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LG4HG-WE-0871 1st WSMW 085 N G.Exp VN65
LG4HG-WE-0871 1st WSMW 085 N G.Exp VN65
No.LG4HG-WE-0871
LG4HG-WE-0871_57328_Maegaki 08.9.19 10:22 AM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
LG4HG-WE-0871_57328_Maegaki 08.9.19 10:22 AM ページ 2
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Engine Mechanical (4HG1)
TABLE OF CONTENTS
GENERAL DESCRIPTION ................................... 1B-3 Special Tools ...................................................1B-45
Cylinder Head.................................................... 1B-3 ENGINE ASSEMBLY ..........................................1B-47
Cylinder Block.................................................... 1B-3 Component ......................................................1B-47
Piston, Connecting Rod and Crankshaft ........... 1B-4 Removal...........................................................1B-51
Valve Train ........................................................ 1B-4 Installation........................................................1B-53
Fuel System....................................................... 1B-5 ENGINE MOUNT (RH,LH) ..................................1B-59
Intake and Exhaust Systems ............................. 1B-6 Component ......................................................1B-59
Lubrication System ............................................ 1B-6 Removal...........................................................1B-59
Cooling System ................................................. 1B-7 Installation........................................................1B-59
Important Operations......................................... 1B-7 List of Tightening Torques ...............................1B-60
TROUBLESHOOTING .......................................... 1B-8 CYLINDER HEAD COVER..................................1B-61
Hard Starting ..................................................... 1B-8 Component ......................................................1B-61
Unstable Idling................................................. 1B-14 Removal...........................................................1B-61
Insufficient Power ............................................ 1B-15 Installation........................................................1B-61
Excessive Fuel Consumption .......................... 1B-16 INLET COVER / INLET CASE.............................1B-63
Excessive Oil Consumption............................. 1B-16 Component ......................................................1B-63
Overheating ..................................................... 1B-16 Removal...........................................................1B-63
White Exhaust Smoke ..................................... 1B-17 Installation........................................................1B-65
Dark Exhaust Smoke....................................... 1B-17 EXHAUST MANIFOLD ........................................1B-69
Oil Pressure Does Not Rise............................. 1B-17 Component ......................................................1B-69
Abnormal Engine Noise................................... 1B-18 Removal...........................................................1B-69
Engine Cooling Trouble ................................... 1B-19 Installation........................................................1B-70
Starter Motor Does Not Stop ........................... 1B-20 List of Tightening Torques ...............................1B-72
SERVICE STANDARD........................................ 1B-21 TIMING GEAR REPLACEMENT.........................1B-73
Engine ............................................................. 1B-21 Component ......................................................1B-73
Cylinder Head.................................................. 1B-21 Removal...........................................................1B-74
Rocker Arm and Rocker Arm Shaft ................. 1B-22 Inspection.........................................................1B-78
Valve................................................................ 1B-22 Installation........................................................1B-79
Cylinder Block.................................................. 1B-23 List of Tightening Torques ...............................1B-85
Crankshaft ....................................................... 1B-25 VALVE GUIDE SEAL & VALVE SPRING............1B-86
Piston............................................................... 1B-26 Component ......................................................1B-86
Piston Pin ........................................................ 1B-26 Removal...........................................................1B-86
Piston Ring ...................................................... 1B-27 Installation........................................................1B-88
Connecting Rod............................................... 1B-27 VALVE SPRING, VALVE GUIDE OIL SEAL,
Flywheel .......................................................... 1B-28 VALVE, VALVE GUIDE ......................................1B-90
Gear Train ....................................................... 1B-28 Component ......................................................1B-90
Lubrication System .......................................... 1B-28 Disassembly.....................................................1B-90
Cooling System ............................................... 1B-29 Inspection and Repair ......................................1B-91
Fuel System..................................................... 1B-30 Reassembly .....................................................1B-96
Engine Electrical.............................................. 1B-30 ROCKER ARM SHAFT ASSEMBLY ...................1B-98
SERVICING ........................................................ 1B-32 Component ......................................................1B-98
Model Identification.......................................... 1B-32 Removal...........................................................1B-98
Air Cleaner....................................................... 1B-32 Disassembly.....................................................1B-98
Lubricating System .......................................... 1B-33 Inspection and Repair ......................................1B-99
Fuel System..................................................... 1B-35 Reassembly ...................................................1B-101
Accelerator Control.......................................... 1B-37 Installation......................................................1B-103
Engine Stop Control ........................................ 1B-37 CAMSHAFT ASSEMBLY ..................................1B-105
Valve Clearance Adjustment ........................... 1B-38 Component ....................................................1B-105
Injection Timing Adjustment ............................ 1B-39 Removal.........................................................1B-105
Quick-On-Start II System................................. 1B-41 Disassembly...................................................1B-106
Primary Specifications ..................................... 1B-42 Inspection and Repair ....................................1B-106
SPECIAL TOOLS................................................ 1B-45 Reassembly ...................................................1B-108
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
GENERAL DESCRIPTION
The engine is a four-cycle, four-cylinder, in-line, direct • The valve diameter is increased to offset the mass
fuel injection type diesel engine with the piston displace- of the valve operating system reduced by the intro-
ment of 4,570L (278.9 cu⋅in). It features a gear driven duction of the OHC mechanism.
OHC (overhead camshaft) timing train and the unique In addition, the intake and exhaust ports are put in
mechanisms and systems designed for outstanding a smoother and less resistant layout to enhance in-
cleanness, economy and durability. Its torque character- take and exhaust efficiency.
istics promise dynamic ride at high speed, high power at • The cylinder head gasket is of the laminated steel
low speed, and smooth and continuous torque at medi- of least fatigue in combination with the angular cyl-
um to high ranges. inder head bolt tightening method, equally de-
For 4HG1 signed to increase reliability against gas and water
leakage, in addition, selective assembly of gaskets
of various thicknesses minimizes the wasted
space between the piston and the cylinder head to
maintain performance at a high level.
• The cylinder head cover is made of aluminum to re-
duce noise.
Cylinder Block
• The cylinder block (1) is made of cast iron having
dry cylinder liner and five bearings.
The bearing cap has a ladder frame (2) construc-
tion integrating the crankcase to increase rigidity.
• The cylinder liner is made of thin iron plus special
alloys and is combined with the chrome-plated pis-
ton ring to ensure good resistance against wear.
• The oil pan is made of vibration-damping steel to
reduce noise.
LNW91BSH002101
For 4HG1
LNW91BSH002201
Cylinder Head
• The cylinder head is made of cast iron and has a
crossflow layout with the intake system in the left
side and the exhaust system in the right side, de-
signed to reduce resistance in the intake and ex-
haust systems. N6A0369E
LG4HG-WE-0871.book 4 ページ 2008年9月25日 木曜日 午後5時58分
N6A1629E
Legend
A. Crankshaft oil seal
1. Axial type
2. Radial type
3. Slinger
Valve Train
• The gear train is located at the end of the cylinder
N6A0370E
block to minimize influence of the torsional vibra-
tion of the crankshaft and the radiant sound. Noise
is further reduced, to the same level as a timing
Legend belt driven system, by integrating the crank gear
1. Ring trigger with the crankshaft by shrink fit and by careful turn-
2. Strut ing of the gear precision, teeth contact ratio of
gear, backlash, bearing rigidity, neutral frequency,
• The crankshaft is made of cast carbon steel with etc. (See figure).
five bearings and eight counterweights to reduce
revolution load to the bearing. The ladder frame
design that integrates the bearing cap and the
crankcase increases bearing rigidity. The angular
tightening method of the bearing bolt further in-
creases reliability and durability.
• The connecting rod is made of cast carbon steel
and the cap is bolted by angular tightening method
to maintain reliability.
• The bearing, as well as the crank journal and crank
pin bearings, are made of Kelmet metal.
Oil clearance is controlled accurately through se-
lective assembly by thickness to reduce noise and
increase reliability.
• The crankshaft has the axial type oil seal that dras-
tically improves durability and reliability.
Compared with the conventional radial type (lips in
a radial orientation), the axial type oil seal has lips
in an axial orientation to minimize lip wear. It also
LG4HG-WE-0871.book 5 ページ 2008年9月25日 木曜日 午後5時58分
N6A0373E
Legend N6A0374E
1. Camshaft gear
2. Power steering pump gear Legend
3. Power steering pump idle gear 1. Pin
4. Crankshaft gear 2. Roller
5. Oil pump drive gear
6. Injection pump gear • The rocker shaft is chrome plated to secure suffi-
7. Idle gear A cient durability.
8. Idle gear B
9. Idle gear C
Fuel System
LINE Pump
• Gears are of the forged type. Gears are tufftrided
• The injection pump is of Bosch A type with the
to secure sufficient durability.
plunger outside diameter of 10 mm (0.39 in) and
• The camshaft is made of carbon steel with five cam lift of 11 mm (0.43 in).
bearings. The cam’s nose and the journal are in- The plunger has a special notch for advancing the
duction-hardened to secure sufficient durability. timing at starting.
• The cam has a Fourier-dyne profile to maximize • The governor is of a mechanical RLD type to en-
the intake and exhaust valve lifts and the valve sure sustained power at high speed.
opening and closing timing is optimized to increase
• The timer is of the SCDM (eccentric) type.
intake and exhaust efficiency.
