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4HK1 6HK1 ISUZO Engine CX350 Service Manual 9-44061na-Linked PDF
4HK1 6HK1 ISUZO Engine CX350 Service Manual 9-44061na-Linked PDF
4HK1-6HK1
ISUZU ENGINES
9-44061 NA
Replaces 9-44060 NA
Revised 05-2006
Issued 02-2006
SERVICE MANUAL
4HK1-6HK1
ISUZU ENGINES
REVISION HISTORY
Issue Issue Date Applicable Machines Remarks
First Edition 02-2006 4HK1- 6HK1 ISUZU ENGINES 9-44060 NA
Revision 1 05-2006 4HK1- 6HK1 ISUZU ENGINES 9-44061 NA
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America, LLC. Racine, WI 53403 U.S.A..
1
INDEX OF CHAPTERS
FUEL SYSTEM....................................................................................................................................................... 1C
ENGINE ELECTRICAL........................................................................................................................................... 1D
NOTE: CNH Company reserves the right to make changes in the specification and design of the machine with-
out prior notice and without incurring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in accordance with the technical specifica-
tions known as of the date of design of this document.
UNITS OF MEASURE
This manual adopts the units of measure based on International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
The following table converts the International System units of measure in some of the main units belonging to other
system.
GENERAL INFORMATION
General Information
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2
Reading the model . . . . . . . . . . . . . . . . . . . . . . . 0A-6
General information . . . . . . . . . . . . . . . . . . . . . . 0A-7
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.
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 fat spilt onto rubber parts the part to stand for approximately 10 minutes,
must be wiped off immediately, as it will cause after which the old liquid gasket residue will be
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 7 minutes of applying
the liquid gasket.
0A-4 General Information
If more than 7 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
Application procedure
1. Wipe the contact surfaces clean of all water, fat 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, fat, and oil.
After tightening the bolt, do not apply excessive torque
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 Plastiguage
WSHK0185
General Information 0A-7
6HK1
WSHK0186
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.
0A-8 General Information
Term Explanation
Notes Items that should receive special mention within a work procedure.
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.
General Information 0A-11
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.
0A-12 General Information
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
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)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-1
ENGINE
ENGINE MECHANICAL (4HK1, 6HK1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1, 6HK1) . . . . . . . 1A-3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-82
Precautions on Service Work . . . . . . . . . . . . . . 1A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-88
Main Data and Specifications . . . . . . . . . . . . . 1A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-94
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . 1A-14 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-101
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-101
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Piston, Connecting Rod . . . . . . . . . . . . . . . . . . 1A-103
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-16 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103
Inlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-104
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-110
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-112
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-114
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-24 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Turbocharger and Exhaust Manifold . . . . . . . . . 1A-25 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-25 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-27 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-32 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-119
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-121
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-51 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-124
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1A-126
Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-53 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-126
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-126
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-128
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-54 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-133
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-56 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-57 Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 1A-134
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-59 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-134
Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-134
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-61 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-138
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-62 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-64 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139
Fixing torque . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-66 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-66 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-67 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-69 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-70 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-146
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-70 Torque Specifications . . . . . . . . . . . . . . . . . . 1A-150
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-70 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-150
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-71 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-72 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-153
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Lubrication System . . . . . . . . . . . . . . . . . . . . . . 1A-157
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-79 Precautions on Service Work . . . . . . . . . . . . 1A-157
1A-2 ENGINE MECHANICAL (4HK1, 6HK1)
Function Check . . . . . . . . . . . . . . . . . . . . . . . 1A-158
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Oil Port Cover ASM . . . . . . . . . . . . . . . . . . . . . 1A-160
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-163
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-165
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-169
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-174
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 1A-178
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-178
ENGINE MECHANICAL (4HK1, 6HK1) 1A-3
Name
1. Cast The Engine Model 2. Stamp An Engine Number
ENGINE MECHANICAL (4HK1, 6HK1) 1A-5
6HK1
WSHK0001
Name
1. Stamp An Engine Number
Name
1. Rocker Arm
2. Bridge Cap
3. Bridge
Tightening torque:
Rocker arm adjustment 22 N⋅m (2.2 kg⋅m/16 lb ft)
screw nut
Bridge adjustment screw 22 N⋅m (2.2 kg⋅m/16 lb ft)
nut
1A-8 ENGINE MECHANICAL (4HK1, 6HK1)
Adjustment table (4HK1)
Cylinder No. 1 2 3 4
Valve arrangement IN EX IN EX IN EX IN EX
No. 1 cylinder
{ { { {
Compression top dead center position
No. 4 cylinder
× × × ×
Compression top dead center position
6HK1
WSHK0002
ENGINE MECHANICAL (4HK1, 6HK1) 1A-9
4HK1
WSHK0003
Note:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
• Install the cylinder head cover.
Refer to the “Cylinder Head Cover”.
Compression pressure inspection
• Warm-up the engine.
1
• Remove a negative terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
WSHK0004
built on the lower head cover (no fuel will be
injected). Name
1. Fuel Injection Harness Connector
Caution:
When the harness connector is removed, ECM judges
• Install the negative terminal of the battery.
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory • Turn on the starter to emit foreign matter within the
of ECM. cylinders.
(For how to clear memory of ECM, refer to the Engine • Install an adapter and a gauge of a compression
Control System Section) gauge of the special tool.
1A-10 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
Compression pressure MPa (psi) / 200 rpm
Standard 3.24 (469)
Limit 2.26 (327)
Differences among
294 kPa (43)
the cylinders
Caution:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.
• Remove a negative terminal of the batteries.
• Install a harness connector for the fuel injector built
on the lower head cover.
• Install all the glow plugs.
Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft)
• Install the negative terminal of the battery.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-11
Main Data and Specifications
Special tool
380.002.626
Compression gauge
EN-46722
Compression gauge
adapter
380.002.627
Compression gauge
adapter
(6HK1)
1A-14 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
ENGINE MECHANICAL (4HK1, 6HK1) 1A-15
6HK1
WSHK0005
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
Removal
1. Remove the head cover.
2. Remove the gasket.
1A-16 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1 4HK1
Name Name
1. Head Cover 1. Head Cover Case
2. Fuel Injector Harness Connector
6HK1
6HK1
WSHK0006
WSHK0007
Name
1. Head Cover Name
1. Head Cover Case
3. Remove the fuel injector harness connector. 2. Fuel Injector Harness Connector
4. Remove the head cover case.
5. Remove the gasket.
Installation
1. Install the gasket on the lower cover.
2. Install the head cover case.
Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft),
6HK1: 13 N⋅m (1.3 kg⋅m/9.6 lb ft)
3. Install the fuel injector harness connector.
6HK1
Name
1. Head Cover Case
2. Fuel Injector Harness Connector
6HK1
WSHK0008
WSHK0007
Name
1. Head Cover Case
2. Fuel Injector Harness Connector
13 {1.3 / 9.6}
13 {1.3 / 9.6}
WSHK0009
1A-20 ENGINE MECHANICAL (4HK1, 6HK1)
Inlet Cover
Components
4HK1
Name
1. Case ASM 4. Inlet Pipe
2. Inlet Cover 5. Reed Valve
3. Inlet Pipe Gasket
ENGINE MECHANICAL (4HK1, 6HK1) 1A-21
6HK1
4
6
WSHK0177
Name
1. Case ASM 4. Inlet Pipe
2. Inlet Cover 5. Reed Valve
3. Inlet Pipe Gasket 4. Bolt
Removal 4HK1
1. Remove the common rail.
Refer to the “Common Rail” in the fuel system
section.
2. Remove the inlet pipe.
3. Remove the case ASM.
• Remove the reed valve from the case ASM.
• Inspect the valve whether the carbon has not come
in contact around the valve.
1A-22 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1 Caution:
• Be careful not to forget to fasten the bolt indicated
with an arrow.
• Tighten up the stud part together with the common
rail.
WSHK0048
4. Remove the inlet cover.
• On the place where the case ASM is to be installed
inside the inlet cover (arrowed) is a bolt. Be careful
not to forget to remove it.
* 4HK1 is shown for illustration.
• Peel the liquid gasket off carefully.
2. Install the reed valve to the case ASM
Tightening torque: 9.8 N⋅m (1.0 kg⋅m/7.2 lb ft)
3. Install the case ASM.
• Apply the liquid gasket and mount within 7
minutes.
Installation
1. Install the inlet cover.
• Apply the liquid gasket (ThreeBond 1207C or
equivalent) by using a bead diameter of 2.5 – 5.5
mm (0.1 – 0.2 in) along a groove of the inlet cover.
WSHK0179
Name
1. Case ASM
2. Reed Valve
3. Bolt
6HK1
20 (2 / 15) 39 (3 / 29)
WSHK0063
ENGINE MECHANICAL (4HK1, 6HK1) 1A-25
Name
1. Oil Feed Pipe 5. Turbo Charger ASM
2. Water Return Pipe 6. Exhaust Adapter
3. Exhaust Manifold 7. Oil Return Pipe
4. Water Feed Pipe
1A-26 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
4 3 2
WSHK0012
Name
1. Oil Feed Pipe 4. Exhaust Adapter
2. Exhaust Manifold 5. Oil Return Pipe
3. Turbo Charger ASM
Removal
1. Loosen the radiator drain cock to drain coolant.
(4HK1 only)
2. Remove the air intake duct from the turbocharger
and the air cleaner.
3. Remove the charge air pipe from the turbocharger
and the charge air cooler.
4. Disconnect the front exhaust pipe.
5. Remove the EGR pipe.
6. Remove the oil feed pipe.
7. Remove the oil return pipe.
8. Remove the water feed pipe. (4HK1 only)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-27
• Remove the water return pipe. (4HK1 only) 6HK1
1 3 2
WSHK0013
Name Name
1. Water Return Pipe 1. Exhaust Manifold
2. Turbocharger
9. Remove the heat protector on the turbocharger. 3. Exhaust Adapter
10. Remove the exhaust adapter bolts.
11. Remove the four turbocharger clamping nuts.
12. Remove the turbocharger from the exhaust Inspection
manifold. • Inspection of exhaust manifold
13. Remove the exhaust manifold. Inspect the plane surface of the plane on which the
4HK1 manifold and the cylinder head are to be installed.
Caution:
If the plane surface exceeds the limit, replace it.
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
6HK1
Axial play mm (in)
Standard 0.06 – 0.09 (0.0024 – 0.0036)
Name
Limit 0.11 (0.0043)
1. Oil Outlet
2. Oil Inlet
Installation
1. Put the gasket in to install the exhaust manifold.
• 4HK1: Tighten up with the 2 nuts and 6 bolts
according to the order given on the figure.
Caution:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
Wheel shaft and bearing clearance manifold.
Use a dial gauge to measure the clearance between
the wheel shaft and the bearing.
4HK1
Clearance mm (in)
Standard 0.056 – 0.127 (0.0022 – 0.0050)
Limit 0.14 (0.0055)
6HK1
Clearance mm (in)
Standard 0.10 – 0.17 (0.0039 – 0.0067)
Limit 0.205 (0.0081)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-29
4HK1 4HK1
6HK1
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
6HK1
1 3 2
WSHK0014
Name
1. Water Feed Pipe
4HK1
Name
1. Oil Return Pipe
WSHK0015
1A-34 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Crankshaft Position Sensor
5. PTO Idle Gear Cover 11. Oil Pan
6. Flywheel 12. Fuel Supply Pump
1A-36 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
10
1
3
5 8
12
11
WSHK0017
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Idle Gear A Shaft
5. PTO Idle Gear Cover 11. PTO Idle Gear Shaft
6. Flywheel 12. Oil Pump
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
3. Remove the camshaft ASM.
Refer to “Camshaft ASM”.
4. Remove the cylinder head ASM.
Refer to the “Cylinder Head”.
5. Remove the fuel supply pump ASM.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-37
Refer to “Fuel Supply Pump” in the fuel system 6HK1
section.
WSHK0064
7. Remove the flywheel.
* 4HK1 is shown for illustration. • Install the crankshaft stopper on the starter part of
6. Remove the crankshaft position sensor. the flywheel housing to stop the crankshaft from
• Remove the crankshaft position sensor before rotating.
remove flywheel.
Caution:
4HK1 Check if the stopper meshes with the ring gear without
fail and is installed properly.
Special tool
Crankshaft stopper: 380.002.628
Special tool
Slinger remover:
380.002.608 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
380.002.625 (For 6HK1)
Inspection
* 4HK1 is shown for illustration. 1. Measurement of idle gear backlash
13. Remove the flywheel housing. • Apply a dial gauge on the teeth of the idle gear to
be measured and move the gear to right and left
lightly to read how much the dial gauge shook
(never fail to fix the gear).
4HK1
2. Measurement of end clearance of the idle gear.
Outside diameter of idle gear shaft mm (in)
• Insert a thickness gauge between the idle gear and
the thrust collar to measure a clearance. Standard 29.959 – 29.980 (1.179 – 1.180)
Limit 29.80 (1.173)
• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
External diameter of the idle gear A shaft mm (in)
Axial play of idle gear mm (in) Standard 39.959 – 39.975 (1.573 – 1.574)
Standard 0.080 – 0.140 (0.003 – 0.006) Limit 39.80 (1.567)
Limit 0.20 (0.008)
Outside diameter of idle gear shaft mm (in) Clearance between the idle gear and the mm (in)
shaft
Standard 29.959 – 29.980 (1.179 – 1.180)
Standard 0.020 – 0.062 (0.0007 – 0.0024)
Limit 29.9 (1.177)
Limit 0.200 (0.0079)
External diameter of the idle gear A shaft mm (in)
Clearance between the idle gear A and the mm (in)
Standard 49.950 – 49.975 (1.967 – 1.968)
shaft
Limit 49.9 (1.965)
Standard 0.025 – 0.075 (0.0010 – 0.0030)
Limit 0.200 (0.0079)
4HK1
Tightening torque: 31 N⋅m (3.2 kg⋅m/23 lb ft)
Clearance between the idle gear and the mm (in) • After installation, apply engine oil to the shaft.
shaft
Standard 0.020 – 0.062 (0.0007 – 0.0024)
Limit 0.200 (0.0079)
Name
1. Idle Gear
2. Thrust Collar
3. Bolt
Name
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. PTO Gear 9. Idle Gear A
5. PTO Idle Gear
WSHK0043
4HK1
1A-44 ENGINE MECHANICAL (4HK1, 6HK1)
1
1 2
5
1
3
6
1
3
4
1
WSHK0044
7. Install the PTO idle gear.
• Apply engine oil over the part where the gear of the
idle gear shaft is to be put together.
• Put the idle gear and the shaft together and install
it on the location given on the figure and tighten up
with the specified torque.
5
3
2
Special tool
4HK1
Use acceptable: Oil seal installer kit:
6HK1
Oil seal setting tool: 380.001.712
• Apply engine oil to the oil seal lip.
Caution:
Do not allow engine oil to come in contact with the
outside oil seal and felt ring.
• Insert the oil seal (1) into the adapter (2).
• Insert the oil seal sleeve (3) to the adapter.
• Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-49
6HK1 13. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
14. Remove the oil drain adapter.
15. Install the O-ring on the fuel supply pump and
make the slits with an arrow meet and with the stud
bolt as a guide, install the fuel supply pump
tentatively.
Caution:
• When removing the fuel supply pump, if the stud
bolt on the cylinder block side loosens, or the stud
bolt is replaced, apply the Loctite No. 262 on the
side where the stud bolt is to be buried before
assembly.
B
Tightening torque:
1st step = 78 N⋅m (8.0 kg⋅m/58 lb ft)
2nd step = 60°
3rd step = 60°
Name
1. Plug Hole
2. Alignment Mark
16. Install the oil drain adapter ASM on the plug hole
and tighten with the specified torque.
