning failure of starter relay contact
3. Short circuit in magnetic switch coil
Preheating System
Glow Plug Replacement Precautions on Service Work
Adequate care should be taken as over-tightening the
Precautions during maintenance glow plug could lead to damage.
Adequate care should be taken as over-tightening the Explanations on functions and operation
glow plug could lead to damage.
The preheating system consists of the ECM, the glow
Removal Procedure relay, glow plugs and the glow indicator lamp. The
1. Remove the glow plug connector. preheating system is operated when the engine coolant
2. Remove the glow plug. temperature is low, and make the engine easy to start.
Glow plug check
• Use the circuit tester and measure the resistance
of the glow plug.
• If the measured value deviates from the specified
value, then replace the glow plug.
• Resistance value of glow plug is approximately
less than 6Ω.
Caution:
Use a set of glow plug from the same manufacturer.
WSJJ0207
Installation Procedure
1. Install the glow plug.
Tightening torque: 15 — 20 N⋅m
(1.5 — 2.0 kg⋅m/11 — 15 lb ft)
2. Install and tighten the glow connector with the
designated torque.
Tightening torque: 1.5 — 2.0 N⋅m
(0.15 — 0.20 kg⋅m/13 — 17 lb in)

• The glow indicator lamp does not light up.
• Preheating does not work.
• Preheating time is too long or too short.
Trouble Shooting
The glow indicator lamp does not light up.

The glow indicator lamp does not Slow blow fuse has blown. Replace the slow-blow fuse.
light up. Fuse is unavailable. Replace the fuse.
Indicator valve is burnt out. Replace the indicator valve.
Engine control system is faulty. Refer to Engine Control System
section.
Preheating does not work.

Preheating does not work. Slow blow fuse has blown. Replace the slow-blow fuse.
Defective or faulty glow plug relay Re-mount or replace the glow plug
connector contact. relay.
section.
Preheating time is too long or too short.

Preheating time is too long or too Thermo-sensor fault and break in Replace the thermo-sensor. Repair
short. circuit or short circuit. the circuit.
Fault in glow plug. Replace or tighten the glow plug.
section.
Items Model
Preheating device model Glow plug
Glow plug rated voltage/ current (V-A) 23 – 3.5
Engine
Contents
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2
Precautions on Service Work . . . . . . . . . . . . . . . 1F-2
Explanations on Functions and Operation . . . . . 1F-2
EGR Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 1F-6
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-7
A List of Defective Phenomena . . . . . . . . . . . . . 1F-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 1F-7
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-8
Measurement Tool. . . . . . . . . . . . . . . . . . . . . . . . . 1F-9
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-9
1F-2 Exhaust System and Turbocharger
EGR System
Precautions on Service Work Explanations on Functions and Operation
Perform EGR related assembly according to the usual Re-circulate a part of the exhaust gas of the EGR
procedure of temporarily fitting and then permanently system in the intake manifold. Reduce the combustion
tightening the parts so that unnecessary stresses are temperature and inhibit NOx generation since inert
not applied on the parts. gases may be mixed up in the intake air.
An electronic control system is used in this EGR to
balance the requirements of operability and low
emissions. A DC motor is operated using the control
current of the Engine Control Module (ECM) to control
the EGR.
Refer to the chapter on Engine Control System for
details on fault diagnosis of the EGR system.
Name
1. EGR Cooler 3. EGR Valve DC Motor
2. Engine Control Module (ECM)
Exhaust System and Turbocharger 1F-3
EGR Cooler
Components
2 3
WSJJ0030
Name
1. EGR Cooler 3. Coolant Hose (Out)
2. Coolant Pipe (In)
Removal Installation
1. Drain the coolant. 1. Install the EGR cooler.
2. Remove the bolt that fixes the water feed pipe • Temporarily tighten the bolts and nuts according to
bracket of turbocharger to the EGR cooler. the order given on the illustration.
3. Remove the coolant pipe and hose.
4. Remove the EGR cooler.
1 1
2
2
3
WSJJ0236
Name
1. EGR Cooler
2. Coolant Pipe and Hose (In)
3. Coolant Pipe and Hose (Out)
3 4 5
Caution:
WSJJ0280
After removing the EGR cooler, seal so that foreign
matter does not enter. Name
1 — 6 Show the Order to Tighten Bolts and Nuts.
Inspection
Gas leak check

• Check for gas leak in various parts of the EGR gas
line.
If the results of the check show abnormalities,
repair or replace the defective parts.
EGR valve check

• Refer to the chapter on Engine Control System for
details on the method of checking the EGR valve.
• Temporarily tighten the bolts and nuts to the
specified torque according to the order given on
the figure.
6
WSJJ0265
3. Install the bolt that fixes the water feed pipe

bracket of turbocharger to the EGR cooler.
1 2 3
WSJJ0281
Name
1 — 6 Show the Order to Tighten Bolts and Nuts.
Tightening torque
M10 bolt: 52 N⋅m (5.3 kg⋅m/38 lb ft)
Nut: 27 N⋅m (2.8 kg⋅m/20 lb ft)
2. Connect the coolant pipe and hose.
Tighten the bolt to the specified torque.
Tightening torque
M6 bolt: 10 N⋅m (1.0 kg⋅m/87 lb in)
N m(kg m/lb ft)
10 ( 1.0 / 87 lb ft )
52 ( 5.3 / 38 )
27 ( 2.8 / 20 )
27 ( 2.8 / 20 )
10 ( 1.0 / 87 lb ft )
25 ( 2.5 / 18 )
25 ( 2.5 / 18 )
WSJJ0282
Exhaust System
• Vibration or rattling noise from the exhaust system
• Clogging of exhaust system
• Exhaust leakage or noise
Troubleshooting
Vibration or rattling noise from the exhaust system