• The valve spring is a single spring having an egg- Injection Nozzle
shaped cross section to reduce weight while reduc- • The injection nozzle is of the P type to bring it as
ing stress. Coupled with the unique cam profile, the technically close as possible to the center of the
spring increases the jump-and bounce-free limit at combustion chamber. The nozzle inclination is also
high-speed operation to provide reserve character- reduced to minimum to increase combustion effi-
istics. ciency.
• The rocker arm is made of diecast aluminum and is The nozzle has five jets and the valve opening
of the center pivot type having a roller. This in- pressure is set at 185 kg/cm2 (2,630 psi, 18,142
creases reliability while reducing friction and con- kPa) (See figure).
LG4HG-WE-0871.book 6 ページ 2008年9月25日 木曜日 午後5時58分
N6A0376E
Legend
1. Straightening wall
Lubrication System
• The oil pump is driven by the crank gear directly to
increase durability while maintaining sufficient de-
N6A0375E
livery.
The pump body is partially integrated with the cyl-
• The injection pipe is laid in such a way that the inder block to reduce the overall size and weight
overall length is minimized to enhance perfor- (See figure)
mance. • The oil filter is of the cartridge type integrating the
full flow filter and bypass filter as a single unit. This
Intake and Exhaust Systems presents several advantages such as an extended
• The resin-made intake manifold is of the cover type interval between oil exchanges and greater ease of
having an inner cover made of rubber and steel. maintenance resulting in cost reduction. The by-
This design effectively reduces radiant sound and pass valve is fitted to the body itself to avoid flow of
transmitted sound. foreign matter due to bypassing of oil thereby
• The intake manifold has a straightening vane in- maintaining sufficient reliability.
side to stabilize swirl and improve performance. It • The oil cooler is of a large-capacity, water-cooled
also contains a built-in Positive Crankcase Ventila- and multiple-partition type built into the side of the
tion (PCV) valve to minimize the overall size (See cylinder block. This design maintains necessary
figure). stability in oil temperature. It also has a bypass
• The exhaust manifold is mode of cast iron and he- valve to minimize delay of the oil gallery pressure
atresisting alloys. Ports are shaped carefully to build-up for cold starting.
minimize exhaust resistance.
LG4HG-WE-0871.book 7 ページ 2008年9月25日 木曜日 午後5時58分
N6A0377E
Legend
1. Oil pump gear
Important Operations
1. Axial Type Oil Seal
• As crankshaft front and rear oil seals are both axial type, attention must be paid to the following:
when replacing, replace oil seal and slinger as a set.
• Be sure to use the special tool correctly since oil seal and slinger must be set accurately in their longitudinal
direction.
2. Valve Cap
• As intake and exhaust valves have caps, take sufficient care not to let them fall into the gear case or oil return
hole during disassembly or reassembly.
3. Application of Liquid Gasket
• Oil pan, crankcase, oil cooler, retainer front, and water pump are not sealed with sheet gasket but with liquid
gasket only.
• Prior to application, be sure to remove old hardened liquid gasket or oil from those surfaces to which new
gasket will be applied. Further, if the old gasket can hardly be removed, mask such surfaces with gasket re-
mover (ThreeBond PANDO-391D; ISUZU Genuine Parts No. 1-8844-0542-0) or equivalent in accordance
with the instructions manual.
• Liquid gasket should be applied evenly so that no breaks and omissions may be made. Further, were O-ring
is used should not be exposed to liquid gasket.
4. Plastic-Region Angular Bolt Tightening Method
• Clamping bolts of connecting rod and cylinder head (M14 only) are tightened by plastic region angular bolt
tightening method. This method is applied with bolt threads and setting faces coated with molybdenum dis-
ulfide grease.
LG4HG-WE-0871.book 8 ページ 2008年9月25日 木曜日 午後5時58分
TROUBLESHOOTING
Hard Starting
1. Starter Inoperative
N6A0001E
LG4HG-WE-0871.book 11 ページ 2008年9月25日 木曜日 午後5時58分
N6A0002E
LG4HG-WE-0871.book 12 ページ 2008年9月25日 木曜日 午後5時58分
N6A0003E
LG4HG-WE-0871.book 13 ページ 2008年9月25日 木曜日 午後5時58分
N6A0004E
LG4HG-WE-0871.book 14 ページ 2008年9月25日 木曜日 午後5時58分
Overheating
3. Continuous Noise
4. Slapping Noise
LNW91ELF000601
LG4HG-WE-0871.book 21 ページ 2008年9月25日 木曜日 午後5時58分
SERVICE STANDARD
Engine
Cylinder Head
N6A1400E
Camshaft
N6A1407E
Camshaft Journal Uneven Wear mm (in) 0.015 (0.0006) or less 0.05 (0.002)
Camshaft Journal Wear mm (in) 39.950 — 39.975 (1.5728 — 1.5738) 39.850 (1.569)
Camshaft Journal and Bearing Clear- mm (in)
0.025 — 0.087 (0.00098 — 0.00343) 0.15 (0.0059)
ance
Camshaft Run-Out 0.04 (0.0016) or less
mm (in) 0.05 (0.002)
against the adjacent journal
LG4HG-WE-0871.book 22 ページ 2008年9月25日 木曜日 午後5時58分
Valve
N6A1408E
Valve Contact Width mm (in) Inlet Nominal size 2.5 (0.098) 3.0 (0.118)
N6A1409E
LG4HG-WE-0871.book 23 ページ 2008年9月25日 木曜日 午後5時58分
N6A1410E
Valve Stem Seal Lip Wear mm (in) 8.3 — 8.7 (0.3268 — 0.3425) 8.8 (0.346)
Valve Spring Tension N (kg / lb) 414 — 477 (42.2 — 48.6 / 93 — 107)
40.9 (98 / 401)
Set length 47.0 mm (1.85 in)
Valve Spring Free Height mm (in) Nominal size 62.5 (2.46) 59.4 (2.34)
Valve Spring Squareness mm (in)
1.0 (0.04)
N6A1411E
N6A1412E
Cylinder Block
115.021 — 115.050
115.20 (4.535)
(4.5284 — 4.5295)
N6A1413E
1. 20 mm (0.79 in)
2. 90 mm (3.54 in)
3. 160 mm (6.30 in)
Cylinder Liner Projection mm (in) 0.10 — 0.14 (0.0039 — 0.0055) There must be a
The difference in the cylinder liner pro- projection on the
jection height between any two adja- cylinder liner.
cent cylinders must not exceed 0.03
(0.0012)
Cylinder Block Upper Face mm (in) 0.05 (0.002) or less
Warpage 0.02 (0.008)
Do not regrind the cylinder body upper
face.
LG4HG-WE-0871.book 24 ページ 2008年9月25日 木曜日 午後5時58分
Piston
Piston
Cylinder Liner Bore Diameter Piston Outside Diameter
Service
mm (in) mm (in)
Grade
115.040 — 115.060 114.944 — 114.959
—
(4.5291 — 4.5299) (4.5253 — 4.5259)
Piston Pin
The direction of the piston ring connecting end Alternately at 180°. Don’t position the
connecting end in the side pressure
direction. Place the connecting end of
the oil ring and that of the expander coil
at 180° alternately.
Connecting Rod
Gear Train
Lubrication System
Engine Electrical
SERVICING
Servicing refers to general maintenance procedures to
be performed by qualified service personnel.
Model Identification
Engine Serial Number
The engine number is stamped on the front left hand
side of the cylinder block.
N6A0007E
Legend
1. Dust indicator
2. Red color
Air Cleaner
Dust Indicator
1. The dust indicator is installed to the air cleaner.
Inspect the dust indicator. If the indicator plate is
red, the air cleaner element must be cleaned or re-
placed.
2. Clean the air cleaner element once and reinstall it.
Press the dust indicator button to clear the dust in-
dicator.
LNW71JSH001901
LNW21JSH000201 N6A0011E
Carbon and Dust Fouled Element 4. Dry the element in a well ventilated area.
1. Prepare a cleaning solution of Isuzu Genuine Ele- An electric fan will hasten drying.
ment Cleaner diluted with water. Caution:
2. Immerse the element in the solution for twenty min- Do not use compressed air or an open flame to dry the
utes. element quickly. Damage to the element will result.
It will usually take two or three days for the element to
dry completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.
HCW31BSH057501
N6A0013E
Replenishment
1. Remove the filler cap.
2. Pour the specified engine oil into the crankcase
through the oil filler.
3. Replace the filler cap.
7. Start the engine and check for oil leakage from the
main oil filter.
N6A0018E N6A0020E
Fuel Filter
Replacement Procedure
1. Loosen the used fuel filter by turning it counter-
clockwise with the universal filter wrench.
LNW21DSH000301
Note:
Check for fuel leakage from around the injection pump
and the fuel filter.
N6A0024E
LNW91DMH000101
N6A0040E
N6A0027E
Accelerator Control
N6A0043E
Accelerator Pedal Clearance mm (in) 2. Tighten the rocker arm shaft bracket nuts and bolts
to the specified torque in numerical order a little at
0 — 2 (0 — 0.079) a time as shown in the illustration.
Tighten:
Rocker arm shaft bracket nut and bolt to
• Bolt (1): 56 N⋅m (5.7 kg⋅m/41 lb⋅ft)
• Nut (2): 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
• Bolt (3): 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
N6A0044E
Legend
1. Full stroke 0 — 2 mm (0 — 0.079 in)
2. Stopper bolt
3. Accelerator pedal LNW21BSH016301
LNW21BSH066501
Legend LNW21BSH001201
1. Feeler gauge
Injection Timing Adjustment
Adjust the No.1 or the No.4 cylinder valve clear-
ance while their respective cylinders are at TDC on Injection Pump Notched Line Inspection
the compression stroke. 1. Check the injection pump bracket nuts (1) for
looseness.