Tightening torque: 6 N⋅m (0.6 kg⋅m/53 lb in)
• Apply engine oil over the O-ring nice and thin and
install it.
Name
1. Adapter
2. O-Ring
ENGINE MECHANICAL (4HK1, 6HK1) 1A-51
Torque Specifications
31 {3.2 / 23}
76 {7.7 / 56}
19 {1.9 / 14}
78 {8 / 58} 60 60
6 {0.6 / 4}
WSHK0065
1A-52 ENGINE MECHANICAL (4HK1, 6HK1)
Special Tool
Illustration Tool Number/Description
380.002.628
Crankshaft stopper
380.002.608
Slinger remover
5-8840-2703-0
J-43282
Oil seal installer kit
380.001.712
Oil seal setting tool
(6HK1)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-53
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
• Along with the camshaft bracket, remove the
rocker arm shaft ASM.
1A-54 ENGINE MECHANICAL (4HK1, 6HK1)
• Because the bolt(s) shown on the figure is are 6. Remove the camshaft bracket to take the shaft out.
designed to fix the rocker arm shaft, do not remove
it for now.
Name
Caution: 1. Camshaft Bracket
Pay full attention so as not to drop the bridge cap in the 2. Rocker Arm
gear case of the rear part of the cylinder head or the 3. Wave Washer
hole into which oil pours back in the front. 4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
Disassembly 7. Rocker Arm Shaft
1. Remove the camshaft bracket.
2. Remove the rocker arm. 7. Check if the oil hole is clogged of the camshaft
bracket (on the rear side).
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
• Disassemble according to the order (2) – (4)
thereafter.
Installation
1. Install the rocker arm shaft ASM.
• If the bridge cap comes off, apply engine oil over
the inside of the bridge cap and put it together with
the bridge.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
Tightening torque:
4HK1
Bolt (3) = 56 N⋅m (5.7 kg⋅m/41 lb ft)
Nut (1), Bolt (2), (4) = 27 N⋅m (2.8 kg⋅m/20 lb ft)
1A-58 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Camshaft Bracket Fixing Nut
2. Camshaft Bracket Fixing Bolt
3. Rocker Arm Bracket Fixing Bolt
4. Rocker Arm Shaft Set Bolt
6HK1
Nut (1) – (4) and Bolt (10) – (13) =
27 N⋅m (2.8 kg⋅m/20 lb ft)
Bolt (5) – (9) = 56 N⋅m (5.7 kg⋅m/41 lb ft)
4 6 8 9 7 5 3 1
2
11 12 13 10
Camshaft ASM
Components
4HK1
Name
1. Bearing Cap 3. Knock Pin
2. Bearing 4. Camshaft Gear
ENGINE MECHANICAL (4HK1, 6HK1) 1A-61
6HK1
WSHK0055
Name
1. Bolt 7. Sub Gear
2. Washer 8. Dish Spring
3. Gear 9. Snap Ring
4. Pin 10. Pin
5. Spring 11. Camshaft
6. Pin
Removal Caution:
Put the removed bearings in order with a tag, for
1. Remove the cylinder head cover.
example, by cylinder.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
5. Remove the camshaft ASM.
6. Remove the bearing lower.
1A-62 ENGINE MECHANICAL (4HK1, 6HK1)
WSHK0057
Name
Disassembly 1. Snap Ring
1. Remove the scissors gear ASM. (6HK1) 2. Dish Spring
3. Sub Gear
• Fix the hexagon portion of the camshaft in a vise
4. Spring
using a mouth ring. Use snap ring pliers to remove
5. Camshaft Gear
the sub gear.
2. Remove the camshaft gear.
Caution:
Take care not to damage to the cam portion and the • Remove the fastening bolts of the camshaft gear
journal portion of the camshaft. and put the block of wood in a puller to remove the
camshaft gear.
WSHK0056
Name
1. Wood
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
WSHK0057
Name WSHK0059
1. Snap Ring • Assemble onto the cylinder head.
2. Dish Washer
3. Sub Gear
4. Spring
5. Camshaft Gear
WSHK0056
1A-66 ENGINE MECHANICAL (4HK1, 6HK1)
Fixing torque
WSHK0060
ENGINE MECHANICAL (4HK1, 6HK1) 1A-67
Installation 4HK1
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
4HK1
WSHK0066
6HK1
6HK1
Name
1. Bridge Cap
2. Bridge
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front. Caution:
Do not reuse the removed oil seal.
6. Remove the split collar.
• Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home Inspection
position.
Check the valve spring.
• Use a replacer to compress the valve spring to Caution:
remove the split collar. Check the valve spring visually and if there is clear
damage or wear-out, replace it.
Special tool 1. Free length
Use acceptable: Valve spring replacer:
• Measure free length of the spring and if it is shorter
Use acceptable: Pivot:
than the specified limit, replace the spring.
4HK1
6HK1
6HK1
6HK1
Installation
1. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a valve
stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted 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.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-73
Special tool 3. Install the spring upper seat.
4HK1 4. Install the split collar.
Use acceptable: Valve stem seal installer: • Apply compressed air over the cylinder from the
6HK1 glow plug holes to keep the valve at the home
Use acceptable: Valve guide oil seal position.
installer:
• Use a replacer to compress the valve spring and
install the split collar.
Special tool
Use acceptable: Valve spring replacer:
Use acceptable: Pivot:
Paint mark 5. Apply engine oil over the bridge and install it.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
Name
1. Spring Pitch
2. Paint Mark
1A-74 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Bridge Cap
2. Bridge
Cylinder Head
Components
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the ‘OFF’ position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Disconnect the front exhaust pipe.
1A-76 ENGINE MECHANICAL (4HK1, 6HK1)
4. Remove the turbocharger.
Refer to the “Turbocharger and Exhaust Manifold”.
5. Remove the left-hand EGR adapter and right-hand
EGR pipe.
6. Remove the EGR water feed pipe.
7. Remove the EGR water return pipe.
8. Remove the EGR cooler.
9. Remove the water feed pipe for coolant water for
the EGR cooler and the water return pipe.
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal Nut
4. Nozzle Leak-Off Pipe
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
1
1 2
WSHK0019 WSHK0020
Name Name
1. High Pressure Pipe 1. Water Bypass
2. Leak-Off Pipe
20. Remove the EGR valve and EGR valve connector.
19. Remove the water bypass hose from the cylinder 21. Remove the cam angle sensor connector.
head side.
22. Remove the rocker arm shaft ASM.
• Remove the engine coolant temperature sensor Refer to “Rocker Arm Shaft ASM”.
connector.
23. Remove the camshaft ASM.
4HK1 Refer to “Camshaft ASM”.
24. Remove the bridge cap carefully so that it does not
fall into inside the engine.
25. Remove the bridge.
Caution:
Store the removed bridge and bridge cap so that they
can be placed in their original locations.
26. Remove the glow plug connector.
27. Remove the glow plug.
Name
1. Water Bypass
1A-78 ENGINE MECHANICAL (4HK1, 6HK1)
28. Remove the injection pipe clip, and remove the 31. If you have difficulty in removing the fuel injector,
injection pipe. set the fuel injector remover in the fuel injector,
4HK1 tighten the attachment part on the joint of the leak-
off pipe and pull out the fuel injector upward.
Special tool
Fuel injector remover: 380.002.601
Sliding hammer: 380.002.602
Caution:
When removing an fuel injector ID code, be sure to
attach the cylinder number.
When pulling out the fuel injector using a special tool,
check that the fuel injector sleeve does not come off.
Name
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
6HK1
Name
1. Sliding Hammer
2. Fuel Injector Remover
WSHK0021
3. Fuel Injector ASM
Name
1. Fuel Injection Pipe Caution:
2. Fuel Injection Pipe Clip Attach a cylinder number to the removed fuel injector
when storing it.
29. Remove the common rail. Be sure not to make the nozzle touch something.
• Remove the common rail pressure sensor
connector.
Special tool
Use acceptable: Valve spring replacer:
Use acceptable: Pivot:
• Remove the special tool, then remove the upper
sheet and springs.
Special tool
Nozzle sleeve remover: 380.001.720
Caution:
• Be sure not to scratch the bottom side of the
cylinder head.
• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.
Name
1. Nozzle Sleeve
– Improper installation
– Defective tightening of the cylinder head.
– Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening torque
Caution:
Replace suspicious bolt.
b. Inside the combustion chamber, glow plug hole.
• 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.
Name
1. Nut
Gap mm (in)
Assembly standard 0.020 (0.00079) –
0.057 (0.00224)
Usage limit 0.1 (0.0039)
6HK1
Valve seat
• Remove carbon, water stain and others on the
under surface of the cylinder head.
Install the valve in the cylinder head.
Measure the depth of the valve from the under
surface of the cylinder head, using a depth
gauge or straight edge ruler.
If the value exceeds the limit, replace the valve
insert or the cylinder head ASM.
4HK1
• Measure the contact width of the valve seat. If Repair of the seat surface
the seat contact surface has a scratch or is
• Remove carbon from the surface of the valve
rough, or if the abrasion of the contact surface
seat.
exceeds the limit, modify or replace it.
• Use a seat cutter to minimize the scratch and
Contact width of the valve seat mm (in) other roughness (15/45/75°-blade), thereby
returning the contact width to the standard
Standard Limit value.
Intake valve 2.5 (0.0984) 3.0 (0.1181)
Exhaust valve 2.0 (0.0787) 2.5 (0.0984)
Caution:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Contact surface of the valve seat
Do not let the valve cutter pilot waver inside the valve
• If the contact surface of the valve seat is guide.
defective, modify it or replace the valve, valve
guide and valve seat altogether.
Angle of the contact Exhaust side of 4HK1 and
surface: 6HK1: 45°
Intake side of 6HK1: 30°
ENGINE MECHANICAL (4HK1, 6HK1) 1A-87
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve
seat insert.
• Cool the valve seat insert for two to three
minutes. Contraction due to cooling makes it
easier to remove the valve seat insert.
• Remove the valve seat insert, using a screw
driver. Be sure not to hurt the cylinder head.
Caution:
Remove compound completely after grinding.
Name
1. Arc-Weld
2. Valve Seat Insert
3. Screw Driver
Caution:
Do not apply too much pressure with the press.
Attach compound on the valve seat surface, rotate the
valve and hit it lightly to grind them, and confirm that it
Replace the valve seat insert has even contact all round.
1A-88 ENGINE MECHANICAL (4HK1, 6HK1)
Name Name
1. Press 1. Cylinder Head
2. Attach Compound 2. Oil Seal Installer
3. Valve Seat
2. Install the bridge guide.
• Apply engine oil on the outer diameter of the guide,
Reassembly then use the installer to hammer it into the depth of
the finishing part of the hole of the cylinder head.
1. Install the oil seal. (Note: the height of the bridge guide is about
• Install on the surface of injection pipe insert. 37.5 mm {1.48 in} from the upper surface of the
head)
• Hammer it in so that the seal does not incline.
Special tool
Caution: Bridge guide installer: 380.001.722
Be sure not to hurt the rip. Engine oil
Special tool
Oil seal installer: 380.001.719
3. Nozzle sleeve
• Install the O-ring on the nozzle sleeve, apply
engine oil.
Name
1. Apply Seal Material
2. O-Ring Name
1. Punch Bar
• Install the nozzle sleeve on the cylinder head, 2. Ball
insert the guide sleeve. 3. Guide Sleeve
4. Nozzle Sleeve
• Use the guide sleeve to push in so that the nozzle 5. Bracket
sleeve fully contacts with the under surface of the 6. Bolt
cylinder head.
4. Install the valve guide.
• Insert the sleeve and fix it with the tighten and bolt.
• Hammer in the valve guide from the upper surface
• Insert the ball (bearing steel ball 9.525 mm of the cylinder head, using the valve guide
{0.375 in}) into the guide sleeve, attach the punch replacer.
bar and hammer out the ball.
Caution:
• Leave the cylinder head floating so that the ball
comes off from the under surface.
1A-90 ENGINE MECHANICAL (4HK1, 6HK1)
Special tool Special tool
Use acceptable: Valve guide replacer: 4HK1
Use acceptable: Valve stem seal installer:
6HK1
Use acceptable: Valve guide oil seal
installer:
5. Install the valve stem oil seal. 7. Install the valve spring.
• Apply engine oil on the outer diameter of the valve • Install the valve spring with the paint mark or the
guide, use the valve stem seal installer to install narrower side of the spring pitch on the under side
the oil seal. (the cylinder head side).
Caution:
After installation of the valve stem seal, confirm that the Paint mark
oil seal is not inclining and the garter spring is in place.
Intake side Light blue
Exhaust side Yellow
ENGINE MECHANICAL (4HK1, 6HK1) 1A-91
Name
1. Spring Pitch
2. Paint Mark Name
1. Idle Gear C
8. Install the spring upper seat. 2. Shaft
9. Install the split collar.
11. Install the idle gear C cover.
• Use a replacer to compress the valve spring and
install the split collar. • Apply liquid gasket (Loctite 262 or 962T) on the
outer diameter of the idle gear C cover, use the
Special tool sealing cup setting tool to hammer it in so that the
Use acceptable: Valve spring replacer: measurements follow the drawing.
Use acceptable: Pivot:
Special tool
Sealing cup installer: 380.002.604
6HK1
Name
1. Thermostat
6HK1
WSHK0025
WSHK0014
Name • Install the heat protector.
1. Distance Tube
2. Conical Spring
Tightening torque: 10 N⋅m (1.0 kg⋅m/89 lb in)
3. Nut
16. Install the inlet cover.
• Tighten the exhaust manifold in the order • Apply liquid gasket (ThreeBond 1207C or
described in the drawing. equivalent) in accordance with the groove of the
inlet cover, with the bead diameter of φ2.5 mm
Tightening torque: 34 N⋅m (3.5 kg⋅m/25 lb ft) (0.0984 in) – 5.5 mm (0.2165 in).
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
4HK1
• Tighten the stud bolts (6) and (9) jointly with the
common rail.
WSHK0026
Name
1. Grade Recognition Hole
Tightening torque:
M14 bolt (4HK1: 1 – 18, 6HK1: 1 – 26)
1st step = 98 N⋅m (10.0 kg⋅m/72 lb ft)
2nd step = 147 N⋅m (15.0 kg⋅m/108 lb ft)
3rd step = 30° – 60°
M10 bolt (4HK1: 19, 20; 6HK1: 27, 28)
4th step = 38 N⋅m (3.9 kg⋅m/28 lb ft)
Use a stud bolt for (4HK1: 16).
Special tool
Angle gauge: 380000304
4HK1
Caution:
Be sure not to hurt the head gasket when installing it.
6HK1
Name
1. Fuel Injector ASM
2. Fuel Injector Tighten Bolt
Caution:
Move it up and down to check if it moves smoothly.
12. Apply a thin coat of engine oil inside the bridge
cap, install it.
6HK1
WSHK0028
21. Install the terminal nuts on the fuel injector.
Tightening torque: 2 N⋅m (0.2 kg⋅m/18 lb in)
Caution:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
20. Install the fuel injector harness connector from
unified.
inside, tighten the harness bracket with the
designated torque. • Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb ft)
1A-100 ENGINE MECHANICAL (4HK1, 6HK1)
26. Connect the exhaust pipe.
• Connect the front exhaust pipe and tighten to the
specified torque.
Name
1. Fuel Injector
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
Special Tool
Illustration Tool Number/Description
380.002.602
Sliding hammer
1A-102 ENGINE MECHANICAL (4HK1, 6HK1)
Illustration Tool Number/Description
Illustration Tool Number/Description
380000304 380.002.604
Angle gauge Sealing cup installer
380.001.721
Nozzle sleeve installer
380.001.722
Bridge guide installer
380.001.719
Oil seal installer
380.001.720
Nozzle sleeve remover
380.002.601
Fuel injector remover
ENGINE MECHANICAL (4HK1, 6HK1) 1A-103
2
6
WSHK0184
Name
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
1. Remove the oil pan.
Refer to “Oil Pan”.
2. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
3. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
4. Remove the camshaft ASM.
Refer to “Camshaft ASM”.
5. Remove the cylinder head.
Refer to the “Cylinder Head”.
6. Remove the connecting rod cap.
Caution:
Sort the removed bearings according to cylinders by
using tags.
Caution:
Be sure not to damage the oil jet and cylinder liner
when pushing out the connecting rod.
Caution:
Sort the disassembled piston pins, pistons and
connecting rods together in the order of cylinders.
Caution:
Sort the bearings in the order of cylinders when reusing
them so that they will not be confused with the bearing
of other cylinders.
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.
4. Remove the connecting rod from the piston.
5. Piston
• Clean carbon carefully that is adhered to the head
of the piston and the groove of the piston ring.
Caution:
Do not use wire brush to clean the piston because it
scratches the piston.
Inspect the piston with eyes for cracks, burns and other
excessive wear, and replace it if there is any
abnormality.
6. Measure the gap between the piston and the inner
diameter of the cylinder liner.
Cylinder liner inner diameter liner inner diameter both in the thrust and radial
• Use a cylinder bore dial indicator to measure the directions in the designated position.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-105
• Measurement position (from the upper surface of 6HK1
the cylinder block)
1. 20 mm (0.79 in) 2. 110 mm (4.33 in) Piston diameter mm (in)
3. 190 mm (7.48 in) Standard 114.974 – 114.989
• Measure the liner inner diameter based on the (4.52652 – 4.52711)
average value of the actual measurement values
on 6 positions.
Gap between the piston and the inner mm (in)
diameter of the cylinder liner
Cylinder liner inner diameter mm (in)
Standard 0.042 – 0.066
115.021 – 115.050 (4.52838 – 4.52952) (0.00165 – 0.00259)
Caution:
If it is found that the gap between the cylinder liner
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder liner.
Name
1. 20 mm (0.79 in)
2. 110 mm (4.33 in)
3. 190 mm (7.48 in) 7. Piston replacement
Piston outside diameter • You do not need to select grades because there is
• Use a micrometer to measure the outside diameter only one grade for each of the piston and the
of the piston in the right angle to the piston pin in cylinder liner inner diameter.
the designated position. If you replace the cylinder liner, you must select
the cylinder block (1, 2, 3) because there are two
• Measurement position (from the upper surface of types of the liner outer diameter.
the piston) 82 mm (3.2 in). • Refer to “Cylinder Block” if you replace the cylinder
liner.
4HK1
Caution:
Piston diameter mm (in) The head of piston has a marking of grade B or C when
Standard 114.920 – 114.949 it is shipped from the factory.
(4.52440 – 4.52554)
4HK1
• Measure the bush of the small edge of the
Piston pin outer diameter mm (in)
connecting rod. If the clearance between the
Standard 35.995 – 36.000 (1.4171 – 1.4173) bushing inner diameter and the pin diameter
exceeds the limit, replace the bushing or
Limit 35.970 (1.4161)
connecting rod ASM, and the pin.
6HK1
Piston pin and connecting rod small end mm (in)
Piston pin outer diameter mm (in) bushing clearance
Standard 40.0 (1.5748) Standard 0.012 – 0.027
(0.0005 – 0.0011)
Limit 39.95 (1.5728)
Limit 0.05(0.0020)
1A-108 ENGINE MECHANICAL (4HK1, 6HK1)
Standard 0.004 – 0.017 (0.00016 – 0.00067) • Use the bench press to replace the bush.
Limit 0.04 (0.0016)
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
11. Remove the bushing. (EN-47682)
• Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
Name
1. Bolt
2. Connecting Rod Bushing Replacer
• Install the bearing cap and tighten the bolt with the
designated torque.
Apply molybdenum disulfide on the screw part and
the bearing surface.
Connecting rod bearing cap bolt torque: N⋅m 14. Select the connecting rod bearing.
(kg⋅m/lb ft) • Refer to the bearing selection table when installing
1st step 39 (4.0/29) a new connecting rod or replacing bearings in use.
2nd step 60° • Select and install the bearing, paying attention to
3rd step 30° the large edge hole diameter of the connecting rod.
Caution:
Do not rotate the crankshaft.
1A-110 ENGINE MECHANICAL (4HK1, 6HK1)
Reassembly
1. Install the bush
• Place the connecting rod bushing replacer base on
the bench press, set the connecting rod and
tighten the fixation bolt.
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
(EN-47682)
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
• Adjust the oil hole of the connecting rod and the oil
hole of the bush, and use the bench press to install
the bush.
Name
1. Grade Identification Color
ENGINE MECHANICAL (4HK1, 6HK1) 1A-111
Name Name
1. Setting Bar 1. Snap Ring
2. Connecting Rod 2. Front Mark
3. Nut 3. Forging Mark (Projecting)
4. Collar
5. Bushing 4. Apply enough engine oil on the piston pin, push it
6. Collar in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
• After installing the new bush, use a grinder to
machine the pin hole so that the pin clearance Caution:
equals the standard value. Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.
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 liner when
pushing in the piston.
Special tool
Piston ring compressor: 5-8840-9018-0 (J-8037)
Name
1. Top Ring
2. Second Ring
3. Third Ring
4. Oil ring
Caution:
Note that the shapes are different for each piston ring.
Make sure that there is not gap in the position indicated
in the drawing when the oil ring coil expander was
installed.
Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, apply
engine oil on the bearing.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-113
5. Install the camshaft ASM.
Refer to “Camshaft ASM”.
6. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
7. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
8. Install the oil pan.
Refer to “Oil Pan”.
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
Tightening torque:
1st step = 39 N⋅m (4.0 kg⋅m/29 lb ft)
2nd step = 60°
3rd step = 30°
Special tool
Angle gauge: 380000304
Caution:
Make sure that the crankshaft rotates smoothly.
Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
5-8840-2340-0
EN-47682 1-8522-1029-0
Connecting rod bushing Piston ring setting tool
replacer
380000304
5-8840-9018-0
J-8037
Piston ring compressor
Angle gauge
ENGINE MECHANICAL (4HK1, 6HK1) 1A-115
Flywheel
Components
Name
1. Flywheel Housing 3. Washer
2. Flywheel ASM 4. Crankshaft Position Sensor
Removal 4HK1
1. Remove the starter motor.
• Remove the ground cable of the starter motor.
WSHK0030
2. Remove the crankshaft position sensor.
• Remove to prevent contact damage when the • Gradually loosen the flywheel installation bolts in
flywheel is removed. the order shown in the drawing so that the flywheel
does not rotate.
• Do not throw or drop because it is vulnerable to
shock. • After loosening all the bolts, remove the stopper to
* 4HK1 is shown for illustration. remove the flywheel.
3. Remove the washer and flywheel. 4. Take out the ring gear.
• Install the crankshaft stopper to the starter • Put a bar on the ring gear and hit it with a hammer
installing portion of the flywheel housing. to remove it.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-117
Inspection Installation
1. Visual check 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks and • After heating the ring gear with a gas burner
damages, and replace it if it has abnormality. equally, install it in the flywheel.
• Inspect the tooth part of the ring gear, replace the • In the case of shrinkage cooling of the ring gear,
ring gear if it has damage or serious wear. maintain the flatness by applying weight of 68.6 kN
(15,400 lbf).
2. Measurement of the friction surface
• Measure the depth of the flywheel friction surface. Caution:
• Install the ring gear so that the side with a pattern
• Adjust it if the measured value is within the faces forward.
standard value and the limit. • Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
• If the measured value exceeds the limit, replace
complete.
the flywheel.
Tightening torque:
1st step = 78 N⋅m (8.0 kg⋅m/58 lb ft)
2nd step = 120° – 150°
Special tool
Crankshaft stopper: 380.002.628
Angle gauge: 380000304
6HK1
WSHK0030
• Install the ground cable of the starter motor.
78 {8 / 58} 60 60
8 {0.8 / 5.9}
WSHK0067
Special Tool
Illustration Tool Number/Description
380.002.628
Crankshaft stopper
380000304
Angle gauge
1A-120 ENGINE MECHANICAL (4HK1, 6HK1)
Front Cover
Components
4HK1
ENGINE MECHANICAL (4HK1, 6HK1) 1A-121
6HK1
10 9 8
5
11
12 7 6
WSHK0171
Name
1. Adjusting Plate 7. Crankshaft Pulley
2. Generator 8. Water Pump ASM
3. Front Cover 9. Fan Belt
4. Oil Pan Gasket 10. Water Pump Pulley
5. Oil Pan 11. Spacer
6. Front Oil Seal 12. Fan ASM
Removal
1. Remove the front oil seal.
Refer to “Crankshaft Front Oil Seal”.
2. Remove the oil pan.
Refer to “Oil Pan”.
3. Remove the water pump.
Refer to the “Water Pump” in the cooling system
section.
4. Remove the front cover.
• Remove the generator adjust plate.
1A-122 ENGINE MECHANICAL (4HK1, 6HK1)
• Install within seven minutes after applying liquid
gasket.
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
4HK1
Name
1. O-Ring
6HK1
Installation
1. Install the front cover.
• Clean the cylinder block front surface. In particular,
remove liquid gasket leaked during installation of
the crankcase.
Tightening torque
Oil relief valve: 39 N⋅m (4.0 kg⋅m/29 lb ft)
WSHK0032
Name
1. Bolt: L = 35
2. Bolt: L = 25
3. Bolt: L = 65
4. Bolt: L = 30
5. Oil Relief Valve
6HK1
Tightening torque
Front cover bolts (13 bolts): 18 N⋅m (1.8 kg⋅m/13
lb ft)
• Tighten bolt with (*) mark together with the adjust
plate of the generator.
Tightening torque
Stud bolt for water pump: 12.7 N⋅m (1.3 kg⋅m/9.4
lb ft)
1A-124 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
4HK1
39 {4 / 29}
39 {4 / 29}
24 {2.4 / 18}
WSHK0037
ENGINE MECHANICAL (4HK1, 6HK1) 1A-125
6HK1
39 (4 / 29)
20 (2 / 14)
39 (4 / 29)
18 (1.8 / 13)
WSHK0164
1A-126 ENGINE MECHANICAL (4HK1, 6HK1)
Removal 4HK1
1. Drain coolant.
2. Remove the starter.
• Disconnect the starter ground cable.
WSHK0030
3. Disconnect the upper radiator hose on the engine
side. 10. Remove the crankshaft front oil seal.
4. Disconnect the coolant reserve tank hose on the • Remove the oil seal off with a screwdriver or the
radiator side. like avoiding damage to the oil seal contact surface
5. Disconnect the lower radiator hose on the engine on the front cover and the shaft.
side.
6. Remove the radiator (with the fan guide) detaching
right and left brackets.
7. Remove the fan ASM.
• Remove the fan ASM unscrewing four mounting
bolts.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
Name
1. Felt
2. Slinger
3. Oil Seal
Caution:
Be sure to replace the slinger and oil seal as a set.
11. Remove the front slinger.
• Use the slinger remover to remove the front
slinger.
5
3
2
Caution:
Be sure to replace the slinger and oil seal as a set.
2. Install the crankshaft front oil seal.
• Press fit the oil seal using an oil seal installer,
setting tool.
Name
1. Adapter
• Apply engine oil to the lip of the oil seal and place it
on the front side adapter.
• Put the front side adapter ring in the sleeve and fix
the sleeve on the adapter with the center bolt and
Name a washer.
1. Oil Seal
2. Adapter (Front) • Tighten the bolt until the sleeve touches the
3. Adapter Ring (Front) adapter to press fit the front oil seal.
4. Fixing Bolt
5. Sleeve (Front)
6. Washer (Front)
7. Center Bolt
1A-130 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
Name
1. Oil Seal Name
2. Adapter Ring 1. Adapter Ring
3. Sleeve 2. Sleeve
4. Bolt and Washer 3. Adapter
4. Oil Seal
6HK1
WSHK0033
Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
380.001.712
380.002.628
Oil seal setting tool
Crankshaft stopper
(6HK1)
380.002.608
Slinger remover
1A-134 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Flywheel 2. Crankshaft Rear Oil Seal
Removal
1. Remove the flywheel.
Refer to the “Flywheel”.
2. Remove the crankshaft rear oil seal.
• Remove the oil seal off with a screwdriver or the
like avoiding damage to the oil seal contact surface
on the flywheel housing and the shaft.
Name
1. Felt
2. Slinger
3. Oil Seal
ENGINE MECHANICAL (4HK1, 6HK1) 1A-135
3. Use the slinger remover to remove the slinger.
Caution:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
380.002.608 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
380.001.712 (For 6HK1)
5
3
2
Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
Use acceptable: Oil seal installer kit:
6HK1 • After pressing in the slinger, make sure that the
Oil seal setting tool: 380.001.712 distance between crankshaft end surface and the
• Install the slinger (1) to the end of adapter (2). slinger is A as specified.
Install the adapter to the crankshaft (3).
• Install the slinger sleeve (4) to the adapter. Tighten
the center bolt (5) until the sleeve comes in contact
with the adapter stopper.
1A-136 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
Name
Distance (A): 17.3±0.3 mm (0.7±0.01 in) 1. Adapter (Rear)
Distance (B): 10.8±0.1 mm (0.4±0.004 in) 2. Fixing Bolt
6HK1 3. Center Bolt
4. Sleeve (Rear)
5. Collar (Rear)
6. Adapter Ring (Rear)
7. Oil Seal
Special tool
4HK1
Use acceptable: Oil seal installer kit:
6HK1
A
Oil seal setting tool: 380.001.712
Caution:
• Put a collar on the fixing bolt and mount the
Be sure to replace the slinger and oil seal as a set.
adaptor onto the crankshaft.
2. Install the crankshaft rear oil seal.
• Press-fit the rear oil seal using an oil seal installer,
setting tool.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-137
• Apply engine oil to the lip of the oil seal and place it
in the rear side adapter.
• Put the rear side adapter ring in the sleeve and put
the sleeve on the adapter and fix with the center
bolt.
Name
1. Rear Part of The Crankshaft
2. Oil Seal
3. 4HK1: 7.8 ± 0.3 mm (0.31 ± 0.012 in),
6HK1: 7.5 ± 0.15 mm (0.3 ± 0.006 in)
4. Collar
5. Adapter Ring
6. Sleeve
* 4HK1 is shown for illustration. 7. Adapter
Name
3. Install the flywheel.
1. Sleeve
Refer to the “Flywheel”.
2. Adapter Ring
380.002.608
Slinger remover
380.001.712
Oil seal setting tool
(6HK1)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-139
Crankshaft
Components
the replacer holes (arrowed holes in the figure). 15. Remove the lower thrust bearing.
4HK1 16. Remove the lower crankshaft bearings.
Special tool
Crankshaft gear puller: 380.002.613
Disassembly
Name
1. Remove the gear.
1. Alignment Mark
• Remove the gear using a gear puller.
Special tool
Use acceptable: Crankshaft gear puller: Inspection
1. Thrust clearance
• Set a dial gauge as shown and measure the
crankshaft thrust clearance.
Caution:
Measure the thrust clearance before dismounting.
Reassembly
1. Install the gear.
• Heat the gear to 170 – 250°C (338 – 482°F) and
install it aligning the groove on the gear with the
pin on the crankshaft.
• Insert the gear at one push into the flange with its
end side with the alignment mark “S” facing
outward. If you are fitting the gear while it is cold,
beat the gear in until it impinges on the end using
the installer.
1A-142 ENGINE MECHANICAL (4HK1, 6HK1)
Caution:
Turn the crankshaft about 30° to allow the bearings to
settle in.