Vibration or rattling noise from the Loose or misaligned components Match the joints and then re-tighten.
exhaust system Or, check for damage in the hanger,
mounting brackets and clamps.
Clogging of exhaust system

Clogging of exhaust system Clogging or deformation of the Repair or replace the exhaust
exhaust piping piping.
Exhaust leakage or noise

Exhaust leakage or noise Defect or misalignment in mounting Match the joints and then re-tighten.
Damage or burn-out of exhaust Replace the damaged part.
piping or silencer
Defective components in the Replace the defective part.
exhaust system (clamps, pipes,
silencer)
Internal damage to silencer Replace the silencer
Turbocharger
Turbocharger inspection
Inspection
Caution:
Turbocharger on 4JJ1 engine cannot be overhauled
structurally.
Perform only the following inspection.

• Measurement of axial play of turbine shaft
Axial play mm (in)

Service limit 0.11 (0.004)
WSHK0129
• Check of radial play of turbine shaft
Insert a thickness gauge into the gap between the
compressor impeller and housing, and measure
the clearance.
The thickness gauge to be inserted must be 0.2
mm (0.0078 in) or less.
Measurement Tool
Shape Name Part number Usage

Caliper Measurement of the seal ring groove width
Measurement of inner diameter of the seal ring
insertion part
Measurement of turbine shaft journal outer diameter
— Measurement of thrust bushing groove clearance
Measurement of thrust bearing thickness
Measurement of floating metal inner/outer diameter
WSHK0157 Measurement of inner diameters of the center
housing metal portion and ring portion
Dial gauge Measurement of turbine shaft axial gap, radial gap
and runout
WSHK0158
Other Material
Name Usage
Besco super engine oil Floating metal sliding portion
Thrust bushing sliding portion
Thrust bearing sliding portion
Turbine shaft journal portion
ThreeBond No. 1207 Housing installing surface of the seal plate
Flange of the compressor housing
Loctite No. 242 Seal plate tightening screw thread

4JJ1-Engine Manual (KM-4JJ1-E-00)

Uploaded by

Copyright:

Available Formats

4JJ1-Engine Manual (KM-4JJ1-E-00)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4JJ1-Engine Manual (KM-4JJ1-E-00)

Uploaded by

Copyright:

Available Formats

I n t roduct ion

Hitachi Construction Machinery Co., Ltd

Disassemble and Assemble Engine

Engine Manual (1/2)

Disassemble and Assemble Engine

6. All regular tools, gauges and special tools should

4. Do not perform painting work or leave the engine

8. Always check that there are no fuel leaks when

Seal section Product name Manufacturer's name

• Always use the liquid gasket products listed above,

Type Measurable range mm (in)

Example: Procedure for measuring the clearance

Example: Measuring the clearance between the crank

Description of abbreviations Abbreviation Description

Abbreviation Description SI (International System of Units)

R/H, RH Right Hand With regards the conversion to SI (International

Connection between main SI units and conventional units

SI Conventional Unit Item, unit conversion

*1 Published service data may conveniently use kg for

M Mega 106 1,000,000

• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa

Pipe diameter tightening torque Flare nut 2 side width (mm)

Special Tool Classification

Isuzu Diesel Engine (4JJ1)

Matters that require attention in specifically dealing

Explanations on functions and operation EGR system

• Install the cylinder head cover.

• Measure each cylinder one by one.

Name • Install the negative terminal of the battery.

• Install the negative terminal of the battery.

Items Engine model 4JJ1

Items Engine model 4JJ1

6. Remove the bolt with arrow mark which holds the

3. Install the bolt which holds the blow-by hose to the

Tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb ft)

Cylinder Head Cover

3. Disconnect the leak-off hose.

6. Remove the packing.

4. Connect the blow-by hose.

N m(kg m/lb ft)

5. Disconnect the fuel injection pipe (common rail to

WSJJ0006 2. Connect the air intake pipe.

7. Remove the intake manifold and gasket.

5. Install the leak-off pipe.

N m(kg m/lb ft)

6. Remove the EGR cooler.

Distortion of manifold installation surface mm (in)

11. Disconnect the front exhaust pipe.

7 3 1 5 4. Connect the front exhaust pipe.

8 4 2 6 Tightening torque: 22.5 N⋅m (2.3 kg⋅m/17 lb ft)

Tightening torque: 10 N⋅m (1.0 kg⋅m/87 lb in)

2. Install the gasket and turbocharger to the exhaust

Tightening torque: 28 N⋅m (2.9 kg⋅m/21 lb ft)

N m(kg m/lb ft)

22.5 ( 2.3 / 16.6 )

22.5 ( 2.3 / 16.6 ) 10 ( 1.0 / 87 lb ft )

22.5 ( 2.3 / 16.6 )

Timing Gear Train

Removal Refer to the “Water Pump” in the Cooling System