Valve Clearance mm (in) Tighten as required.
At cold 0.40 (0.016) 2. Check that the notched lines (2) on the injection
pump bracket and the timing gear case are
4. Loosen each valve clearance adjusting screw as aligned.
shown in the illustration. If the notched lines are not aligned, the injection
timing must be checked.
LNW21BSH001101
N6A0050E
LG4HG-WE-0871.book 40 ページ 2008年9月25日 木曜日 午後5時58分
N6A0054E
N6A0330E
N6A0056E
LNW91BSH002501 N6A0063E
5. Connect a tachometer and check that engine 4. Check the glow plug heating time.
cranking speed is 200 r/min or higher.
6. Turn the engine over with the starter motor and Approximate Glow Plug Heating Time sec
take the compression gauge reading.
18
7. Repeat the procedure (steps 4,5 and 6) for the re-
maining cylinders.
Compression Pressure
kPa (kg/cm2/psi) at 200 r/min
Standard More than 2,942 (30/426)
Limit for use 2,157(22/312)
Variance in pressure Less than 294 (3/43)
between cylinders
Quick-On-Start II System
Inspection Procedure
1. Disconnect the thermoswitch connection on the
thermostat outlet pipe.
2. Turn the key switch to the “ON” position.
If the Quick-ON-Start II system is operating proper-
ly, the flow relay will make a clicking sound within
three seconds.
3. Measure the glow plug terminal voltage with a cir-
cuit tester as soon as possible after turning the key
switch to the “ON” position.
LG4HG-WE-0871.book 42 ページ 2008年9月25日 木曜日 午後5時58分
Engine Model
4HG1
Engine type Four-cycle, overhead camshaft, water cooled
Combustion chamber type Direct injection
Cylinder liner type Dry liner, special compound metal
Timing drive system Gear drive
No. of cylinders — Bore × mm (in) 4 — 115 × 110 (4 — 4.53 × 4.33)
stroke
No. of piston rings Compression rings: 2, Oil ring: 1
Total piston displacement L (cu⋅in) 4.570 (278.9)
Compression ratio to : 1 19
2
Compression kPa (kg / cm / psi) 3,040 (31.0/441) — 200
pressure — rpm
Fuel injection order 1—3—4—2
Fuel injection timing deg 7
(BTDC)
Specified fuel type SAE No. 2 diesel fuel
Idling speed r/min 550 — 600
Valve system
Engine Model
4HG1
Injection nozzle opening
Injection nozzle type Hole type (with 5 orifices)
2
Pressure MPa (kg / cm / psi) 18.1 (185 / 2,631)
Pressure adjustment Shim adjusted
Main fuel filter type Disposal spin-on cartridge and remote mounted water separator
Lubricating system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CD or above
Oil pressure kPa (kg /cm2 / psi) 147 (1.5 / 21) — 700
— r/min (SAE 10W-30 API CD grade engine oil at 80°C (176°F))
Oil pump type Gear type
Oil filter type Spin-on cartridge
Oil capacity lit (lmp. gal) When changing oil only: 10.5 (2.31)
When changing oil and filter 2WD model: 12.0 (2.64)
4WD model: 11.5 (2.53)
Oil cooler type Water cooled
Cooling system
Radiator type Corrugated fin with reserve tank
Coolant capacity lit (lmp. gal) NMR model: 13.6 (2.99)
NPR / NQR / NPS model: 14.0 (3.08)
Item Water pump type Centrifugal impeller, V-belt drive
Pump to crankshaft speed to : 1 1.19 (175 / 147)
ratio
Delivery volume lit (lmp. gal)/min 200 (44.0)
(Pump speed at 3,300 rpm Water temperature at 82°C (180°F))
Pump bearing type Double row shaft
Thermostat type Wax pellet
Valve initial opening tem- °C (°F) With jiggle valve: 83.5 — 86.5 (182 — 188)
perature Without jiggle valve: 80.5 — 83.5 (177 — 182)
Valve lift mm (in) With jiggle valve: 8 (0.3) or more at 100°C (212°F)
Without jiggle valve: 8 (0.3) or more at 95°C (203°F)
Air cleaner type Dry paper element
Battery type Volt-amp.hr. 75D23L / 80D26L : 2 pcs
Generator
Type AC brush with IC regulator and vacuum pump
Voltage V 24
Drive and rotation V-belt, clockwise viewed from the drive pulley
Ground polarity Negative
Maximum output A 50 at 5,000 r/min
80 at 5,000 r/min
Maximum speed r/min 7,500 — 10,000
LG4HG-WE-0871.book 44 ページ 2008年9月25日 木曜日 午後5時58分
Engine Model
4HG1
Regulator
Type IC
Regulating voltage V 28 — 29
Vacuum pump
-66.7kPa (-500 mmHg / -9.67 psi) build- 13 seconds or less at 1,000 r/min
up time
4 seconds or less at 5,000 r/min
Maximum vacuum -90.7 kPa (-680 mmHg / -13.1 psi) or more at 5,000 r/min
Starter motor
Type Magnetic solenoid-controlled
Item
Model S25-501B S25-505G
Rated voltage V 24 24
Rated output kW 4 4.5
Load characteristics
Terminal voltage V 18.55 14.3
Load current A 250 400
Torque N⋅m (kg⋅m / lb⋅ft) 14.0 (1.43 / 10.34) 25 (2.55 / 18.44)
at 1,500 r/min or more at 1,500 r/min or more
Preheating system Quick-On-Start System II
LG4HG-WE-0871.book 45 ページ 2008年9月25日 木曜日 午後5時58分
SPECIAL TOOLS
Special Tools
Tool Number /
Tool Number / Illustration
Illustration Description / Remarks
Description / Remarks
5-8840-2360-0 / Slinger
puller / For crankshaft
1-8522-1097-0 / Oil filter
front and rear slinger
wrench / 2WD model
remove
5884023600
1852210970
5884027030
5884026750
5-8840-2790-0 / Clutch
5-8531-7001-0 / Adapter;
pilot aligner
Compression gauge
5884027900
5853170010
5884022280
5884002660
5-8840-2227-0 / Valve
5-8840-9018-0 / Piston
guide replacer
installer
5884022270
5884090180
8-9439-6815-0 / Valve
5-8840-2230-0 / Crank-
guide seal installer
shaft stopper
8943968150
5884022300
LG4HG-WE-0871.book 46 ページ 2008年9月25日 木曜日 午後5時58分
5884022220 5884020940
9-8523-1169-0 / Cylinder
liner remover
9852311690
5-8840-2220-0
5-8840-2397-0 (4HG1) /
Cylinder liner remover
ankle
5884022200
5884023970
5-8840-2337-0 / Cylin-
der Liner Installer (4HE1-
TC only)
5884023370
8-9439-6818-0 / Crank-
shaft gear remover
8943968180
8-9439-6819-0 / Crank-
shaft gear installer
8943968190
5-8840-2340-0 / Conrod
bush replacer
5884023400
LG4HG-WE-0871.book 47 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE ASSEMBLY
Component
Transmission Side
N6A1643E
Legend
1. Propeller shaft assembly 8. Select cable
2. Car speed sensor connector 9. Clutch slave cylinder
3. Neutral switch connector 10. Starter earth cable
4. Back-up lamp connector 11. Starter
5. Harness connector 12. Transmission mounting nut
6. Parking brake cable 13. Transmission assembly
7. Shift cable
LG4HG-WE-0871.book 48 ページ 2008年9月25日 木曜日 午後5時58分
N6A0761E
Legend
1. Intake air duct 5. Accelerator control cable
2. Heater hose 6. Fuel return hose
3. Vacuum hose 7. Fuel feed hose
4. Engine stop cable
LG4HG-WE-0871.book 49 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BMF000601
LNW91BMF000201
LG4HG-WE-0871.book 50 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. Radiator upper hose 4. Fan guide
2. Coolant reserve tank hose/Bypass hose 5. Fan
3. Radiator 6. Radiator lower hose
LNW91BMF000301
Legend
1. Power steering pump 4. ACG vacuum hose
2. A/C compressor 5. Front exhaust pipe
3. ACG harness
LG4HG-WE-0871.book 51 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSF000101
Legend
1. Engine mount 2. Engine assembly
Removal
Preparation
• Disconnect battery ground cable
• Tilt the cab
• Remove the transmission panel
• Drain coolant
Transmission Side
1. Propeller shaft Assembly
1) Put in advance an alignment mark to the drum
and the flange yoke.
2) Put the drum and the flange yoke aside and
hang them with a wire so that they do not inter-
fere with servicing work.
2. Vehicle Speed Sensor Connector
3. Neutral Switch Connector N6A0750E
4. Back-up Lamp Connector
5. Harness Connector 6. Parking Brake Cable
Remove the connectors from the harness bracket. Remove the clip and slide the cover provided in the
At that time, take care not to cause any damages middle of the cable. Then, loosen the longer nut on
to the clips. the front side of the vehicle to disconnect the park-
ing brake cable.
LG4HG-WE-0871.book 52 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH000301
LNW91BSH000201
Tighten:
Mounting rubber nut to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
LNW21ESH000301
Legend
1. ACG vacuum hose
2. ACG harness
Note:
When tightening the compressor fixing bolts, tighten the
first 2 bolts on the rear side, and then the remaining 2 on
the front.