Tightening torque:
M14 bolt 4HK1: (1 – 10), 6HK1: (1 – 14)
1st step = 98 N⋅m (10.0 kg⋅m/72 lb ft)
2nd step = 132 N⋅m (13.5 kg⋅m/97 lb ft)
3rd step = 30° – 60°
M10 bolt 4HK1: (11 – 27), 6HK1: 15 – 39)
4th step = 37 N⋅m (3.8 kg⋅m/27 lb ft)
• Tighten bolts from 1 to 10 (M14) and confirm that
they are tightened to a torque of 142 N⋅m (14.5
kg⋅m/105 lb ft) or more.
Special tool
Angle gauge: 380000304
Caution:
Do not rotate the crankshaft after tightening the
crankcase.
• Loosen the bolts and gently remove the
* 4HK1 is shown for illustration.
crankcase.
4HK1
• Measure the widest part of the Plastigauge
flattened by tightening the crankcase to determine
the clearance.
4HK1
6HK1
37 33 29 25 21 17 16 20 24 28 32 3639
14 10 6 2 3 7 11
13 9 5 1 4 8 12
38 34 30 26 22 18 15 19 23 27 31 35
WSHK0035
1A-144 ENGINE MECHANICAL (4HK1, 6HK1)
• If the journal oil clearance exceeds the limit, 4. Measure the journal and the crank pin diameters
replace the main bearings altogether or the and uneven wear.
crankshaft. • Measure outer diameters of the journal and the pin
and calculate differences between the maximum
• Remove the plastigauge from the bearing and and the minimum values. Take measurements at
crank pin. four positions for both the journal and the pin.
Inspection of crankshaft
• Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil seal
contact surface for excessive wear and damage.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowly
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
4HK1
Standard 0.06 or less (0.0024 or less) Journal #1, 2, 4, 5 81.905 – 81.925 81.85
(3.22460 – 3.22538) (3.222)
Limit 0.45 (0.018)
Journal #3 81.891 – 81.911 81.85
(3.22408 – 3.22483) (3.222)
Pin 65.902 – 65.922 65.850
(2.59456 – 2.59535) (2.5925)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-145
6HK1
Caution:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
shall not polish the surface of the crankshaft.
Name
1. Upper Bearing
2. Oil Gallery
3. Grade Identification Color
4. Oil Groove
5. Lower Bearing
6. Grade Identification Color
1A-146 ENGINE MECHANICAL (4HK1, 6HK1)
Bearing selection table
4HK1
6HK1
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing in the cylinder block and
apply oil.
Caution:
When replacing the crankshaft bearings, select grades
referring to the Crankshaft Bearing Grade Selection.
Do not apply oil to the bearing installation surface on
the cylinder block and external surface of the bearing.
6HK1
mm(in)
12(0.47)
10
(0
2(0.08)
.4
)
2.5(0.1)
15
(0
10(
8(0.31)
0.4
59
)
5(0.2)
)
8(0.31)
8(0.31)
2.5(0.1) 2.5(0.1)
WSHK0036
ENGINE MECHANICAL (4HK1, 6HK1) 1A-149
• Apply Molybdenum Disulfide to M14 bolts’ threads 6HK1
and setting faces and tighten them to the specified
tightening torque in the sequence shown.
Special tool
Angle gauge: 380000304 WSHK0035
380.002.613
Crankshaft gear installer
ENGINE MECHANICAL (4HK1, 6HK1) 1A-151
380000304
Angle gauge
1A-152 ENGINE MECHANICAL (4HK1, 6HK1)
Cylinder Block
Components
Caution:
You need not select cylinder liner bore grade since the
liners are only available in one size.
6. Cylinder block upper face warpage
• Pull out the cylinder liners and remove water stains
on the cylinder block.
Caution:
Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
6HK1
Lubrication System
Precautions on Service Work • Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the start and end of the application should
and apply the specified new fluid gasket at each be overlapped.
location.
Explanations on functions and operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating system diagram
1A-158 ENGINE MECHANICAL (4HK1, 6HK1)
Function 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 on the oil filter volume is appropriate if the engine oil is between
body. the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lower
4. Install the oil pressure gauge on the oil filter body.
limit. Also, check for contamination of the engine
oil.
Special tool
Oil pressure gauge: J43620-20
Hose: J43630
Connector (4HK1 only): J43630-14
Oil pressure testing adapter (4HK1 only): EN-46333
Name
1. Oil Pressure Testing Adapter (4HK1 only)
2. Connector (4HK1 only)
3. Hose
4. Oil Pressure Gauge
Name
5. Warm the engine. 1. Upper Limit
6. Measure the oil pressure, to check whether it is 2. Lower Limit
more than 343 kPa (50 psi) at 2000 rpm.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-159
Engine oil leakage
• In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
1A-160 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Oil Pressure Switch 3. O-Ring
2. Oil Port Cover
Removal
1. Remove the oil pressure switch.
2. Remove the oil port cover.
3. Remove the O-ring.
Installation
1. Install the O-ring on the oil port cover.
Name
1. O-Ring
2. O-Ring
ENGINE MECHANICAL (4HK1, 6HK1) 1A-161
2. Install the oil port cover on the cylinder block and
tighten it to the specified torque.
Tightening torque:
4HK1 48 N⋅m (4.9 kg⋅m/35 lb ft)
6HK1 39.2 N⋅m (4.0 kg⋅m/29 lb ft)
Name
1. Bolt M10X L = 80
2. Bolt M10X L = 25
Oil Cooler
Components
4HK1
Name
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Common Rail
ENGINE MECHANICAL (4HK1, 6HK1) 1A-163
6HK1
5 1 2 3 4
WSHK0038
Name
1. EGR Cooler Water Return Pipe 4. Fuel Supply Pump
2. Oil Cooler 5. Suction Pipe
3. Common Rail
Removal
1. Remove the common rail.
Refer to the “Common Rail” in the fuel system
section.
2. Remove the fuel supply pump.
Name
1. Bypass Hose Disassembly
2. EGR Cooler Water Return Pipe 1. Remove the element mounting bolts.
3. EGR Cooler Water Feed Pipe
2. Remove the element.
4. Suction Pipe
3. Remove the O-ring.
6HK1
1 2
WSHK0039 * 4HK1 is shown for illustration.
Name Name
1. Suction Pipe 1. Element
2. EGR Cooler Water Return Pipe 2. O-Ring
Name
1. O-Ring
* 4HK1 is shown for illustration. 2. O-Ring
3. Liquid Gasket
Name
1. Element – Align the oil cooler holes with the cylinder block
2. O-Ring studs.
– Install the oil cooler and glow plug controller
bracket to the cylinder block.
Installation – Tighten the bolts to the specified torque in the
1. Install the oil cooler ASM. order shown in the illustration.
• Apply liquid gasket (ThreeBond 1207B or Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)
equivalent) to the flange surface groove (cylinder • Liquid gasket quickly hardens.
block). Bead diameter must be between 2 and 4 Make it complete within 7 minutes after
mm (0.08 and 0.16 in). applying the liquid gasket.
Refer to the illustration for the offset position (no
more than 1 mm {0.04 in}). 4HK1
• Install the O-rings (1) and (2) to the oil passage
inlet and outlet. Do not allow the liquid gasket to
contact the O-ring.
1A-166 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1 6HK1
WSHK0040 WSHK0041
2. Connect the water suction pipe.
Name
• Apply liquid gasket (ThreeBond 1207B) to the 1. Gasket
flange of the water suction pipe. Bead diameter 2. Suction Pipe
must be between 2 and 5 mm (0.08 and 0.20 in).
Refer to the illustration for the offset position (no
more than 1 mm {0.04 in}). (4HK1) Caution:
The water suction pipe must be installed immediately
• Install the water suction pipe to the oil cooler. Refer after the oil cooler (the pipe and cooler use the same
to the illustration. liquid gasket).
4HK1
• Tighten the bolts to the specified torque.
Oil Pan
Components
Removal
1. Drain engine oil.
2. Remove the oil pan.
ENGINE MECHANICAL (4HK1, 6HK1) 1A-169
3. Remove the Oil strainer. 4HK1
WSHK0180
Installation
1. Install the oil strainer with new O-ring to the crank
case.
Tightening torque:
M8 Bolt (4HK1): 32 N⋅m (3.3 kg⋅m/24 lb ft)
M8 Bolt (6HK1): 24 N⋅m (2.4 kg⋅m/18 lb ft)
M10 Bolt: 48 N⋅m (4.9 kg⋅m/35 lb ft)
WSHK0181
• Apply the liquid gasket and install the oil pan within
7 minutes.
1A-170 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
6HK1
6HK1 • Fastening the oil pan from the part of A or B in
clock wise order.
• It tightens again by specified torque.
Tightening torque: 24.5 N⋅m (2.5 kg⋅m/18 lb ft)
Name
1. Oil Pan
2. Gasket
4HK1
• Tighten the locations (1), (2), (3), and (4) as shown
in the figure and then tighten others. (In any
sequence)
Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft)
ENGINE MECHANICAL (4HK1, 6HK1) 1A-171
Oil Pump
Components
Disassembly
* 4HK1 is shown for illustration. 1. Remove the driven gear and shaft.
12. Remove the idle gear A. 2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin and fold it according to (1).
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Measure the clearance between the gear and oil
pump body using a thickness gauge.
6HK1
WSHK0043
• Align with the knock pin of the cylinder block and
install the flywheel housing.
6HK1
1
1 2
5
1
3
6
1
3
4
1
WSHK0044
ENGINE MECHANICAL (4HK1, 6HK1) 1A-177
5. Install the oil pan.
Refer to “Oil Pan”.
6. Install the rear seal of the crankshaft.
Refer to “Rear Oil Seal of Crankshaft”.
7. Install the flywheel.
Refer to the “Flywheel”.
8. Install the fuel supply pump ASM.
Refer to “Fuel Supply Pump” in the Fuel System
section.
9. Install the cylinder head ASM.
Refer to “Cylinder Head Cover”.
10. Install the camshaft ASM.
Refer to “Camshaft ASM”.
11. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
12. Tighten the cylinder head cover.
Refer to “Cylinder Head Cover”.
1A-178 ENGINE MECHANICAL (4HK1, 6HK1)
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
Cooling System 1B-1
ENGINE
Cooling System
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Precautions on Service Work . . . . . . . . . . . . . . 1B-2
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
A List of Defective Phenomena . . . . . . . . . . . . . 1B-7
Main Data and Specifications . . . . . . . . . . . . . . 1B-7
Water Pump (4HK1) . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-11
Water Pump (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1B-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1B-18
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Torque Specifications . . . . . . . . . . . . . . . . . . . 1B-26
1B-2 Cooling System
Cooling System
Precautions on Service Work Explanations on functions and operation
WARNING: Cooling water system
Do not remove the radiator cap when the cooling water The cooling water system, which is the forced
is at high temperature. Steam or boiling water will gush circulation system, consists of a water pump,
out and you may be burnt. To open the radiator cap, thermostat, and radiator as its main components. The
cover the cap with a thick cloth when the cooling water oil in automatic transmission is cooled due to the
is cool, release the pressure by slowly turning the cap, cooling water in the radiator.
and then remove the cap.
4HK1
Name
1. Water Jacket 10. Reservoir Tank
2. Drain Plug 11. Air Bleeding Plug
3. Oil Cooler 12. Water Outlet Pipe
4. Water Pump 13. Thermostat (2 units)
5. Drain Cock 14. Thermometer Unit
6. Radiator 15. Bypass Route
7. Cooling Fan 16. Turbocharger
8. Radiator Cap 17. EGR Cooler
9. Heater Core
Cooling System 1B-3
6HK1
10
8 9
11 14
12
13
7
6 1
3 2
5
WSHK0045
Name
1. Water Jacket 8. Radiator Cap
2. Drain Plug 9. Reservoir Tank
3. Oil Cooler 10. Water Outlet Pipe
4. Water Pump 11. Thermostat (2 units)
5. Drain Cock 12. Thermometer Unit
6. Radiator 13. Bypass Route
7. Cooling Fan 14. EGR Cooler
1B-4 Cooling System
Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.
Name
1. Jiggle Valve 4. Gasket
2. Stamp Mark (Valve Initial Opening Temperature) 5. Piston
3. Valve
Coolant
1. About the engine coolant concentration
• Take the concentration corresponding to the
minimum temperature because the freezing
temperature varies according to the
concentration of the engine coolant.
• Use only genuine Isuzu engine coolant.
• Use engine coolant with a mix ratio in the range
of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.
Name
1. Antifreeze Hydrometer
2. Radiator
Engine overheats
Engine overcools
Name
1. Fan 4. Fan Belt
2. Spacer 5. Water Pump ASM
3. Water Pump Pulley 6. Gasket
Removal
1. Drain the coolant.
2. Remove the four mounting bolts and then the fan
ASM and spacer, water pump pulley.
Cooling System 1B-9
Name Name
1. Fan 1. Water Pump
2. Spacer
3. Water Pump Pulley 5. Remove the gasket.
4. Bolt
3. (2) and (3) that tighten the setting plate and water Inspection
pump together. Loosen the adjusting bolts (1) in 1. Appearance check
the generator and remove the fan belt. • 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. Bearing nut check
• 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.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
Name
1. Fan ASM
2. Spacer
3. Water Pump Pulley
4. Bolt
7. Pour coolant.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
3
1
3
2
1
Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
1 6
Name
1. Adapter 4. Bypass hose
2. Fan pulley 5. Water duct
3. Water pump 6. Water duct
Tightening torque:
Bolt (1) : 221.6 N⋅m (22.6 kg⋅m/163 lb ft)
Bolt (2) : 24.5 N⋅m (2.5 kg⋅m/18 lb ft)
Water pump
Alternator
1 Crankshaft
3
2
1
Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
1B-16 Cooling System
Torque Specifications
39(4 /29)
20(2 / 14)
221.6(22.6 / 163)
20(2 / 14)
52(5.3 / 38)
F06E100076
Cooling System 1B-17
Disassembly
15
14
13
11
12
16
10
8
7
6
5
3
2
1
Name
1. Center 9. Shaft
2. Dust cover 10. Water pump body
3. Snap ring 11. Dowel pin
4. Bearing 12. Seal unit
5. Bearing 13. Impeller
6. Spacer 14. Gasket
7. Bearing 15. Cover
8. Washer 16. Bolt
1B-18 Cooling System
1. Remove the rear cover from the water pump body. Inspection and Repair
2. Use a remover to remove the impeller Make the necessary adjustments, repairs and part
from the water pump. replacements if excessive wear or damage is
3. Use a puller to remove the water pump center. discovered during inspection.
4. Remove the dust cover and snap ring.
Water pump impeller
5. Remove the water pump shaft with ball bearings.
• Use a plastic hammer to lightly tap on the water 1. Check the impeller for corrosion.
pump shaft from the impeller side.
NOTE :
2 To prevent damage to the water pump shaft, place soft
brass or copper sheets between the base plates and
the water pump shaft.
1B-20 Cooling System
• Position the pump shaft with bearings to the 4. Install the seal unit to the water pump body.
water pump body. • Press in the seal unit to the specified position
• Use a bench press to gradually press the water using a bench press and installer.
pump shaft into the water pump body. .
Seal unit installation position A:
NOTE :
11.0 – 11.6 mm (0.433 – 0.457 in)
Do not drive the bearing into position with a hammer or
similar object. Bearing damage will result.
Thermostat
Components
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.
2. Disconnect the water outlet pipe.
3. Remove the thermostat.
4. Remove the gasket from the thermostat.
Inspection
• Place the thermostat in water and increase the
temperature while stirring it sufficiently.
• Measure the temperature when the valve is just
opened and when it is fully open.
Cooling System 1B-23
Installation 6HK1
1. Mount the gasket on the thermostat and mount it at
the position shown in the figure.
• The thermostat with the jiggle valve (A) is
installed to the left side of the engine. The jiggle
valve faces the rear of engine.
• Fit the thermostat gasket ensuring that it does
not come out of and on top of the external
housing on the cylinder head side.
WSHK0024
Name
1. Thermostat
031EY00026
4HK1
Drive Belt
Components
Name
1. Crankshaft Pulley 5. Adjusting Bolt
2. Generator Drive Belt 6. Lock Nut
3. Bolt 7. Adjusting Plate
4. Generator 8. Water Pump Pulley
Name
1. Crankshaft Pulley
2. Bolt
3. Generator
4. Adjusting Bolt
5. Lock Nut
6. Water Pump Pulley
7. Generator Drive Belt
1B-26 Cooling System
Torque Specifications
ENGINE
Fuel System
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2
Precautions on Service Work . . . . . . . . . . . . . .1C-2
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-9
Fuel Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-10
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16
Torque Specifications . . . . . . . . . . . . . . . . . . .1C-20
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-21
Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . .1C-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-24
Torque Specifications . . . . . . . . . . . . . . . . . . .1C-27
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-28
Components . . . . . . . . . . . . . . . . . . . . . . . . . .1C-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1C-31
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32
Torque Specifications . . . . . . . . . . . . . . . . . . .1C-35
1C-2 Fuel System
Fuel System
Precautions on Service Work • Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
Parts of the fuel system such as the internal part of the
exposed ends of the hose or pipe.
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy. • If parts are to be replaced (fuel hose, fuel pipe,
They are therefore highly sensitive to foreign matter etc.) do not open the new part packaging until
and the entry of foreign matter could cause damage to installation.
the fuel passage. Therefore, effective measures should Discard gaskets and O-rings and replace them with
be taken to prevent the entry of foreign matter. new ones.
If water removal agent is used in the fuel then it will Work procedure
absorb moisture in the light oil and may cause rust. • The fuel opening must be quickly sealed when
Therefore, do not use water removal agent in the fuel removing the fuel pipe, injection pipe, fuel injector,
tank. fuel supply pump, and common rail.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the • The eyebolts and gasket must be stored in a clean
system. parts box with a lid to prevent adhesion of foreign
matter.
• Before beginning the service procedure, wash the
fuel line and the surrounding area. • Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
• Perform the service procedures with clean hands. out and make sure there is no fuel leakage after
Do not wear work gloves. starting the engine.
2 4HK1
3
1
6
7
5 6HK1
6 8
WSHK0068
Name
1. Common Rail 5. Fuel Tank
2. Fuel Filter 6. Supply Pump
3. Electromagnetic Pump 7. Fuel Injector
4. Pre-fuel Filter 8. Leak-Off Pipe
Fuel System 1C-3
Caution:
• Be careful foreign material does not into the fuel
system, because the precise fuel system is used.
Common rail
4HK1
Name
1. Flow Damper 3. Pressure Sensor
2. Pressure Limiter
1C-4 Fuel System
6HK1
MFW41DMF000201
Name
1. Flow Damper 3. Fuel Inlet
2. Pressure Limiter 4. Pressure Sensor
Fuel System 1C-5
Fuel supply pump
4HK1
Name
1. Fuel Temperature Sensor 4. Camshaft Key
2. Suction Control Valve 5. Camshaft Nut
3. High Pressure Pipe
1C-6 Fuel System
6HK1
1 3
WSHK0046
Name
1. Fuel Temperature Sensor 3. High Pressure Pipe
2. Suction Control Valve 4. Camshaft Key
Fuel System 1C-7
Fuel injector Fuel filter
Name Name
1. Terminal Stud 1. Priming Pump
2. Part for Mounting Leak Off Pipe 2. Air Bleed
3. O-ring 3. Case
4. Part for Mounting Injection Pipe 4. Drain Plug
5. Parts Number
6. ID Code Plate
Function check
Air bleeding
1. Before starting the engine
a. Fit a tray below the fuel filter (below the air
bleed plug).
b. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
near the plug overflows.
c. Tighten the plug, and operate the priming pump
more than 10 times until it is filled with fuel.
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.)
d. Tighten the plug firmly and wipe the fuel in the
surrounding area. Operate the priming pump
(10 to 15 times) till it is filled with fuel and then
send fuel to the engine.
1C-8 Fuel System
2. After starting the engine
a. Start the engine by rotating the starter without
depressing the accelerator pedal.
b. After starting, maintain the idling rotation for 5
seconds.
c. Slowly rotate the idling control knob clockwise
and maintain it for 3 minutes.
d. Fully depress the accelerator pedal and
increase the rotations to maximum. (Repeat
this operation several times)
e. Rotate the idling knob counterclockwise and
return to idling mode.
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.
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 it 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 out the air.
• Refer to “Fuel System”.
Fuel System 1C-11
380.002.630
Main filter wrench
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Installation
1. Assemble the Fuel Filter element.
2. To simplify air bleed, fill light oil in the case.
3. Tighten the case by hand. During this process take
adequate care that the light oil that is inside does
not flow out.
4. Use the filter wrench and tighten rotating by 1/3 to
2/3.
1C-12 Fuel System
Fuel Injector
Components
4HK1
Fuel System 1C-13
6HK1
11
8
7
10
12
5 3
1
2
WSHK0162
Name
1. Fuel Injection Pipe Clip 7. EGR Adapter
2. Fuel Injection Pipe 8. EGR Cooler
3. Fuel Injector Leak-Off Pipe 9. EGR Valve
4. Fuel Injector 10. Cylinder Head Cover
5. Fuel Injector Clamp 11. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 12. Fuel Injector Terminal
Name
6HK1 1. Cylinder Head Cover
WSHK0163
Name
1. EGR Adapter
2. EGR Valve
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak Off Pipe
Fuel System 1C-15
9. Remove the fuel injection pipe clips and the
injection pipes.
4HK1
6HK1
Name
1. Sliding Hammer
2. Remover
3. Fuel Injector ASM
Caution:
WSHK0021
• Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function
Name will result in injector failure.
1. Fuel Injection Pipe
2. Pipe Clip Recording Fuel Injector Flow Rate Information from
the QR plate on the replaced injector housing;
10. Loosen the fuel injector clamp fixing bolts and Record all numbers of replaced fuel injector's from QR
remove the fuel injectors. plate.
If the fuel injectors are difficult to remove, use the fuel
injector remover. Install the fuel injector remover to the
leak-off pipe attachment part on the fuel injector. Use a
sliding hammer to force the fuel injector clamp off the
fuel injector.
Caution:
Do not remove the fuel injector sleeve.
Special tool
Fuel injector remover: 380.002.601
Sliding hammer: 5-8840-0019 (J-23907)
1C-16 Fuel System
3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface
of the fuel injector side sleeve nuts.
6. Install the fuel injector pipes to the position shown
in the illustration.
7. Use a spanner to carefully the sleeve nuts until the
fuel injector pipes contact the fuel injector and
common rail.
8. Tighten the fuel injection pipe clips to the specified
torque.
Name
1. QR Plate
2. Fuel Injector Flow Rate
3. Fuel Injector
Installation
Important:
Install each of the fuel injectors on its original position.
(the cylinder from which it was removed)
1. Install a new gasket and O-ring to each of the fuel
injector clamps. Refer to the illustration.
* 4HK1 is shown for illustration.
Name
1. Fuel Injection Pipe
2. Pipe Clip
Name
1. Gasket
2. Fuel Injector
3. Bolt
4. Fuel Injector Clamp
11. Install the nozzle leak off pipes together with the
new gaskets. Tighten the pipes to the specified
torque.
WSHK0028
14. Install the fuel injector terminal nuts to the injector.
15. Alternately tighten each nut 2 or 3 turns at a time
until the specified torque is reached.
Caution:
Do not overtighten the nuts. Damage to the terminal
studs will result.
* 4HK1 is shown for illustration.
12. Install the fuel injector harness connectors. Work
from the inside out.
13. Install the harness bracket and tighten the bolts to
the specified torque.
Tightening torque: 4HK1: 48 N⋅m (4.9 kg⋅m/35 lb ft)
6HK1: 22 N⋅m (2.2 kg⋅m/16 lb ft)
1C-18 Fuel System
Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)
Name
1. Fuel Injector * 4HK1 is shown for illustration.
2. Harness
Name
3. Terminal Nut
1. EGR Adapter
2. EGR Valve
16. Install the gasket to the cylinder head cover.
17. Install the cylinder head cover and tighten the bolts 20. Attach the engine harness connectors. Each
to the specified torque. composite connector should make a loud click
Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft) when it is securely attached.
6HK1: 13 N⋅m (1.3 kg⋅m/9.6 lb ft) Before Programming the Fuel Injector Flow Rate
Important:
DO NOT program the fuel injector flow rate unless you
are directed by a service procedure or you are directed
by a service bulletin. Programming the fuel injector at
any other time will not permanently correct a customers
concern.
Ensure the following conditions are met before
programming the ECM.
• System voltage for machine
– There is no charging system concern. All
charging system concerns must be repaired
before programming the ECM.
– Battery voltage is greater than 12 volts but less
than 16 volts. 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
* 4HK1 is shown for illustration. voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
Name
1. Cylinder Head Cover – Turn OFF or disable and system that may put a
load on the machine’s battery.
18. Install the gasket to the EGR valve and tighten the • The ignition switch is in the proper position. DO
bolts to the specified torque. NOT change the position of the ignition switch
during the programming procedure, unless
Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) instructed to do so.
19. Install the gasket to the EGR adapter and tighten • All tool connections are secure.
the bolts to the specified torque. – RS-232
Fuel System 1C-19
– The connection at the data link connector
(DLC) is secure.
– Voltage 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 must be 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.
Fuel Injector Flow Rate Programming Procedure
1. Connect the scan tool to the data link connector.
2. Connect the RS-232 to the scan tool and PC.
3. Start TIS 2000 and select the Service
Programming System (SPS).
4. In the "Select Diagnostic Tool and Programming
Process" screen, select the following menu.
• Diagnostic tool "Pass-Thru".
• Select Programming Process "Reprogram
ECU".
• ECU Location on the “Machine”.
Then, follow the SPS screen instructions.
5. Ensure that ALL programming contents are
entered correctly and were programmed
successfully by turning OFF the ignition for 30
seconds.
6. Using the scan tool to check each programmed
fuel injector flow rate.
7. Start the engine and let idle.
8. Inspect for a proper engine running condition and
for no DTCs. Refer to the “Diagnostic System
Check − Engine Control” if needed.
1C-20 Fuel System
Torque Specifications
2 (0.2 / 1.5)
12 (1.2 / 8.9)
30 (3.0 / 22)
24 (2.4 / 17)
6 (0.6 / 4.4)
44 (4.5 / 32)
WSHK0047
5-8840-0019-0
J-23907
Sliding hammer
380.002.601
Fuel injector remover
1C-22 Fuel System
6HK1
Name Name
1. Fuel Supply Pump 1. Fuel Supply Pump
2. O-ring 2. O-ring
3. Fuel Supply Pump Bracket 3. Fuel Supply Pump Bracket
Caution:
Take care not to twist the O-ring.
Name
1. Fuel Supply Pump
2. Fuel Supply Pump Gear
3. Nut
Fuel System 1C-25
4. Apply white paint to the top of the fuel supply pump 6HK1
gear tooth directly above the stamped ‘O’ mark.
Refer to the illustration.
WSHK0049
6. Remove the oil drain adapter.
7. Install the O-ring to the fuel supply pump.
* 4HK1 is shown for illustration.
8. Align the slits as shown in the illustration.
5. Turn the crankshaft in the normal direction of
9. Insert the stud bolts into the guides and
engine rotation until the No. 1 or No. 4 cylinder is
temporarily tighten them.
at TDC on the compression stroke.
Refer to the illustration. Caution:
4HK1 • If the stud bolts (cylinder block side) have been
loosened or replaced, apply Loctite 262 to the
recessed portion of the bolts.
Name
1. Plug Hole
2. Alignment Mark
WSHK0050
15. Install the fuel pipe and fuel leak-off pipe.
16. Start and idle the engine.
Important:
* 4HK1 is shown for illustration.
In order to make the fuel supply pump characteristic
Name learn into the ECM, let the engine idle until warm-up. If
1. Oil Drain Adapter the fuel system DTC' stored in the meantime, once
2. O-ring clear DTD and warm-up the engine again.
Common Rail
Components
4HK1
Name
1. Fuel Leak Off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Common Rail
4. EGR Cooler 9. Common Rail Bracket
5. EGR Adapter
Fuel System 1C-29
6HK1
WSHK0165
Name
1. Fuel Leak Off Pipe 5. EGR Adapter
2. Fuel Pipe 6. Injection Pipe Clip
3. EGR Valve 7. Injection Pipe (#1 to #6)
4. EGR Cooler 8. Common Rail
Parts of the fuel system such as the internal part of the • Cover the removed fuel hose with a lid, keep it
fuel injector, holes and clearances that form passages facing upward and secure it using wire, etc.
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter Note:
and the entry of foreign matter could cause damage to Cover the areas exposed during part removal to
the fuel passage. Therefore, effective measures should prevent the entry of foreign material into the fuel
be taken to prevent the entry of foreign matter. system.
3. Disconnect the connected of common rail pressure
sensor, and all the connectors.
Removal
4. Remove the EGR valve and the EGR adapter.
1. Remove the air intake pipe. 5. Tape the EGR case holes shut to prevent the entry
• Disconnect the connector for the intake air of foreign material.
temperature sensor.
2. Remove the fuel leak off hose from the leak off
pipe.
1C-30 Fuel System
4HK1 4HK1
6HK1 6HK1
2 1
2
WSHK0166 WSHK0167
Name Name
1. EGR Adapter 1. Fuel Injection Pipe
2. EGR Valve 2. Pipe Clip
6. Remove the injection pipe clip and remove the 7. Remove the fuel pipe.
injection pipes.
Note:
Note: Cover the areas exposed during part removal to
Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel
prevent the entry of foreign material into the fuel system.
system. 8. Remove the clip and the fuel leak off pipe.
Note:
Cover the areas exposed during part removal to
prevent the entry of foreign material into the fuel
system.
Fuel System 1C-31
4HK1
Name Name
1. Fuel Leak Off Pipe 1. Common Rail Bracket (4HK1)
2. Common Rail
6HK1
Disassembly
1. Remove the fuel pressure limiter.
4HK1
WSHK0051
Name
1. Fuel Leak Off Pipe
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.
1C-32 Fuel System
6HK1 6HK1
3 3
1 1
2 2
WSHK0168 WSHK0168
Name Name
1. Common Rail 1. Common Rail
2. Pressure Sensor 2. Pressure Sensor
3. Pressure Limiter 3. Pressure Limiter
Reassembly Installation
1. Install the fuel pressure limiter. 1. Tighten the common rail bracket to the specified
Tightening torque: 172 N⋅m (17.5 kg⋅m/127 lb ft) torque. (4HK1)
Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb ft)
4HK1
2. Tighten the common rail to the specified torque.
Tightening torque: 4HK1: 19 N⋅m (1.9 kg⋅m/14 lb ft)
6HK1: 25 N⋅m (2.5 kg⋅m/18 lb ft)
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.
Fuel System 1C-33
4HK1
Tightening torque 7
4HK1 (2): 18 N⋅m (1.8 kg⋅m/13 lb ft)
6HK1 (2): 10 N⋅m (1.0 kg⋅m/7.4 lb ft)
4HK1 (3): 12 N⋅m (1.2 kg⋅m/106 lb in) 1
6HK1 (3): 14.2 N⋅m (1.4 kg⋅m/126 lb in) 6
4HK1 (4): 8 N⋅m (0.8 kg⋅m/71 lb in)
4HK1 (7): 6 N⋅m (0.6 kg⋅m/53 lb in)
6HK1 (7): 8.8 N⋅m (0.9 kg⋅m/78 lb in)
8 5
2
4. Tighten the fuel pipe (5) using the mounting sleeve
nut and the specified torque.