LNW21BSH028101
Tighten:
Locking nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
4. Power Steering Pump
Tighten:
Bolt to
• (1): 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
• (2): 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
• (3): 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
LG4HG-WE-0871.book 55 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH001801 LNW91BSH000101
LNW21BSH012201
2. Radiator
Tighten:
Radiator bracket bolt to 55 N⋅m (5.6 kg⋅m/41 lb⋅ft)
LG4HG-WE-0871.book 56 ページ 2008年9月25日 木曜日 午後5時58分
N6A0778E
LNW46BSH000101
3) Operate the priming pump to bleed the air from
the injection pump.
Legend 4) Retighten the bleeder valve.
1. Nut 5) Operate the priming pump.
2. Rubber Check for fuel leakage from around the injec-
3. Stud bolt tion pump and the fuel filter.
4. Frame side bracket 6) Lock the priming pump cap to the injection
5. Radiator side bracket pump.
6. Washer 3. Accelerator Control Cable
1) Check to see if the idling control knob is turned
3. Fan Guide
to the extreme left.
4. Radiator Lower Hose 2) Attach the end tip of the cable to the engine
5. Coolant Reserve Tank Hose/Bypass Hose control lever.
6. Radiator Upper Hose 3) Pull the outer cable toward the front of the vehi-
cle, and provide the engine control wire and the
Engine Left Side
inner cable with an appropriate play before fas-
1. Fuel Feed Hose tening the clamp with a nut.
2. Fuel Return Hose
Air Bleeding
1) Loosen the priming pump cap (2) at the side of
the injection pump.
2) Loosen the bleeder valve (1) at the top of the
fuel filter.
N6A0526E
LNW21BSH027501
Transmission Side
1. Transmission Assembly
N6A0525E
Fasten the transmission to the transmission jack
5. Vacuum Hose with a chain in the same manner as when dis-
mounting it, and tighten the clutch housing clamp-
6. Heater Hose
N6A0787E
N6A0786E
LNW91BMF000401
Legend
1. Engine mount 2. Fan guide
Removal Tighten:
Preparation Chassis frame side bolt to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
• Disconnect battery ground cable.
• Tilt the cab. Tighten:
Engine foot side nut to 106 N⋅m (10.8 kg⋅m/78 lb⋅ft)
1. Fan Guide
Remove the fan guide and hang it on the fan side. 2. Fan Guide
2. Engine Mount 3. Connect the negative battery cable.
1) Hang the engine by the hoist before dismount- • Lower the cab
ing the engine mount. • Start the engine, and check for any abnormal con-
2) Remove the nuts that fix the engine foot and ditions with the engine mount.
the engine mount.
3) Remove the fixing bolts on the chassis frame
side of the engine mount.
4) Hoist the engine assembly a little, and dis-
mount the engine mount.
Installation
1. Engine Mount
Tighten the fixing bolts to the specified torque.
LG4HG-WE-0871.book 60 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BLF001501
(a) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) (d) 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
(b) 51 N⋅m (5.2 kg⋅m/38 lb⋅ft) (e) 45 N⋅m (4.6 kg⋅m/33 lb⋅ft)
(c) 106 N⋅m (10.8 kg⋅m/78 lb⋅ft) (f) 97 N⋅m (9.9 kg⋅m/72 lb⋅ft)
LG4HG-WE-0871.book 61 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BLF000301
Legend
1. Cylinder head cover 3. Nozzle cover
2. Cylinder head cover gasket 4. Rubber plug
N6A1630E
4. Nozzle Cover
• Connect the negative battery cable.
• Lower the cab.
Start engine and check for oil leakage carefully.
LG4HG-WE-0871.book 63 ページ 2008年9月25日 木曜日 午後5時58分
N6A0384E
Legend
1. Intake air duct 7. Injection pipe
2. Vacuum hose 8. Engine harness
3. Nozzle cover 9. Oil level guide tube
4. Leak off pipe 10. Inlet cover
5. Fuel pipe 11. Inlet case
6. PCV hose
N6A0385E N6A0387E
N6A0386E
Legend
1. Fuel filter
2. Leak off
8. Engine Harness
Disconnect thermometer unit, thermo switch, ta-
chometer sensor and glow plug harness connec-
tors and separate harness from clips.
LG4HG-WE-0871.book 65 ページ 2008年9月25日 木曜日 午後5時58分
N6A0389E N6A0391E
Legend Legend
1. Engine harness 1. Inlet cover
2. Inlet case
9. Oil Level Guide Tube 3. Gasket
Remove the guide tube fixing bolt and pull out the
guide tube.
Installation
1. Inlet Case
1) Apply 4 mm (0.16 in) bead of the recommended
liquid gasket (ThreeBond 1207C) or its equiva-
lent on the groove of the inlet case fitting sur-
faces shown in the illustration.
• Clean the inlet case fitting surface of the cylin-
der head.
N6A0390E
LNW21BSH064301
N6A0390E
N6A1500E
N6A0393E N6A0395E
5. Injection Pipe
Legend
1) Install the injection pipe assembly and tempo-
1. Inlet cover
rarily tighten the injection pipe sleeve nuts.
2. Mounting rubber
2) Set the clips in the prescribed position shown in
3. Bolt
the illustration.
3. Oil Level Guide Tube Caution:
Make absolutely sure that the clip is correctly positioned.
LG4HG-WE-0871.book 67 ページ 2008年9月25日 木曜日 午後5時58分
Tighten:
Fuel pipe joint bolt (1) to 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Tighten:
Fuel pipe joint bolt (2) to 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
Tighten:
Clip screw to 4 N⋅m (0.4 kg⋅m/35 lb⋅in)
N6A1631E
N6A0399E
Legend
1. Fuel pipe joint bolt
2. Fuel pipe joint bolt
3. Clip
N6A0387E
LG4HG-WE-0871.book 68 ページ 2008年9月25日 木曜日 午後5時58分
N6A0400E
9. Nozzle Cover
10. Vacuum Hose
11. Intake Air Duct
• Connect the negative battery cable.
• Lower the cab.
• Start engine and check for fuel leakage careful-
ly.
LG4HG-WE-0871.book 69 ページ 2008年9月25日 木曜日 午後5時58分
EXHAUST MANIFOLD
Component
LNW91BLF000401
Legend
1. A/C compressor bracket (If equipped with A/C) 4. Exhaust manifold
2. A/C compressor (If equipped with A/C) 5. Heat protector
3. Exhaust gasket 6. Front exhaust pipe
LNW21BSH063001
3. Heat Protector
Tighten:
Heat protector bolt to 10 N⋅m (1.0 kg⋅m/7 lb⋅ft)
LNW21BSH062901
2. Exhaust Manifold
1) Install exhaust manifold gaskets (1), exhaust
manifold (2), distance pieces (3), dish washers
(4) and nuts (5) to the stud bolts shown in the
illustration.
N6A0415E
Tighten: Tighten:
Exhaust manifold nut to 34 N⋅m (3.5 kg⋅m/25 lb⋅ft) A/C compressor bracket bolt to 48 N⋅m (4.9 kg⋅m/35
lb⋅ft)
LG4HG-WE-0871.book 71 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH001801 LNW21BSH028101
LNW21ESH000301
LNW91BLF001401
(a) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft) (d) 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
(b) 34 N⋅m (3.5 kg⋅m/25 lb⋅ft) (e) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(c) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft) (f) 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
LG4HG-WE-0871.book 73 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BLF000501
LG4HG-WE-0871.book 74 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. Engine assembly 16. Slinger
2. Nozzle cover 17. Flywheel housing
3. Cylinder head cover 18. Stiffener (RH)
4. Head cover gasket 19. Power steering pump idle gear
5. Rocker arm shaft assembly 20. Power steering pump idle gear cover
6. Valve cap 21. Clutch pressure plate assembly
7. Camshaft bearing cap 22. Clutch disc
8. Camshaft bearing upper 23. Flywheel
9. Camshaft assembly 24. Rear oil seal
10. Camshaft bearing lower 25. Stiffener (LH)
11. Cylinder head assembly 26. Oil pipe
12. Cylinder head gasket 27. Oil pan
13. Idle gear B shaft 28. Injection pump assembly
14. Idle gear B 29. Engine control wire
15. Idle gear A 30. Engine control lever assembly
Removal
Preparation
• Disconnect battery ground cable.
• Tilt the cab.
• Drain coolant and engine oil.
1. Engine Assembly
Above works refer to “ENGINE ASSEMBLY” sec-
tion in this manual.
2. Nozzle Cover
3. Cylinder Head Cover
4. Head Cover Gasket
5. Rocker Arm Shaft Assembly
1) Loosen the rocker arm shaft bracket nuts and
bolts in numerical order a little at a time and re-
move the rocker arm shaft assembly with the
camshaft brackets. N6A0420E
2) Leave the (1) indicated bolt unremoved on this
occasion, since it is the rocker arm fixing bolt. 6. Valve Cap
Caution: Caution:
Failure to loosen the rocker arm shaft bracket nuts and Take sufficient care not to let valve caps fall into the gear
bolts in numerical order a little at a time will adversely af- case or oil return hole.
fect the rocker arm shaft. 7. Camshaft Bearing Cap
8. Camshaft Bearing Upper
9. Camshaft Assembly
10. Camshaft Bearing Lower
If the camshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with
the cylinder number from which it was removed.
LG4HG-WE-0871.book 75 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH002201 LNW21BSH002501
LNW21BSH002601
Legend
LNW91BSH001901 1. Clutch pilot aligner
N6A0425E LNW21BSH007701
N6A6504E
Legend
N6A0426E 1. Washer
2. Pilot bearing
19. Tachometer sensor
20. Flywheel 3) Remove the flywheel stopper and the flywheel
1) Use the crankshaft stopper to prevent the assembly.
crankshaft from turning. 21. Crankshaft Rear Oil Seal
Crankshaft Stopper: 5-8840-2230-0
Caution:
Be careful not to damage the crankshaft oil seal contact
surface during the removal procedure.
LG4HG-WE-0871.book 77 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH002801 LNW91BSH002401
LNW91BSH000401
LNW21BSH072301 LNW21BSH003301
LNW21BSH003201
Inspection
Idle Gear Backlash Measurement
1. Set a dial indicator to the timing gear to be mea-
sured.
Hold both the gear to be checked and the adjoining
gear stationary.
2. Move the gear to be checked right and left as far as LNW21BSH003401
possible. Take the dial indicator reading.
Idler Gear Shaft Outside Diameter
Timing Gear Backlash Gear to Gear mm (in)
Use a micrometer to measure the idler gear shaft out-
Standard Limit side diameter.
0.10 — 0.17 (0.0039 — 0.0067) 0.30 (0.012) If the measured value is less than the specified limit, the
idler gear must be replaced.
LG4HG-WE-0871.book 79 ページ 2008年9月25日 木曜日 午後5時58分
Idler Gear Shaft Outside Diameter mm (in) Idler Gear Shaft and Idler Gear clearance
Standard Limit mm (in)
29.959 — 29.980 Standard Limit
29.80 (1.1732)
(1.1795 — 1.1803)
0.020 — 0.062
0.200 (0.0079)
(0.0008 — 0.0024)
Installation
1. Idler Gear B Shaft
Tighten:
Idle gear B shaft bolt to 31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
Apply the engine oil to the idle gear shaft after in-
stallation.
LNW21BSH003501
Tighten:
Idle gear B bolt to 110 N⋅m (11.2 kg⋅m/81 lb⋅ft)
LNW21BSH003601
LNW21BSH003801
Legend
1. Idle gear
2. Thrust collar
3. Bolt
3. Idle Gear A
LNW21BSH007801
N6A0441E
LG4HG-WE-0871.book 81 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. Camshaft gear 6. Injection pump gear
2. Power steering pump gear 7. Idle gear A
3. Power steering pump idle gear 8. Idle gear B
4. Crankshaft gear 9. Idle gear C
5. Oil pump drive
4. Flywheel Housing
1) Carefully wipe any foreign material from the cyl-
inder block rear face.
2) As shown in the diagram, uniformly apply liquid
gasket (ThreeBond 1207C) to the inside of the
bolt hole (excluding the bolt hole at the arrow).
LNW91BSH000601
LNW21BSH072501
LG4HG-WE-0871.book 82 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH004301 LNW91BSH002401
LNW91BSH000701
7. Oil Pan
8. Stiffener (RH/ LH)
Tighten:
Stiffener M10 bolt to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
M12 bolt to 76 N⋅m (7.7 kg⋅m/56 lb⋅ft) N6A0448E
N6A0449E LNW21BSH002501
LNW21BSH002601
LNW91BSH002301
LNW91BLF001301
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (l) 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
(b) 22 N⋅m (2.2 kg⋅m/16 lb⋅ft) (m) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
(c) 56 N⋅m (5.7 kg⋅m/41 lb⋅ft) (n) 94 N⋅m (9.6 kg⋅m/69 lb⋅ft)
(d) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft) (o) 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
(e) 142 N⋅m (14.5 kg⋅m/105 lb⋅ft) (p) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(f) 95 N⋅m (9.7 kg⋅m/70 lb⋅ft) (q) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
(g) 110 N⋅m (11.2 kg⋅m/81 lb⋅ft) (r) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(h) 31 N⋅m (3.2 kg⋅m/23 lb⋅ft) (s) 133 N⋅m (13.6 kg⋅m/98 lb⋅ft)
(i) 133 N⋅m (13.6 kg⋅m/98 lb⋅ft) (t) 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
(j) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (u) 8.0 N⋅m (0.8 kg⋅m/69 lb⋅in)
(k) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
LG4HG-WE-0871.book 86 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BLF000601
Legend
1. Leak off pipe 10. Camshaft bearing upper
2. Injection pipe 11. Camshaft assembly
3. Injection nozzle holder assembly 12. Camshaft bearing lower
4. Glow plug 13. Rocker arm shaft assembly
5. Glow plug connector 14. Valve cap
6. Nozzle cover 15. Spring upper seat
7. Cylinder head cover 16. Split collar
8. Cylinder head cover gasket 17. Valve spring
9. Camshaft bearing cap 18. Valve guide seal
N6A0453E
N6A0454E
Legend
1. Glow plug connector
2. Glow plug
3. Injection nozzle holder assembly
LNW21BSH016701
N6A0457E
3. Spring Upper Seat
4. Split Collar
Legend 1) Use the valve spring compressor to push the
1. Oil seal valve spring into position.
Valve Spring Compressor: 5-8840-2228-0
Installation 2) Install the split collar to the valve stem.
1. Valve Guide Seal 3) Set the split collar by tapping around the head
of the collar with a rubber hammer.
• Apply a coat of engine oil to the valve guide
seal inner face.
• Use a valve guide seal installer to install the
valve guide seal to the valve guide
Valve Guide Seal Installer: 8-9439-6815-0
LNW21BSH066701
Tighten:
Nozzle holder flange nut to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
N6A0400E
N6A0115E
N6A0462E
LNW91BLF000101
Legend
1. Split collar 4. Valve guide seal
2. Spring upper seat 5. Spring lower seat
3. Valve spring 6. Inlet and exhaust valve
Disassembly
Preparation Do not allow the valve to fall from the cylinder
• Remove all the parts only with the cylinder head head.
assembly left. Valve Spring Compressor: 5-8840-2228-0
(Above works refer to “CYLINDER HEAD GAS- 2. Spring Upper Seat
KET” section in this manual.) 3. Valve Spring
1. Split Collar
1) Place the cylinder head on a flat wooden sur-
face.
2) Use the valve spring compressor to remove the
split collar.
LG4HG-WE-0871.book 91 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH066701 N6A0119E
LNW21BSH016801
LNW21BSH017001 LNW21BSH056701
N6A0123E
(Measuring Method-II)
1. Measure the valve stem outside diameter.
Refer to the “Valve Stem Outside Diameter”.
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
3. Calculate the clearance between the valve guide
inside diameter and the valve stem outside diame-
ter.
If the clearance exceeds the specified limit, the
valve and the valve guide must be replaced as a LNW21BSH017301
set.
Valve Guide Replacement
Valve Guide Removal
Use a hammer and the valve guide replacer to drive out
the valve guide from the cylinder head lower face.
Valve Guide Replacer: 5-8840-2227-0
N6A0124E
LNW21BSH018701
Note:
If the valve guide has been removed, both the valve and
the valve guide must be replaced as a set.
N6A0130E
LNW41ESH000201
Standard Degrees
45°
LNW21BSH068201
LNW21BSH018601
LNW21BSH018401
Reassembly
LNW21BSH018201
1. Spring Lower Seat
LG4HG-WE-0871.book 97 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH016701
Legend
1. Spring pitch
2. Paint mark
LNW21BSH018801
LNW91BMF000501
Legend
1. Camshaft bracket 5. Valve cap
2. Rocker arm 6. Rocker arm shaft
3. Spring 7. Rocker arm shaft assembly
4. Rocker arm bracket
Removal Caution:
Preparation Failure to loosen the rocker arm shaft bracket nuts and
• Disconnect battery ground cable. bolts in numerical order a little at a time will adversely af-
• Tilt the cab. fect the rocker arm shaft.
1. Nozzle Cover Disassembly
2. Cylinder Head Cover 1. Rocker Arm Shaft Assembly
3. Cylinder Head Cover Gasket 1) Loosen the rocker arm shaft bracket nuts and
4. Rocker Arm Shaft Assembly bolts in numerical order a little at a time and re-
1) Loosen the rocker arm shaft bracket nuts and move the rocker arm shaft assembly with the
bolts in numerical order a little at a time and re- camshaft brackets.
move the rocker arm shaft assembly with the 2) Leave the (1) indicated bolt unremoved on this
camshaft brackets. occasion, since it is the rocker arm fixing bolt.
2) Leave the (1) indicated bolt unremoved on this
occasion, since it is the rocker arm fixing bolt. Caution:
Failure to loosen the rocker arm shaft bracket nuts and
bolts in numerical order a little at a time will adversely af-
fect the rocker arm shaft.
LG4HG-WE-0871.book 99 ページ 2008年9月25日 木曜日 午後5時58分
N6A0150E LNW21BSH056601
LNW21BSH019201
Legend
1. Roller
2. Depth gauge
N6A0155E
LG4HG-WE-0871.book 101 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH019401
Reassembly
N6A0158E
Legend
A. Front mark 4. Spring
1. Rocker arm shaft 5. Rocker arm bracket
2. Camshaft bracket 6. Valve cap
3. Rocker arm
N6A0159E LNW21BSH019701
LNW21BSH019601
LNW21BSH066601
LNW21BSH066501
LNW21BSH016301
LG4HG-WE-0871.book 104 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BMH000101
Legend
1. Stud
2. Nuts
3. Mounting rubber
4. Bolts
5. Head cover
6. Gasket
4. Nozzle Cover
• Connect the battery ground cable.