WSHK0169
Tightening torque (6): 44 N⋅m (4.5 kg⋅m/32 lb ft)
5. Tighten the injection pipe and the clip using the
(8): 44 N⋅m (4.5 kg⋅m/32 lb ft)
specified mounting torque.
Injection pipe sleeve nut
Tightening torque: 44 N⋅m (4.5 kg⋅m/32 lb ft)
6HK1 6HK1
1 2
2
WSHK0167 WSHK0166
Name Name
1. Fuel Injection Pipe 1. EGR Adapter
2. Pipe Clip 2. EGR Valve
N.m
N m(kg m/lb
(lb ft)
39 (4.0 / 29)
24 {17}
(2.4 / 17)
25 (2.5 / 18.4)
44 (4.5
{33} / 33)
10 (1.0 / 7.4)
WSHK0172
Engine Electrical 1D-1
ENGINE
Engine Electrical
TABLE OF CONTENTS
Service Precautions . . . . . . . . . . . . . . . . . . . . . . .1D-2
General Procedure. . . . . . . . . . . . . . . . . . . . . . .1D-2
Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .1D-3
General Description . . . . . . . . . . . . . . . . . . . . . .1D-3
Generator (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-6
Torque Specifications . . . . . . . . . . . . . . . . . . . . .1D-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-7
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .1D-14
General Description . . . . . . . . . . . . . . . . . . . . .1D-14
On-vehicle Service: Starting System . . . . . . . .1D-15
Starter (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-17
Torque Specifications . . . . . . . . . . . . . . . . . . . .1D-17
Main Data and Specifications. . . . . . . . . . . . . .1D-18
Preheating System . . . . . . . . . . . . . . . . . . . . . . .1D-26
Glow Plug Replacement. . . . . . . . . . . . . . . . . .1D-26
Precautions on Service Work . . . . . . . . . . . . . .1D-27
A List of Defective Phenomena . . . . . . . . . . . .1D-27
Main Data and Specifications. . . . . . . . . . . . . .1D-28
Starter (6HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-29
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-29
Sectional view (reference) . . . . . . . . . . . . . . . .1D-30
Output Characteristic (reference). . . . . . . . . . .1D-31
Disassembly and Inspection of Starter. . . . . . .1D-32
Assembly of Starter . . . . . . . . . . . . . . . . . . . . .1D-38
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . .1D-42
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-42
Generator (6HK1) . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . .1D-43
Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-44
Disassembly and Inspection of Generator . . . .1D-45
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-51
Bench Testing. . . . . . . . . . . . . . . . . . . . . . . . . .1D-52
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . .1D-53
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-53
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 will be called out. 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 120-amp,
selfrectifying type with a built-in regulator. The battery
discharge indicator light is mounted in the instrument
panel.
ACG
11
10
12 13
5
4
2
WSHK0053
Name
1. Generator 8. Plate
2. Lower Mount Bolt 9. Bolt
3. Nut 10. ACG Adjust Bolt
4. Spring Washer 11. Sliding Piece
5. Washer 12. Washer
6. Bracket 13. Adjust Nut
7. Bracket Mount Bolt
1D-4 Engine Electrical
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, the first step not defective and generator belts are not slipping. Also,
should be to check its condition as described under the battery must be fully charged for a valid test of the
“Diagnosis of Battery.” In the case of an undercharged charging system.
battery, check for battery drain caused by grounds or Notice:
by accessories left turned on. To avoid damage to the vehicle electrical system,
Keep the generator and all other electrical system always observe the following precautions:
terminals clean and tight. A loose or badly corroded • Do not polarize the generator.
terminal connection will create excessive resistance in
• Do not short across or ground any of the terminals
the system and result in hard starting, dim lights etc.
in the charging circuit except as specifically
Inspect the generator system at regular intervals and
instructed herein.
correct any potential causes of trouble before machine
performance is affected. • NEVER operate the generator with the output
terminal open-circuited.
Diagnosis of Charging System
• Be sure the generator and battery have the same
Trouble in the charging system will be evidenced as ground polarity.
one or more of the following three conditions:
• When connecting a charger or booster battery to
1. The battery discharge warning light will stay on. the vehicle battery, connect negative to negative
2. An undercharged battery as evidenced by slow and positive to positive.
cranking. 1. With the engine control switch “ON” and engine not
3. An overcharge, or overvoltage, condition. running, connect a voltmeter from terminal “E” to
ground. The voltmeter should show 0 volts.
Undercharged Battery 2. With the engine control switch “ON,” and engine
Inspection not running, connect a voltmeter from terminal “B”
1. Accessories to be sure none were left on for to ground. The voltmeter should read at least 24
extended periods. volts.
2. Drive belt for proper tension. Refer to “Generator 3. With the engine control switch “ON” and the engine
Drive Belt” later in this section. not running, connect a voltmeter from white wire
side of the connector to ground. The voltmeter
3. The ECM main relay has been ON stuck at the should show 24 volts.
ignition switch OFF position. (Battery voltage is
consumed.) 4. With the engine control switch “ON” and the engine
not running, the “charge” light should be on. This
4. Refer to “Diagnosis of Battery” earlier in this shows that the other circuit in the connection is
section. working.
5. Wiring and connections for corrosion or looseness. 5. With the engine running and the headlight high
Overcharge (or Overvoltage) condition beams turned on, read the voltage at the “B” post
A charging rate in excess of 29.5-volts for a prolonged on the generator. The voltmeter should read at
period may cause early electrical system failure. least 24 volts.
Blown fuses. light bulbs burned out, and even battery 6. If steps 1 through 4 are not OK, check connectors
failure may result. If this condition exists, test the in the harness for looseness or corrosion and
generator as described under “Generator Output Test” retest.
later in this section. 7. If step 5 voltage is low, substitute a known good
regulator and test again. If the voltage is still low,
Noisy Generator bench test the generator.
Inspection
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.
Engine Electrical 1D-5
Generator (4HK1)
Removal
• Battery negative cable.
1. Electrical wiring at the generator.
2. Loosen the adjust nut.
3. Loosen the ACG adjust bolt.
4. Loosen the lower mount bolt.
5. Drive belt
1D-6 Engine Electrical
6. Generator. 2. ACG Adjust bolt.
3. Adjust nut.
Installation Tightening torque:
Lower Mount Bolt 76 N⋅m (7.7 kg⋅m/56 lb ft)
1. Generator.
Tightening torque: 4. Electrical wiring at the generator.
Lower Mount Bolt 127 N⋅m (13.0 kg⋅m/94 lb ft) • Battery negative cable.
Torque Specifications
52(5.3 / 38)
ACG
68(6.9 / 50)
127(13 / 94)
52(5.3 / 38)
WSHK0054
Engine Electrical 1D-7
Specifications Connector terminal
1 2
WSHK0101
Name
1. R Terminal
2. L Terminal
Internal connections
SG L
IC
REGULATOR
WSHK0102
1D-8 Engine Electrical
Disassembly of generator
5
6
12
7
8 3
11
10 9
13
18
15
14
19
23
21
20
2
1
17
16
22
WSHK0103
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.
Engine Electrical 1D-9
Inspection and repair of generator 3. Diode for initiating excitation, Resistor
Check the continuity between connector terminals
1. Diode
R and L with a tester (at Ω × 100 range). Normal
Check the 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.
Judge that they are faulty other than those above.
WSHK0106
WSHK0104
4. Field coil
2. Condenser
Charge the condenser with a tester (at Ω × 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 × 1000 range). Judge
and returns to the original position. as faulty if it has continuity.
Judge that they are faulty other than those above.
WSHK0107
WSHK0105
1D-10 Engine Electrical
• 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 × 1000 range). Judge as faulty if it has replace the bearing.
continuity.
WSHK0111
WSHK0109
Engine Electrical 1D-11
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
1 V E 6 7
WSHK0112
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
Action to be
Trouble symptom Trouble location Trouble cause
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
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Excessive Regulator Defective regulator.
Replace
charging
Unstable charging Wiring Intermittent contact or nearly disconnected connection
Repair
current in wiring
Generator. Looseness of generator driven belt Repair
Short circuit or nearly disconnected connection in field
Repair
coil
Short circuit or nearly disconnected connection in stator
Repair
coil
Poor contact in each terminal Repair
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Noisy generator Generator. Improper installation of generator Repair
Defective bearing Replace
Contact of rotor core and stator core Repair
Defective diode Replace
Short circuit in stator coil Replace
1D-14 Engine Electrical
Starting System
General Description
Name
1. Starter 3. Ground Cable
2. Nut 4. Bolt
Maintenance
Keep the starter’s exterior clean. Remove corrosion
from the terminals, leads, and connectors.
Tighten the starter to engine mounting bolts and the
electrical cable retaining nuts.
Engine Electrical 1D-15
Diagnosis of Starting System If the voltage is less than 0.5 volt, measure the voltage
at the battery cable terminal on the starter. If the
No Cranking, No Sound voltage is 18 volts or more, repair the starter. If the
• Discharged batteries. Turn on the headlights and voltage is less than 18 volts, clean and tighten the
check the brightness. If the headlights are dim, positive cable connections. If the voltage is still less
charge the batteries. Check for the cause of the than 18 volts, replace the positive cable.
discharged batteries.
• Sulfated battery terminals. Turn on the headlights. On-vehicle Service: Starting System
The headlights will be bright. Attempt to start the
engine. The headlights will be very dim or go out. Maintenance
Clean all the battery terminals and cable ends.
Keep starter terminals and all other terminals in the
• A starter that draws too much current. electrical system clean tight. A loose or corroded
• Starter relay won’t work. Attempt to start and listen connection or terminal will cause excessive resistance
for a “click” at the starter relay. If there is no “click,” in the system that will result in hard starting. At regular
check the starter relay control terminals with a test intervals, inspect the starting system to locate and
light. If the test light shows that power is getting to correct potential causes of trouble before the system
the starter relay, check the ground circuit with the performance is affected. Starting motors do not require
test light. If the ground circuit is OK, replace the lubrication.
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. The 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.
Starter (4HK1)
Removal
1. Battery negative cable from the battery.
2. Cables and electrical leads from the starter.
3. Two mount nuts.
4. Starter.
Engine Electrical 1D-17
Installation 3. Cables and electrical leads to the starter.
1. Starter 4. Battery negative cable to the battery.
2. Two mount nuts.
Tightening torque:
Mount nuts 82.4 N⋅m (8.4 kg⋅m/61 lb ft)
Torque Specifications
S.S
S
B
P1
C3 C
P2
B
C2 C1
M
Fc
Ar
1 4 3
WSHK0113
Name
1. Starter Relay 3. Motor
2. Battery 4. Magnetic Switch
19
16
17 12
18
27 20 13
21 15
14
4 26
2
1 25
24
22
23
3
7
6
8
9
10
11
WSHK0114
Name
1. Clip Ring 15. Ball
2. Pinion Stopper, Pinion, Spring 16. Rubber Bushing
3. Lead Wire 17. Plate
4. Bolt 18. Spring
5. Magnetic Switch 19. Pin
6. Screw 20. Holder
7. Bolt 21. Shift Lever
8. Rear Bracket 22. E Clip
9. Brush Holder ASM 23. Overrunning Clutch ASM
10. Yoke ASM 24. Internal Gear
11. Armature 25. Washer
12. Cover 26. Drive Shaft ASM
13. Packing 27. Front Bracket ASM
14. Idle Gear Assembly is the reverse order of disassembly.
Engine Electrical 1D-21
Inspection and repair of starter Contact Point Check
Service limit of contact point is judged by damaged
1. Magnetic switch
condition on contact surface in the following procedure.
Never perform operational check on magnetic
Measure the load current on starter. Replace it if
switch as single unit.
voltage drop between terminals B and M is 0.3 V or
Inspection of coil more per 100 A.
• Check the pressure coil C1 and holding coil C2 for
open circuit using a tester. Caution:
Check the continuity between magnetic switch and Use a digital voltmeter to measure voltage drop. Using
M terminal. It has open circuit if no continuity. an analog voltmeter may damage itself.
(Resistance approx. 1.6Ω)
WSHK0117
WSHK0115 2. Armature
• Supply 24 V between M terminal of magnetic Bentness measurement of shaft
switch and case, push the plunger by hand, and Measure with a dial gauge, and repair or replace if
then release it. It is normal if it is not sucked. Coil is bentness is 0.05 mm (0.0020 in) or more.
defective if it is sucked.
Caution:
Perform this while the magnetic switch is set up.
WSHK0118
WSHK0116
1D-22 Engine Electrical
Inspection of commutator Inspection of armature coil
• Check the surface of commutator. File the • Using a growler tester, put probe on a armature
surface smooth with No.400 to 600 sand paper core. It is normal if probe does not vibrates.
if it is rough. Repair with a lathe if deflection is • Check with a tester. It is normal if there is no
0.1 mm (0.004 in) or more. continuity between commutator and shaft.
WSHK0119 WSHK0121
• Measure the depth of undercut and repair if it is 3. Field Coil
0.2 mm (0.008 in) or less.
• Check the field coil for open circuit with a tester. It
mm(in) is open circuit if there is no continuity between M
terminal in field coil and lead wire on brush side.
• Check between field coil and yoke with a tester. It
is normal if there is no continuity between them.
2
3
1
0.5-0.8
(0.02-0.03)
WSHK0120
Name
1. Repair is needed
2. Improper repair
3. Good WSHK0122
4. Overrunning clutch
Outside diameter of commutator
Measure the outside diameter of commutator with • Rotate the pinion by hand. It is normal if it is
a slide-caliper. If the measured value is less than rotated smoothly in one direction only.
the limit, replace it. Check the pinion tooth surface. Replace if it has
worn or damage.
mm (in)
Caution:
Standard Limit If the entire overrunning clutch is soaked in liquid when
32.4 (1.276) 31.4 (1.236) washing it, internal grease flows out, causing seizure.
Engine Electrical 1D-23
6. Bearing
• Check if the bearing outer race rotates smoothly by
hand.
WSHK0123
5. Reduction gear
• Check the reduction gear. It is normal if it has no
wear. WSHK0125
7. Brush height
• Measure the brush height. If it is less than the limit,
replace the brush.
mm (in)
Standard Limit
17 — 18 (0.669 — 0.709) 10 (0.394)
WSHK0124
1D-24 Engine Electrical
Handling of starter
1. Precautions on handling
• Improper gap between pinion and ring gear causes
faulty mesh. (Gap 2 — 5 mm {0.079 — 0.197 in})
• Also, the front bracket is installed on the engine
side securely.
• Be sure to turn off the battery switch before
removal/installation of stater.
• Tightening/inserting wiring must be performed
properly. Improper work causes starting trouble
due to high contact resistance.
2. Precautions on starting
• Be careful with charging status of battery.
Insufficiently-charged battery causes starting
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.
Engine Electrical 1D-25
Trouble countermeasure
Preheating System
Glow Plug Replacement
Installation Procedure
1. Install the glow plug.
Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft)
2. Install and tighten the glow connector with the
designated torque.
Tightening torque: 1.2 N⋅m (0.1 kg⋅m/11 lb in)
3. Install the EGR valve and the EGR adapter.
Name
1. EGR Adapter
2. EGR Valve
Name
1. EGR Adapter
2. EGR Valve
Caution:
Use a set of four glow plugs from the same
manufacturer.