• Lower the cab.
• Start the engine and check for the oil leakage
carefully.
LG4HG-WE-0871.book 105 ページ 2008年9月25日 木曜日 午後5時58分
CAMSHAFT ASSEMBLY
Component
LNW91BMF000101
Legend
1. Camshaft 6. Camshaft bearing lower
2. Camshaft bearing cap 7. Camshaft assembly
3. Camshaft bearing upper 8. Rocker arm shaft assembly
4. Key 9. Valve cap
5. Camshaft gear
Disassembly
1. Rocker Arm Shaft Assembly
2. Valve Cap
3. Camshaft Bearing Cap
4. Camshaft Bearing Upper
5. Camshaft Assembly
6. Camshaft Bearing Lower
Above works refer to “CYLINDER HEAD” section
in this manual.
7. Camshaft Gear
Use the universal puller to pull out the camshaft
gear.
Universal puller: 5-8840-2027-0/5-8840-0086-0
8. Key
N6A0144E
LNW21BSH056201
LG4HG-WE-0871.book 107 ページ 2008年9月25日 木曜日 午後5時58分
N6A0145E N6A0147E
N6A0146E
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit,
the camshaft must be replaced.
N6A0472E
LNW21BSH020301
Installation
1. Camshaft Bearing Lower
2. Camshaft Assembly
1) Turn the crankshaft in the direction of normal
rotation until the timing mark on the crankshaft LNW21BSH015901
damper pulley is aligned with the TDC notched
line. • Tighten the bearing cap bolts and studs to the
2) Apply engine oil to the camshaft journal and the specified torque.
camshaft bearing surfaces before installation.
Tighten:
3) Carefully align the camshaft gear “I” mark and Camshaft bearing cap nut and bolt to 27 N⋅m (2.8 kg⋅m/
the cylinder head upper face shown in the illus- 20 lb⋅ft)
tration.
LG4HG-WE-0871.book 109 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH016001
5. Valve Cap
Apply engine oil to the inside of the valve caps and
install them to the valve stem end.
Caution:
Take sufficient care not to let the valve caps fall into the
gear.
LNW21BSH016201
CYLINDER HEAD
Component
Engine Right Side
LNW91BLF000701
Legend
1. Front exhaust pipe 3. A/C compressor drive belt (If equipped with A/C)
2. A/C compressor (If equipped with A/C)
LG4HG-WE-0871.book 111 ページ 2008年9月25日 木曜日 午後5時58分
N6A0477E
Legend
1. Intake air duct 7. Water bypass hose
2. Vacuum hose 8. PCV hose
3. Nozzle cover 9. Injection pipe
4. Leak off pipe 10. Engine harness
5. Fuel pipe 11. Oil level gauge guide tube
6. Fuel filter and bracket
LG4HG-WE-0871.book 112 ページ 2008年9月25日 木曜日 午後5時58分
N6A0482E
Legend
1. Radiator upper hose 8. Valve cap
2. Coolant reserve tank hose/bypass hose 9. Camshaft bearing cap
3. Cylinder head cover 10. Camshaft bearing upper
4. Cylinder head cover gasket 11. Camshaft assembly
5. Glow plug connector 12. Camshaft bearing lower
6. Injection nozzle holder assembly 13. Cylinder head assembly
7. Rocker arm shaft assembly 14. Cylinder head gasket
N6A0388E
N6A0386E
Legend
1. Fuel filter
2. Leak off
Caution:
Failure to loosen the cylinder head bolts in numerical or-
der a little at a time will adversely affect the cylinder
head lower surface.
N6A0390E
Note:
• During disassembly, be sure that the valve train
components are kept together and identified so
that they can be re-installed in their original loca-
tions.
• Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
make a compression test and note the results.
Disassembly
1. Glow Plug Connector
2. Glow Plug
N6A0483
3. Injection Nozzle Holder Assembly
Mark the nozzle holder assemblies fitting positions
Legend by tagging each nozzle holder assembly with the
1. Glow plug connector cylinder number from which it was removed.
2. Injection nozzle holder assembly 4. Rocker Arm Shaft Assembly
1) Loosen the rocker arm shaft bracket nuts and
7. Rocker Arm Shaft Assembly bolts in numerical order a little at a time and re-
8. Valve Cap move the rocker arm shaft assembly with the
9. Camshaft Bearing Cap camshaft brackets.
10. Camshaft Bearing Upper 2) Leave the (A) indicated bolt unremoved on this
11. Camshaft Assembly occasion, since it is the rocker arm fixing bolt.
LG4HG-WE-0871.book 115 ページ 2008年9月25日 木曜日 午後5時58分
Caution: Caution:
Failure to loosen the rocker arm shaft bracket nuts and Failure to loosen the cylinder head bolts in numerical or-
bolts in numerical order a little at a time will adversely af- der a little at a time will adversely affect the cylinder
fect the rocker arm shaft. head lower surface.
• Refer to Section “CYLINDER HEAD”.
N6A0099E
LNW21BSH002301
5. Valve Cap
Caution: Clean
Take sufficient care not to let valve caps fall into the gear • Cylinder head bolts
case or oil return hole.
• Cylinder head
6. Camshaft Bearing Cap Carefully remove all varnish, soot and carbon to
7. Camshaft Bearing Upper the bare metal. Do not use a motorized wire brush
8. Camshaft Assembly on any gasket sealing surface.
9. Camshaft Bearing Lower Inspection and Repair
If the camshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with Make the necessary adjustments, repairs, and part re-
the cylinder number from which it was removed. placements if excessive wear or damage is discovered
during inspection.
• Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause;
– Improper installation
– Loose or warped cylinder head
– Insufficient torque on head bolts
– Warped case surface
1. Cylinder head bolts for damaged threads or
stretching and damaged heads caused by improp-
er use of tools.
Caution:
Suspected bolts must be replaced.
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
LNW21BSH002201
head and porosity.
10. Cylinder Head Caution:
Loosen the cylinder head bolts in numerical order Do not attempt to weld the cylinder head. Replace it.
a little at a time.
LG4HG-WE-0871.book 116 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH021601
LNW21BSH021501
LNW21BSH001601
Reassembly
Install the cylinder head gasket with its “GRADE IDEN-
TIFICATION HOLE” (1) mark facing up and toward the
left of the engine.
Caution:
Do not reuse the cylinder head gasket.
Above works refer to “CYLINDER BLOCK” section in
this manual.
LG4HG-WE-0871.book 117 ページ 2008年9月25日 木曜日 午後5時58分
Tighten:
Cylinder head bolt to (M10: (19) — (20)) to 38 N⋅m (3.9
kg⋅m / 28 lb⋅ft)
LNW91BSH001401
1. Cylinder Head
1) Align the cylinder block dowels and the cylinder
head dowel holes. LNW21BSH026601
2) Carefully place the cylinder head on the cylin-
der head gasket. 2. Camshaft Bearing Lower
3. Camshaft Assembly
1) Turn the crankshaft in the direction of normal
rotation until the timing mark on the crankshaft
damper pulley is aligned with the TDC notched
line. (Confirm that the No. 1 cylinder piston
comes to the compression top dead center.)
LNW21BSH007901
LNW21BSH015901 LNW21BSH016201
2) Apply a coat of engine oil to the bearing cap 7. Rocker Arm Shaft Assembly
bolt and stud threads. 1) Temporarily tighten the bolts marked with the
3) Tighten the bearing cap bolts and studs to the arrow in the illustration.
specified torque.
Tighten:
Camshaft bearing cap nut and bolt to 27 N⋅m (2.8 kg⋅m
/ 20 lb⋅ft)
LNW21BSH066601
LNW21BSH016301 N6A0115E
LNW21BSH068001 LNW91BSH002601
LNW91BSH001401
Legend
1. Grade identification hole
N6A1628E
5) Apply a 3 mm (0.12 in) bead or recommended
Note: liquid gasket (ThreeBond 1207C) or its equiva-
Note that there are three types of a cylinder head gasket lent to the shaded areas shown in the illustra-
available as below, according to the piston projection. tion.
• For each cylinder, calculate the average value (Ti)
of the piston projection.
• Find the maximum value (Ti max) of the average of
each cylinder.
• Based on the Timax obtained, select a gasket of
the appropriate grade.
LG4HG-WE-0871.book 121 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH015501 LNW21BSH007901
LNW21BSH015601
Tighten:
Nozzle holder flange nut to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
N6A0390E
2. Engine Harness
Connect thermometer unit, thermo switch, tachom-
eter sensor and glow plug harness connector and
fasten the engine harness with clips.
N6A0115E
Tighten:
Fuel pipe joint bolt (2) to 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
LG4HG-WE-0871.book 123 ページ 2008年9月25日 木曜日 午後5時58分
Tighten:
A/C compressor bolt to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
Note:
When tightening the compressor fixing bolts, tighten first
the 2 bolts on the rear side, and then the remaining 2 on
the front side.
N6A0399E
Legend
1. Fuel pipe joint bolt LNW21BSH008601
2. Fuel pipe joint bolt
3. Clip 2. A/C Compressor Drive Belt (If equipped with A/C)
1) Install drive belt adjust belt tension by adjusting
8. Leak Off Pipe bolt and tighten locking nut to the specified
Tighten: torque.
Leak-off pipe joint bolt to 13 N⋅m (1.3 kg⋅m/113 lb⋅in) 2) Depress the drive belt mid-portion with a 98 N
(10 kg/22 lb) force.
N6A0400E
LG4HG-WE-0871.book 124 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH028101
Tighten:
Locking nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
3. Front Exhaust Pipe
Tighten:
Front exhaust pipe to
• Exhaust manifold side: 67 N⋅m (6.8 kg⋅m/49 lb⋅ft)
• Exhaust brake side: 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
• Connect the negative battery cable.
• Lower the cab.
• Start engine and check for oil, fuel and water
leakage carefully.
LG4HG-WE-0871.book 125 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BLF001101
(a) 18 N⋅m (1.8 kg⋅m/ 13 lb⋅ft) (d) M14 1st: 98 N⋅m (10 kg⋅m/ 72 lb⋅ft)
(b) M10 38 N⋅m (3.9 kg⋅m/28 lb⋅ft) 2nd: 147 N⋅m (15 kg⋅m/ 108 lb⋅ft)
(c) 104 N⋅m (10.6 kg⋅m/ 77 lb⋅ft) 3rd: 30 - 60°
(e) 48 N⋅m (4.9 kg⋅m/ 35 lb⋅ft)
LG4HG-WE-0871.book 126 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BLF000801
Legend
1. A/C compressor bracket (If equipped with A/C) 8. Fuel filter bracket
2. Thermostat 9. Inlet cover
3. Water outlet pipe 10. Inlet case
4. Idle gear C 11. Heat protector
5. Idle gear C cover 12. Exhaust manifold
6. Glow plug 13. Exhaust gasket
7. Engine hanger
LNW21BSH001801 LNW91BSH002001
3. Heat Protector
Legend
4. Exhaust Manifold
1. Engine hanger
5. Exhaust Gasket
2. Fuel filter bracket
6. Water Outlet Pipe
7. Thermostat
8. Idle Gear C Cover
Installation
Tap the outside of the sealing cup with a screwdriv- 1. Engine Hanger
er to deform one end of it and draw it out with pliers. 2. Fuel Filter Bracket
Tighten:
Fuel filter bracket bolt to 104 N⋅m (10.6 kg⋅m/77 lb⋅ft)
3. Glow Plug
Tighten:
Glow plug to 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
4. Idle Gear C
1) Apply engine oil to the idle gear shaft, bushing
and idle gear before installation.
2) Install the idle gear with the boss side facing to
the camshaft as shown in the illustration.
Tighten:
Idle gear C bolt to 95 N⋅m (9.7 kg⋅m/70 lb⋅ft)
LNW21BSH054701
9. Idle Gear C
10. Glow Plug
11. Fuel Filter Bracket
12. Engine Hanger
LG4HG-WE-0871.book 128 ページ 2008年9月25日 木曜日 午後5時58分
N6A0503E LNW21BSH021901
LNW21BSH022001
N6A1634E
8. Exhaust Gasket
6. Thermostat Insert the gasket into the stud provided to the cyl-
Install the gaskets to the thermostat and install inder head (with the projection of the gasket on this
them to the cylinder head as shown in the illustra- side).
tion.
LG4HG-WE-0871.book 129 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH062901 LNW21BSH063001
N6A0415E
LNW21BSH001801 N6A1500E
N6A0393E
Legend
1. Inlet cover
LNW21BSH064301 2. Mounting rubber
3. Bolt
2) Install the inlet case to the cylinder head.
• Install the inlet case within 7 minutes after ap- Refer to “CYLINDER HEAD” in this section, install
plication of liquid gasket. the remaining parts.
• Attach harness clips ((1), (6) and (7)) and tight-
en the inlet cover bolts and nuts to the specified
torque in the numerical order shown in the illus-
tration.
LG4HG-WE-0871.book 131 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BMF000701
Legend
1. Tachometer sensor 5. Clutch disc
2. Flywheel housing 6. Clutch pressure plate assembly
3. Flywheel assembly 7. Pilot bearing
4. Washer
Removal
Preparation
• Disconnect battery ground cable.
1. Tachometer sensor
2. Starter
1) Disconnect the battery cable at the starter mo-
tor.
2) Remove the starter assembly from flywheel
housing.
LNW21BSH011601
3. Transmission Assembly
LG4HG-WE-0871.book 132 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH007701
LNW21BSH002501
LNW21BSH072801
LNW21BSH012101
LNW21BSH012001
LG4HG-WE-0871.book 134 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH072801 LNW21BSH002501
LNW21BSH002601
LNW91BSH002301
LNW91BLF001001
Legend
1. Radiator upper hose 7. Crankshaft front slinger
2. Coolant reserve tank hose 8. Crankshaft front oil seal
3. Radiator 9. Crankshaft damper pulley
4. Fan guide 10. Starter
5. Fan assembly 11. Radiator lower hose
6. Fan belt
LNW21BSH011601 LNW21BSH012301
2. Radiator Upper Hose 2) Loosen the damper pulley bolts and remove
3. Coolant Reserve Tank Hose/Bypass Hose the damper pulley.
4. Radiator Lower Hose 9. Crankshaft Front Oil Seal
5. Radiator (with Guide) Caution:
6. Fan Assembly Be careful not to damage the crankshaft oil seal contact
surface during the removal procedure.
LNW21BSH012201
LNW21BSH002801
7. Fan Belt
8. Crankshaft Damper Pulley
Legend
1) Use the crankshaft stopper to prevent the
1. Felt
crankshaft from turning.
Crankshaft Stopper: 5-8840-2230-0 2. Slinger
3. Oil seal
Legend
1. Crankshaft
2. Slinger
3. Adapter bolt
4. Sleeve
5. Adapter
6. Washer (5 mm (0.20 in))
7. Center bolt
LNW21BSH012401
Installation
1. Crankshaft Front Slinger
Press in the slinger using the oil seal setting tool
kit.
Oil Seal Setting Tool Kit: 5-8840-2703-0
Front slinger and oil seal setting tools
N6A0603E
LNW91BSH001101
LG4HG-WE-0871.book 139 ページ 2008年9月25日 木曜日 午後5時58分
LNW71BSH011701 LNW21BSH073301
Legend Legend
1. Adapter 1. Oil seal
2. Sleeve 2. Adapter
3. Slinger 3. Adapter ring
4. 40.2 — 40.8 mm (1.58 — 1.61 in) 4. Fixing bolt
5. 33.9 — 34.1 mm (1.33 — 1.34 in) 5. Sleeve
6. Washer
3) With the slinger pressed in, make sure of mea- 7. Center bolt
surements specified in the illustration as well as
of slinger deflection.
(4): 40.2 — 40.8 mm (1.58 — 1.61 in)
(5): 33.9 — 34.1 mm (1.33 — 1.34 in)
Note:
Be sure to replace the slinger and oil seal as a set.
Use about 5 mm (0.20 in) thickness plain washer on the
center bolt.
2. Crankshaft Front Oil Seal
1) Apply engine oil to the lip of the oil seal.
2) Press in the oil seal using the front oil seal set-
ting tool kit.
• Remove the slinger sleeve and insert the oil
seal into the adapter.
• Install the oil seal sleeve to the adapter and
tighten the center bolt until the sleeve comes to
contact the adapter ring.
LNW91BSH001201
• With the oil seal pressed in, make sure of the
measurements specified in the illustration.
(a): 30.7 — 31.3 mm (1.21 — 1.23 in) Legend
1. Adapter ring
Note: 2. Sleeve
Be sure to replace the slinger and oil seal as a set. 3. Adapter
Use about 5 mm (0.20 in) thickness plain washer on the 4. Oil seal
center bolt. (a) 30.7 — 31.3 mm (1.21 — 1.23 in)
LNW21BSH013501
LNW21CSH000101
4. Fan Belt
Check the drive belt tension. 5. Fan Assembly
Depress the drive belt mid-portion with a 98 N
(10 kg/22 lb) force or measure the drive belt vibra- Tighten:
tion frequency. Fan bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
LNW21BSH012201
LNW21ESH000501
LG4HG-WE-0871.book 141 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH000101
Legend
1. Stud bolt
2. Rubber LNW21BSH011601
3. Washer
4. Flange nut 11. Connect battery ground cable.
5. Flame side bracket • Pour engine coolant into engine.
6. Radiator side bracket
LNW91BSH000101
Legend
1. Nut
2. Rubber
3. Stud bolt
4. Flame side bracket
5. Radiator side bracket
6. Washer
LNW21BLF006701
Legend
1. Starter 5. Flywheel assembly
2. Transmission assembly 6. Crankshaft rear oil seal
3. Clutch pressure plate assembly 7. Crankshaft rear slinger
4. Clutch disc
Removal
Preparation
• Disconnect battery ground cable.
1. Starter
1) Disconnect the battery cable at the starter mo-
tor.
2) Remove the starter assembly from flywheel
housing.
2. Tachometer sensor
LNW21BSH011601
3. Transmission Assembly
LG4HG-WE-0871.book 143 ページ 2008年9月25日 木曜日 午後5時58分
N6A6504E
LNW21BSH002901
Legend
1. Washer Installation
2. Pilot bearing 1. Crankshaft Rear Slinger
Press in the slinger using oil seal setting tool kit.