Item Model
Preheating device model Glow plug
Glow plug rated voltage/ current (V-A) 23 – 3.5
Engine Electrical 1D-29
Starter (6HK1)
Specifications
4 7
8
3
1 13 12 11
10
WSHK0069
Name
1. Through Bolt 8. Pinion
2. Bearing 9. Bearing
3. Rear Bracket 10. Front Bracket
4. Brush Holder 11. Gear
5. Magnetic Switch 12. Yoke
6. Shift Lever 13. Armature
7. Gear Shaft
Engine Electrical 1D-31
Output Characteristic (reference)
r/min N.m kW V
6000 120 6 24
3000 60 3 12
2000 40 2 8
Terminal voltage
1000 20 1 4
0 0 0 0
0 200 400 600 800 1000 1200 1400 1500
Current (A)
WSHK0070
1D-32 Engine Electrical
18
19
27 21
9
6
28
29
14
16
17
15 5
20
4 26 8
3
2 22 10
1 25
24 13
23 12
30
11
12
WSHK0071
Disassembly Procedure
1. Snap Ring 16. Plate
2. Stop Ring 17. Packing
3. Pinion 18. Packing
4. Pinion Spring 19. Plate
5. Lead Wire with Terminal 20. Planetary Gear
6. Screw 21. Lever
7. Magnetic Switch 22. E-shaped Retaining Ring
8. Screw 23. Overrunning Clutch
9. Through Bolt 24. Internal Gear
10. Rear Bracket 25. Washer
11. Yoke Assembly 26. Gear Shaft
12. O-Ring 27. Front Bracket
13. Brush Holder 28. Bearing
14. Armature 29. Washer
15. Ball 30. Brush
Engine Electrical 1D-33
Disassembly
Caution:
• Before disassembling the starter, put alignment 5
marks on each magnet switch, yoke front bracket
and rear bracket to facilitate re-assembly. 4
Caution:
Do not reuse the removed O-ring.
WSHK0072 Also, do not reuse also O-ring on tightening screw.
2. Apply the pipe, which just fits the stop ring, on the 5. Apply a socket (outside diameter 32 mm
ring and tap the pipe with a hammer to remove the {1.260 in}) on a commutator of armature.
stop ring toward the pinion side once. Then, slide the brush on the socket to yoke
Then, remove the snap ring and remove the stop assembly and O-ring.
ring, pinion and pinion spring. This facilitates to re-assemble.
Caution: Caution:
Do not reuse the snap ring. Do not reuse the removed O-ring.
6. Remove the brush from brush holder by pulling up
the brush spring, and then remove the brush
holder.
7. Remove the armature.
Remove a bearing using a general puller.
8. Remove the plate in planetary gear and remove
the packing.
Then, remove the packing and plate on the lever
support.
9. Remove the internal gear, gearshift, overrunning
clutch and lever as a unit from front bracket.
1D-34 Engine Electrical
10. Remove the lever. • Check the armature coil for grounding (faulty
insulating) with a circuit tester.
Caution: Replace the armature if grounding is present.
Remember the direction of lever.
11. Remove the two E-shaped retaining ring.
To remove the overrunning clutch, rotate the spline
by one tooth to remove it from gearshift assembly.
Caution:
Do not reuse removed E-shaped retaining ring.
12. Remove the internal gear.
In this time, take out one washer which adjusts
axial play of gearshift.
WSHK0074
WSHK0076
Engine Electrical 1D-35
• Check the depth (undercut) of insulating mold of • Check the coil for grounding (faulty insulating) with
commutator. a circuit tester.
Remove abrasion powder on brush, and repair if Repair or replace the yoke assembly if grounding
faulty. is present.
2
3
WSHK0077 WSHK0079
3. Brush
Name
1. Good • Measure the length of the brush.
2. Insulating If it is worn to the limit, replace the brush holder
3. Commutator Segment assembly on the brush holder as a unit and only
4. Defective brush on the yoke assembly side.
• Make sure the brush moves smoothly in the brush
• Check the gears for wear or damage. holder. Also, check the brush spring pressure.
Replace the armature if fault is present.
• Check the bearings for noise, rattle or grease
leakage.
2. Field coil
• Check the coil for open circuit with a circuit tester.
Replace the yoke assembly if open circuit is
present.
WSHK0078
1D-36 Engine Electrical
• Check the brush holder for grounding (faulty
insulating) with a circuit tester.
Clean the brush holder before checking.
Replace the brush holder assembly if the
continuity is present when putting one probe of
circuit tester to brush holder plate (metal part) and
another one to insulated holder.
WSHK0081
5. Front bracket
Check the bearing and oil seal, and replace the
front bracket assembly (including bearing, oil seal)
if faulty.
6. Internal gear and planetary gear
Check the internal gear and planetary gear, and
WSHK0080 replace them if excessive wear or damage is
Name present.
1. Brush Length 7. Lever
2. Insulated Holder It the portion which contacts the overrunning
switch is worn, the protruded position of pinion will
4. Overrunning clutch and pinion be faulty.
Hold the housing of overrunning clutch by hand. (Refer to “4. Assembly” section to adjust the
Make sure that the pinion can be rotated by hand protruded position of pinion.)
with a light resistance in one direction and cannot
be in the opposite direction. Replace the
overrunning clutch if faulty.
Check the pinion, and replace it if wear or scratch
is present.
Caution:
Grease is present in overrunning clutch. Do not use
wash oil or cleaning agent for cleaning.
Wipe off stain on overrunning clutch with a cloth.
WSHK0082
Name
1. Worn Part
Engine Electrical 1D-37
8. Magnetic switch
Check the continuity between the M terminal and
the body, and replace the magnet switch if no
continuity is present.
Then, make sure that no continuity is present
between B terminal and M terminal. Replace the
magnet switch if continuity is present.
1 3
WSHK0083
Name
1. M Terminal
2. S Terminal
3. B Terminal
1D-38 Engine Electrical
Assembly of Starter
Assembly diagram: Assemble in the order of the numbers.
24
13
12
4 10
22
25
3
2
17
15
14
16 5
11
27 5 23
28
29 9 21
30 6
7 18
8 19
1
20
19
WSHK0084
Assembly Procedure
1. Brush 16. Ball
2. Washer 17. Armature
3. Bearing 18. Brush Holder
4. Front Bracket 19. O-Ring
5. Gear Shaft 20. Yoke Assembly
6. Washer 21. Rear Bracket
7. Internal Gear 22. Through Bolt
8. Overrunning Clutch 23. Screw
9. E-shaped Retaining Ring 24. Magnetic Switch
10. Lever 25. Screw
11. Planetary Gear 26. Lead Wire with Terminal
12. Plate 27. Pinion Spring
13. Packing 28. Pinion
14. Packing 29. Stop Ring
15. Plate 30. Snap Ring
Engine Electrical 1D-39
1. Lubricant locations and tightening torque
I 4.9~8.8
19.6~25.5
(0.5~0.9 / 3.6~6.5)
(2.0~2.6 / 14.4~18.8)
C B
H F
2.4~4.4
(0.25~0.45 / 1.8~3.2)
7.8~12.7 E A D
(0.8~1.3 / 5.8~9.4)
WSHK0085
Lubricant locations
Shown in
the Lubricant locations Lubricant agent
illustration
A Sleeve bearing and ball Molycote AG650
B Clutch shaft sliding surface MULTEMP 6129
C Spline portion and sliding portion of gearshift MULTEMP 6129
D Sliding portion of lever and overrunning clutch Molycote AG650
E Armature shift gear, planetary gear, internal gear Molycote AG650
F Under pinion MULTEMP 6129
G Outer surface of armature bearing (tiny amount) MULTEMP 6129
H Oil seal MULTEMP 6129
I Surface of plunger (tiny amount) MULTEMP 6129
2. Axial play of armature shift Pass the gear shaft through washer, internal gear
Adjustment is unnecessary (assemble the ball into and overrunning clutch. Then move the
a tip of shaft.) overrunning clutch by one tooth of spline to make
3. Axial play of gear shaft sure that the clutch cannot be pulled out.
Adjustment is unnecessary Assemble the E-shaped retaining ring.
Appropriate gap will be obtained automatically
when one washer (removed in step 12 of Caution:
disassembly procedure) is inserted between • Do not reuse removed E-shaped retaining ring.
internal gear and gearshift.
4. Assembly of gearshift
1D-40 Engine Electrical
• If assembling the E-shaped retaining ring prior to
the overrunning clutch, the clutch cannot be
assembled. Be careful with it.
3
3
2
2 5
1
WSHK0087
1
Name
WSHK0086 1. Pinion
2. Clutch Shaft
Name 3. Snap Ring
1. Overrunning Clutch 4. Stop Ring
2. Washer 5. Pinion Spring
3. Gear Shaft
4. E-shaped Retaining Ring 6. Check of the pinion protruded position
5. Internal Gear After assembling the starter, check the protruded
position of pinion.
5. Assembly of pinion How to measure and adjust
Assemble the pinion spring, pinion and stop ring to • Connect the starter to battery.
clutch shaft in this order, then assemble the snap When closing the switches SW1 and SW2, the
ring to the groove of clutch shaft at the end. pinion move forward to the cranking position
Then, pull strongly the stop ring toward the snap and the armature rotates.
ring side with a gear puller and fix both of them. Then, open the switch SW2 to stop the
armature rotating.
Caution:
• Assemble the pinion before assembling the
magnet switch to front bracket.
• Do not reuse the removed snap ring.
Engine Electrical 1D-41
• Push into or pull back a tip of the crankshaft
lightly by hand and measure the moving
distance of it.
Adjust by using one or two packings (0.5 mm
{0.020 in}) of magnet switch and front bracket
so that this measurement value is between 0.5
— 2.0 mm (0.020 — 0.079 in).
If this adjustment cannot be done, replace the
lever.
SW 1 B
S SW 2
M
1
WSHK0088
Name
1. Battery 24 V
WSHK0089
1D-42 Engine Electrical
No Load Test
1. After adjusting the protruded position of pinion,
connect the starter as shown in the illustration
above.
Caution:
Use a thick electric wire and tighten the connected 2 A SW B
portion securely. S
2. Close the switch and read the speed, current and M
voltage.
1 V 3
WSHK0090
Name
1. Battery 24 V
2. Ammeter
3. Voltmeter
Specifications
Generator (6HK1)
Specifications
Charging Circuit
B
3 4 5
L
2 L
R R
E 6
1
7
E
WSHK0091
Name
1. Field Coil 5. Key Switch
2. Stator Coil 6. Battery 24 V
3. Diode Trio 7. IC Regulator
4. Charging Lamp 8. Generator
Charging circuit and internal circuit are shown in the illustration above.
Charging system consists of IC regulator built-in generator, battery, charging lamp and wires to connect them.
1D-44 Engine Electrical
Structure
5 6
4
7
8
1
9
10
WSHK0092
Name
1. Rear Bracket 6. Rotor
2. IC Regulator 7. Bearing
3. Bearing 8. Pulley
4. Rectifier 9. Front Bracket
5. Stator 10. Coil Assembly (Field Coil)
This generator has no brush. terminal (for direct current output), L terminal and R
Main parts are a rotor, stator, rectifier assembly, front terminal.
bracket, rear bracket, IC regulator, bearing, pulley and The L terminal is connected to field coil. Therefore, as
so on. well as R terminal, it becomes input terminal for
Moving parts are a rotor and pulley. A field coil is initiating excitation current until the generator starts to
secured to rear bracket. generate electric power.
Six main diodes and two additional diodes are used to It also provides function as output terminal. (Current
convert three-phase alternating current, generated in capacity is 1 A.)
stator coil, into direct current. Among six main diodes, The charging lamp will be off if the voltage on L
there are three positive diodes and three negative terminal reaches battery voltage.
diodes. Both bearings are sealed, therefore periodic lubricant is
In addition, three tiny diodes, called trio diode, are used not necessary.
to supply field current. IC regulator cannot be disassembled. Handle it as
This generator has three terminals, which are B assembly.
Engine Electrical 1D-45
10
5 7
6
4
1 3
11
12
13
14
15
WSHK0160
Name
1. Nut Washer 9. Ball Bearing
2. Pulley, Fan 10. Screw
3. Collar 11. Cover
4. Through Bolt 12. Rectifier Assembly
5. Front Bracket 13. Regulator Assembly
6. Ball Bearing 14. Stator Assembly
7. Retainer 15. Field Coil Assembly
8. Rotor Assembly
1D-46 Engine Electrical
11
10
6 8
7
5
3
2
1 4
12
13
14
15
16
17
18
WSHK0161
Name
1. Nut Washer 10. Ball Bearing
2. Pulley, Fan 11. Field Coil Assembly
3. Key 12. Connector Set
4. Collar 13. Screw
5. Through Bolt 14. Terminal Set
6. Front Bracket 15. Cover
7. Ball Bearing 16. Rectifier Assembly
8. Retainer 17. Regulator Assembly
9. Rotor Assembly 18. Stator Assembly
A A
1
1
A
WSHK0093
Name
1. Ball
Caution:
Do not lose the tube.
1D-48 Engine Electrical
2 4
12
7
8
13
11
9
1
10
WSHK0095
Name
1. IC Regulator 8. Cap
2. Rectifier 9. Nut
3. B terminal 10. Terminal Bolt
4. Terminal Bolt 11. Terminal Bolt
5. B terminal 12. Terminal Bolt
6. Cap 13. Rectifier
7. Nut
Engine Electrical 1D-49
5
1
N
6
WSHK0159
Name
1. IC Regulator 4. B terminal
2. Terminal Bolt 5. Tube
3. Nut 6. Rectifier
Inspection
1. Stator
Check visually for damage, loose connection and
discoloration of coil.
WSHK0096
• Check the continuity between two lead wires of Name
stator coil with a circuit tester. Replace the stator if 1. Stator Coil Lead
no continuity is present.
• Check the continuity between lead wire of stator
coil and core with a circuit tester. Replace the
stator if continuity is present.
1D-50 Engine Electrical
2. Rotor 4. Rectifier assembly
• Check the bearings for noise, rattle or grease • Check the continuity between positive diode,
leakage (wipe off if tiny amount of grease). additional diode positive heat sink on positive side
Replace it if faulty. It is easier to check for noise and four diode terminals with a circuit tester.
and rattle when it is press-fitted into shaft than The positive diode has short circuit if continuity is
when it is a single unit. present in both directions. Replace the rectifier
assembly.
The positive diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.
• Negative diode and additional diode on negative
side
1
Check the continuity between negative heat sink
and four diode terminals with a circuit tester.
The negative diode has short circuit if continuity is
present in both directions. Replace the rectifier
assembly.
The negative diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.
2
• Diode trio (three tiny diodes)
Check the continuity in both directions with a circuit
tester.
WSHK0097 The diode is faulty if continuity is present in both
directions or no continuity is in both directions.
Name Replace the rectifier assembly.
1. Stator Coil Lead
2. Core
3. Coil assembly
Measure the resistance between terminal portions 2
with a circuit tester.
Replace the coil assembly if the value is out of
specified value.
1 3
1
WSHK0099
Name
2
1. Diode Terminal Portion
2. Positive Diode
3. A Part of Negative Diode
5. Front bearing
WSHK0098 Check the bearings for noise, rattle or grease
leakage (wipe off if tiny amount of grease).
Name Replace them if faulty. It is easier to check for
1. Terminal noise and rattle when the bearing is press-fitted
2. Terminal Portion into bracket than when it is a single unit.
Engine Electrical 1D-51
6. Regulator
The regulator cannot be checked with a circuit
tester. After re-assembling the generator, check it
to make sure that regulator controls the voltage for
generator.
Assembly
Assembly can be performed in the reverse order of
disassembly. However, be careful with the following.
1. Lubrication is not necessary. Bearing is filled with
grease and is sealed.
Caution:
Keep a bearing with resin band for rotor shaft away
from oil. Wipe off oil on bearing box area of rear
bracket. Oil may cause creep.
2. Use a high temperature solder (melting point:
230°C {446°F}).
Using a soldering iron (with 180 — 270 watt),
soldering must be performed quickly (within five
seconds) not to heat the rectifier.
3. Tightening torque
• Pulley fixing nut:
132 — 162 N⋅m {13.5 — 16.5 kg⋅m/97 — 119 lb
ft}
• Through bolt:
12.8 — 18.6 N⋅m {1.3 — 1.9 kg⋅m/9 — 14 lb ft}
• Bearing retainer fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Coil assembly fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Rectifier fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Regulator fixing screw:
2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in}
• Nut for B terminal bolt:
4.9 — 8.7 N⋅m {50 — 88 kgf⋅cm/43 — 77 lb in}
4. Assembly of rear bracket to stator assembly and
front bracket to rotor assembly
• The rotor bearing and rear bracket are engaged
tightly. Heat the bearing box area of rear bracket to
50 — 60°C (122 — 140°F) prior to assembly.
• After re-assembling the generator, rotate the pulley
to confirm that the rotor rotates smoothly.
1D-52 Engine Electrical
Bench Testing 4. Set the generator speed to approx. 5000 rpm and
read an ammeter. If the value is 5 A or less, read
Bench testing is performed as follows.
indication on a voltmeter. This is regulated voltage.
If an ammeter shows 5 A or more, keep charging
Regulated voltage check
for a while until it shows below 5 A or replace the
1. Wire as shown in the illustration. battery with full-charged one.
Use an ammeter with 100 A rating and a voltmeter If regulated voltage is out of specified value,
with 30 V rating. replace the regulator.
Specifications
ENGINE
Exhaust System and Turbocharger
TABLE OF CONTENTS
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2
Precautions on Service Work . . . . . . . . . . . . . . . 1F-2
Explanations on Functions and Operation . . . . . 1F-2
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . . 1F-3
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 1F-5
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
A List of Defective Phenomena . . . . . . . . . . . . . 1F-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
Turbocharger (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1F-7
Table of Specifications . . . . . . . . . . . . . . . . . . . . 1F-7
Turbocharger Structured Diagram . . . . . . . . . . . 1F-8
Disassembly and Inspection of Turbocharger . . 1F-9
Assembly of Turbocharger . . . . . . . . . . . . . . . . 1F-15
Turbocharger (4HK1) . . . . . . . . . . . . . . . . . . . . . 1F-21
Measurement Tool. . . . . . . . . . . . . . . . . . . . . . . . 1F-22
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-22
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
Name
1. EGR Adapter 4. EGR Pipe
2. Cooling Water Pipe (out) 5. Cooling Water Pipe (in)
3. EGR Cooler 6. EGR Valve
Removal
1. Drain the coolant.
2. Disconnect the EGR valve connector.
3. Remove the EGR pipe.
1F-4 Exhaust System and Turbocharger
2. Install the EGR cooler.
• Temporarily fit the EGR cooler to the bracket.
Notice:
Temporarily tighten the bolts.
3. Install the EGR adapter.
• Temporarily fit the EGR adapter between the EGR
cooler and exhaust manifold.
Notice:
Temporarily tighten the bolts.
4. Install the EGR pipe.
• Insert the gasket between the two ends of the EGR
pipe and temporarily fit it.
Notice:
Temporarily tighten the bolts.
During temporary assembly, tighten the nuts
* 4HK1 is shown for illustration. and bolts to the specified torque in the order
shown in the illustration.
Name
1. EGR Adapter
2. Cooling Water Pipe (out)
3. EGR Cooler
4. EGR Pipe
5. Cooling Water Pipe (in)
Caution:
After removing the EGR valve and EGR adapter, seal
so that foreign matter does not enter.
Inspection
Installation Name
1. Mount the EGR valve. 1 ~ 9 Show the Order of Tighten Bolts and Nuts.
• Insert the gasket and temporarily fit the EGR valve. Tightening torque
Notice: 1, 2: 28 N⋅m (2.9 kg⋅m/21 lb ft)
Temporarily tighten the bolts. 3, 4, 5, 6: 24 N⋅m (2.4 kg⋅m/18 lb ft)
Exhaust System and Turbocharger 1F-5
Torque Specifications
Exhaust System
A List of Defective Phenomena
• 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
Turbocharger (6HK1)
Table of Specifications
Assembly
Item Service limit
specifications
Turbine shaft Axial play mm (in) 0.06 — 0.09
0.11 (0.00433)
(0.00236 — 0.00354)
Radial play mm (in) 0.10 — 0.17
0.205 (0.00807)
(0.00394 — 0.00669)
Journal outside diameter (A) mm (in) — φ 11.380 (0.44803)
Sealing groove width (B) mm (in) — 1.33 (0.05236)
Runout mm (in) — 0.11 (0.00433)
Sealing Turbine side (bearing housing) (F) mm (in) — 17.03 (0.67047)
insertion part Compressor side (seal plate) (H) mm (in) — 14.05 (0.55315)
Oil thrower Sealing groove width (G) mm (in) — 1.52 (0.05984)
Bearing Bearing housing inner diameter (B) mm (in) — φ 16.11 (0.63425)
housing Thrust bearing inside diameter for (L) mm (in)
— φ 23.020 (0.90630)
press-fit portion
Thrust Bearing pad height at compressor side (J) mm (in) 0.0 — 0.060
—
bearing (0.0 — 0.00236)
Thrust collar thickness (K) mm (in) — 2.950 (0.11614)
H
F L
B A
K
E G
WSHK0126
1F-8 Exhaust System and Turbocharger
Turbocharger Structured Diagram
4 5
2 3
10 9
1 8
WSHK0127
Name
1. Turbine Housing 6. Seal Plate
2. Heat Protector 7. Compressor Impeller
3. Floating Metal 8. Seal Ring
4. Oil Thrower 9. Seal Ring
5. Compressor Housing 10. Turbine Shaft
Exhaust System and Turbocharger 1F-9
Disassembly and Inspection of Turbocharger
Disassembly diagram: disassemble in the order of the numbers.
4 2
3
6
5
13
14
17
16
16
15
8
18
7
11
12
10
9
WSHK0128
Disassembly Procedure
1. Compressor Housing 10. Seal Ring
2. Nut 11. Gasket
3. Compressor Impeller 12. Heat Protector
4. Seal Plate 13. Thrust Bearing
5. Oil Thrower 14. Thrust Collar
6. Seal Ring 15. Snap Ring
7. G Coupling 16. Floating Metal
8. Turbine Housing 17. Thrust Bearing
9. Turbine Shaft 18. Bearing Housing
1F-10 Exhaust System and Turbocharger
Disassembly 1. Compressor housing
• Put alignment marks between the compressor
Inspection Prior to Disassembly housing and the seal plate, and tap the
• Measurement of axial play of turbine shaft compressor housing to drive it out.
• Liquid gasket is applied to the mating surfaces of
Axial play mm (in) the compressor and the seal plate.
0.06 — 0.09
Assembly specifications Caution:
(0.0024 — 0.0035)
Take care not to damage the impeller during removal of
Service limit 0.11 (0.0043)
the compressor housing.
If it exceeds the service limit, check the thrust
metal, the thrust bushing, and the oil thrower.
WSHK0131
Name
WSHK0129 1. Alignment Mark
• Measurement of radial play of turbine shaft
2. Nut
Radial play mm (in)
• The nut is left-hand screw.
0.10 — 0.17 3. Compressor impeller
Assembly specifications
(0.00394 — 0.00669)
• Attach the box spanner to the turbine-side shaft
Service limit 0.205 (0.00807) end of the turbine shaft, and remove the nut.
• Remove the impeller from the turbine shaft.
If it exceeds the service limit, check the floating
• Washing of impeller
metal.
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic scraper
or hard brush.
Caution:
Do not use a wire brush.
WSHK0130
Exhaust System and Turbocharger 1F-11
• Washing of turbine housing
Soak in the cleaning solvent to remove the foreign
matters.
WSHK0132
Name
1. Left-hand Thread WSHK0134
9. Turbine shaft
4. Seal plate
• Hold the heat protector lightly by hand, and take
• Loosen the pot small screw.
out the turbine shaft.
• Lightly tap the bearing housing in the seal plate
• If it is hard to remove, lightly tap the compressor-
with a wooden hammer.
side shaft end with a wooden hammer.
• Liquid gasket is applied to the mating surfaces of
• Washing of turbine shaft
the seal plate and the bearing housing.
Soak in the cleaning solvent until the foreign
matters soften, and clean it with a plastic scraper
or hard brush.
Caution:
• Do not use a wire brush.
• Foreign matters remaining on the surface causes
the unbalance of weight. Therefore, wash it
thoroughly.
• Take care not to damage the floating metal contact
surface of the shaft and the seal ring groove.
WSHK0133
5. Oil thrower
• Remove the oil thrower from the seal plate.
6. Seal ring; oil thrower
7. G coupling
• Loosen the nut and remove the G coupling from
the turbine housing and the center housing.
8. Turbine housing
• Remove the center housing from the turbine
housing.
WSHK0135
1F-12 Exhaust System and Turbocharger
10. Seal ring Impeller
• Remove the seal ring from the turbine shaft. • Check the impeller for scratch, dent or crack.
11. Gasket
12. Heat protector
• Remove the heat protector from the bearing
housing.
13. Thrust bearing (compressor side)
• Loosen the Plate small screw with a screwdriver,
and remove the thrust bearing and the thrust collar.
14. Thrust collar
15. Snap ring
• Remove the turbine-side snap ring with snap ring
pliers.
16. Floating metal
• Draw out the floating metal from the bearing
housing.
17. Thrust bearing (turbine side)
• Using a brass bar, push out the compressor-side WSHK0137
floating metal from the turbine-side bearing
housing, together with the thrust bearing. Heat protector
• Check the heat protector for damage, thermal
Caution: deformation or corrosion.
• while pushing out with a bar, take care that they do
not run on to damage the snap ring.
Removal of snap ring (also to be done after step
17.)
• Remove the 2 snap rings from the bearing housing
with snap ring pliers.
18. Bearing housing
Inspection
Compressor housing
• Check the compressor housing for crack or
damage, and replace if defective.
WSHK0138
Turbine shaft
• Measure the journal outer diameter of the turbine
shaft, and the groove width of the seal ring
insertion part.
WSHK0139 WSHK0141
Name Oil thrower
1. Journal outer diameter • Inspection of damage on the oil thrower sliding
2. Ring groove width surface, measurement of the seal ring groove
width
• Measurement of turbine shaft runout
Seal ring groove width G mm (in)
Turbine shaft runout mm (in)
Service limit
Service limit 0.011 (0.00043)
G 1.52 (0.0598)
Thrust collar
• Measure the thrust collar thickness (K), and
replace with new one if it exceeds the service limit.
WSHK0140
Seal plate
• Inspection of damage on the seal plate,
measurement of inner diameter of the seal ring WSHK0142
insertion part
Thrust bearing
Inner diameter of the seal mm (in) • Replace the compressor-side and the turbine-side
ring insertion part thrust bearings with new ones.
Service limit
Floating metal
H φ 14.05 (0.5531)
• Replace the floating metal with new one.
1F-14 Exhaust System and Turbocharger
Bearing housing
• Check the casting surface for peeling from
oxidation-deterioration, dent or crack. Replace with
new one if faulty.
mm (in)
Location Service limit
Bearing housing inner diameter (B) 16.11
(0.6343)
Turbine-side seal ring insertion (F) 17.03
part (0.6705)
Turbine-side thrust bearing (L) 23.02
press-fit part inner diameter (0.9063)
F B L
WSHK0143
G coupling
• Replace with new one.
Seal ring
• Replace with new one.
Others
• Check the bolts for deformation, and replace with
new ones if faulty. Also, replace the Plate small
screw with new one.
Exhaust System and Turbocharger 1F-15
Assembly of Turbocharger
Assembly diagram: Assemble in the order of the numbers.
18
15 17
16
13
14
9
8
4
3
3
11
1
12
10
6
5
7
WSHK0144
Assembly Procedure
1. Bearing Housing 10. Gasket
2. Snap Ring 11. Turbine Housing
3. Floating Metal 12. G Coupling
4. Thrust Bearing 13. Seal Ring
5. Seal Ring 14. Oil Thrower
6. Heat Protector 15. Seal Plate
7. Turbine Shaft 16. Compressor Impeller
8. Thrust Collar 17. Nut
9. Thrust Bearing 18. Compressor Housing
1F-16 Exhaust System and Turbocharger
Assembly
1. Bearing housing
• Check that the bearing housing is free of damage
and foreign matters.
2. Snap ring
• Install the 2 snap rings to the bearing housing with
snap ring pliers.
• After assembling the floating metal (turbine side),
install the snap ring at the position shown in the 1
figure.
WSHK0146
Name
1. Apply Oil.
4. Thrust bearing
a. Press-fitting of turbine-side thrust bearing
1
• Press-fit the turbine-side thrust bearing into the
bearing housing.
• Position the pawl of the turbine-side thrust
bearing for more than 2 mm (0.0787 in) apart
WSHK0145 from the existing press-fitting part.
• Do not press the thrust bearing pad surface
Name
during press-fitting.
1. Turbine-Side Floating Metal
• The press-fit pressure must be between 215.6
3. Floating metal N {22.0 kgf} and 1862 N {190 kgf}.
• Apply oil to the floating metal, and assemble it to • After press-fitting, remove the dust powder
the bearing housing. using vacuum.
After securing it with a snap ring, assemble the
compressor-side floating metal.
Caution:
• Place the snap ring with its rounded-side facing to
the floating metal.
• Assemble the inner snap ring with its end gap
facing to the oil outlet-direction of the housing, to
prevent it from blocking the oil path.
• Assemble the turbine-side snap ring to the housing
with its end gap facing to the direction as shown in
the illustration.
• Apply oil to the floating metal before assembly.
1
0
12
WSHK0148
8. Thrust collar
120
• Apply engine oil to the thrust collar, and install ti to
the turbine shaft.
WSHK0147
Name
1. Common Tolerance
5.Seal ring
•Insert the seal ring to the turbine shaft.
1
•Use new seal ring.
6.Heat protector
•Install the heat protector to the bearing housing.
7.Turbine shaft
•Apply engine oil to the journal portion of the turbine
shaft, and insert it from the turbine side of the
bearing housing.
• Take care not to damage the floating metal with the
turbine shaft. Also, insert with the end gap of the
seal ring facing to the oil inlet side so that its core WSHK0149
matches with the turbine shaft.
Name
1. Apply Oil.
9. Thrust bearing
• Apply engine oil to the metal portion of the thrust
bearing, and insert it to the bearing housing.
• Apply Loctite to the Plate small screw threads, and
install it using torque screwdriver.
Tightening torque: 3.7 N⋅m (0.38 kgf⋅m/33 lb in)
1F-18 Exhaust System and Turbocharger
d. Tighten to the specified torque using a torque
wrench.
Tightening torque: 83 N⋅m (8.5 kgf⋅m/61 lb ft)
e. Perform (c) and (d) of the above step again.
1 2
1 A 3
1 2
4 6
WSHK0150
Name 5
1. Apply Oil.
WSHK0151
12. G coupling
a. Check that it does not run on the turbine
housing or the bearing housing.
b. Tighten temporarily to the specified torque
using a torque wrench.
Tightening torque: 83 N⋅m (8.5 kgf⋅m/61 lb ft)
c. Hammering: Perform the hammering of (1) to
(6) in the numerical order, using the following
procedure.
Exhaust System and Turbocharger 1F-19
B
A
150 ~ 200 mm
2 (6 ~ 8 in) 3 4
7 6
WSHK0153 WSHK0154
16. Compressor impeller
Name
1. Approx. φ 13 mm (0.5 in) • Insert the compressor impeller to the turbine shaft.
2. Hammer
3. G Coupling
4. Bearing Housing
5. Gasket
6. Heat Shield Plate
7. Turbine Housing
WSHK0156
Exhaust System and Turbocharger 1F-21
Turbocharger (4HK1)
Inspection of Turbocharger
Inspection
Caution:
Turbocharger on 4HK1 engine cannot be overhauled
structurally.
WSHK0129
• Inspection 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.
1F-22 Exhaust System and Turbocharger
Measurement Tool
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