7. Crankshaft Rear Oil Seal • Insert the slinger (1) into the end of adapter (2)
Caution: and install the adapter on the crankshaft.
Be careful not to damage the crankshaft oil seal contact
surface during the removal procedure.
N6A0618E
LNW21BSH014301 LNW91BSH000901
Legend Legend
1. Crankshaft 1. Crankshaft
2. Adapter 2. Slinger
3. 17.0 — 17.6 mm (0.67 — 0.69 in) 3. Adapter
4. 10.7 — 10.9 mm (0.42 — 0.43 in) 4. Adapter bolt
5. Slinger 5. Collar
6. Sleeve 6. Sleeve
7. Collar 7. Center bolt
• Make sure of measurements specified in the il- 2. Crankshaft Rear Oil Seal
lustration as well as of slinger deflection. 1) Apply engine oil to the lip of the oil seal.
(3): 17.0 — 17.6 mm (0.67 — 0.69 in) 2) Press in the oil seal using rear oil seal setting
(4): 10.7 — 10.9 mm (0.42 — 0.43 in) tool kit.
Note: • Remove the slinger sleeve and insert the oil
Be sure to replace the slinger and oil seal as a set. seal (2) into the adapter (7).
• Install the adapter ring into the sleeve.
Oil Seal Setting Tool Kit: 5-8840-2703-0
• Install the oil seal sleeve (6) to the adapter (7)
Rear slinger and oil seal setting tools
and tighten the center bolt until the sleeve
comes to contact the adapter ring (5).
Part Name Stamp Slinger Oil Seal
Adapter RR ❍ ❍
Sleeve RR ❍ ❍
Oil seal adapter ring RR ❍
Center bolt — ❍ ❍
Adapter bolt — ❍ ❍
Adapter bolt collar RR ❍ ❍
LNW21BSH014801
LG4HG-WE-0871.book 145 ページ 2008年9月25日 木曜日 午後5時58分
N6A6504E
Legend
LNW91BSH001001 1. Washer
2. Pilot bearing
Legend
1. Oil seal 5) Remove the crankshaft stopper.
2. Adapter 4. Clutch Disc
3. Adapter ring 5. Clutch Pressure Plate Assembly
4. Adapter bolt Above works refer to “FLYWHEEL AND PILOT
5. Collar BEARING” section in this manual.
6. Sleeve 6. Transmission Assembly
7. Center bolt Above works refer to “ENGINE ASSEMBLY” sec-
tion in this manual.
3. Flywheel Assembly 7. Tachometer sensor
1) Apply a coat of molybdenum disulfide grease to Tighten:
the flywheel bolt threads and setting faces. Tachometer sensor bolt to 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
2) Align the flywheel with the crankshaft knock pin
and temporarily tighten the flywheel bolts.
3) Use the crankshaft stopper to prevent the
crankshaft from turning.
Crankshaft Stopper: 5-8840-2230-0
4) Install the washer and the flywheel bolts and
tighten to the specified torque in numerical or-
der show in the illustration.
Tighten:
Flywheel bolt to
• 1st step: 78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
• 2nd step: 90 — 120°
LNW91BSH002301
8. Starter
Tighten:
Starter bolt to 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
LG4HG-WE-0871.book 146 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH011601
LNW91BLF000201
Legend
1. Cylinder head assembly 8. Connecting rod
2. Cylinder head gasket 9. Connecting rod bearing
3. Piston pin snap ring 10. Piston and connecting rod
4. Piston pin 11. Connecting rod cap
5. Piston ring 12. Oil pump strainer
6. Piston pin snap ring 13. Oil pan
7. Piston 14. Cylinder block
Disassembly Caution:
1. Cylinder Head Assembly Do not reuse the cylinder head gasket.
Above works refer to “CYLINDER HEAD” section
3. Oil Pan
in this manual.
4. Oil Pump Strainer
2. Cylinder Head Gasket
LG4HG-WE-0871.book 148 ページ 2008年9月25日 木曜日 午後5時58分
N6A0193E LNW21BSH005001
5. Connecting Rod Cap 2) Remove the piston and connecting rod assem-
1) Take out the connecting rod bearing cap bolts bly upward by pushing on the edge of the con-
and remove the bearing cap with the lower necting rod with a hammer handle or
bearing. equivalent.
2) If the connecting rod lower bearings are to be 3) If the connecting rod bearing are to be rein-
reinstalled, mark their fitting positions by tag- stalled, mark their fitting positions by taggfing
ging each bearing with the cylinder number each bearing with the cylinder number from
from which it was removed. which it was removed.
Caution:
Do not bend or damage the oiling jet.
Note:
When removing the piston and connecting rod assem-
bly, pull the connecting rod in parallel with the cylinder
bore.
7. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled,
mark their fitting positions by tagging each bearing
with the cylinder number from which it was re-
moved.
8. Piston Ring
1) Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2) Use piston ring replacer to remove the piston
rings.
LNW21BSH004901
Do not attempt to use some other tool to re-
6. Piston and Connecting Rod Assembly move the piston rings. Piston ring stretching will
1) To facilitate smooth removal of piston, remove result in reduced piston ring tension.
carbon from the upper part of the cylinder wall
using a scraper or equivalent.
LG4HG-WE-0871.book 149 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH065001 LNW21BSH009301
9. Piston Pin Snap Ring 2. Push the piston ring into the cylinder liner bore until
Use a pair of snap ring pliers to remove the piston it reaches the point where the cylinder liner bore is
pin snap rings. the smallest.
10. Piston Pin Do not allow the piston ring to slant to one side or
11. Connecting Rod the other. It must be perfectly horizontal.
12. Piston
Measuring Point mm (in)
If the pistons are to be reinstalled, mark their instal-
lation positions by tagging each piston with the cyl- Approx. 150 (6)
inder number from which it was removed.
Piston Ring
Piston Ring Gap
1. Insert the piston ring horizontally (in the position it
would assume if it were installed to the piston) into
the cylinder liner bore.
LNW61BSH000901
LNW21BSH009601
Piston Pin
Piston Pin Diameter N6A0262E
Use a micrometer to measure the piston pin outside di-
ameter at several points. If an inside dial indicator is not available, use the follow-
If the measured value is less than the specified limit, the ing procedure to check the piston pin clearance.
piston pin must be replaced.
LG4HG-WE-0871.book 151 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH009701
Connecting Rod
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion
and the parallelism between the connecting rod big end
hole and the connecting rod small end hole.
If either the measured distortion or parallelism exceeds
the specified limit, the connecting rod must be replaced.
LNW21BSH010401
LG4HG-WE-0871.book 152 ページ 2008年9月25日 木曜日 午後5時58分
LNW46ASH005001 LNW21BSH010001
3. Set the connecting rod bushing replacer base (2) to 4. Install the two collars (4) and the new bushing (5)
the bench press. to the setting bar (1).
4. Set the connecting rod to the connecting rod bush- Align the bushing clinch line and the collar setting
ing replacer base. marks.
5. Tighten the bolt (1). Tighten the nut (3).
LNW21BSH010001 LNW21BSH009901
6. Use the bench press to force the bushing from the 5. Use the bench press to press the new bushing into
connecting rod. position inside the connecting rod.
Connecting Rod Bushing Installation Check that the bushing oil holes and the connect-
1. Set the connecting rod bushing replacer base (2) to ing rod oil holes are aligned.
the bench press. 6. Use a pinhole grinder to finish the new bushing.
Connecting Rod Bushing Replacer: 5-8840-2340-0
Connecting Rod Small End Bushing mm (in)
2. Set the connecting rod to the connecting rod re-
Inside Diameter
placer base.
The connecting rod must be perfectly horizontal. 36.012 — 36.022 (1.4178 — 1.4182)
3. Tighten the bolt (1) to hold the connecting rod small
end in place.
LG4HG-WE-0871.book 153 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH010301 LNW91BSH001501
LNW21BSH011001
3. Connecting Rod
1) Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2) Install the connecting rod so that the piston
head front mark (1) and the connecting rod
forging mark (projecting) (2) are set in the same LNW91BSH001301
direction.
Legend
1. 1st compression ring
2. 2nd compression ring
3. Oil ring
LG4HG-WE-0871.book 154 ページ 2008年9月25日 木曜日 午後5時58分
Note:
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil before
installing the oil ring.
Install the compression rings with the stamped side fac-
ing up.
2) Apply engine oil to the piston ring surfaces.
3) Check to see if the piston rings rotate smoothly
in the piston ring grooves.
7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from
the connecting rod bearing back face and the con-
necting rod bearing fitting surface.
LNW91BSH001601
Legend
1. 1st compression ring
2. 2nd compression ring
3. Oil ring
4. Front mark
Caution:
Do not bend or damage the oiling jet.
9. Connecting Rod Cap
1) Install the connecting rod bearing caps.
2) Align the bearing cap cylinder number marks
(1) and the connecting rod cylinder number
marks (1).
3) Apply a coat of molybdenum disulfide grease to
the threads and setting faces of each connect-
ing rod cap bolts.
LG4HG-WE-0871.book 155 ページ 2008年9月25日 木曜日 午後5時58分
N6A0279E
Legend
1. Alignment
2. Boss discriminating the front from the rear
LNW21BSH011401
CRANKSHAFT
Component
N6A1640E
LG4HG-WE-0871.book 157 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. Engine cover 29. Crankshaft front slinger
2. Nozzle cover 30. Flywheel
3. Cylinder head cover 31. Crankshaft rear oil seal
4. Cylinder head cover gasket 32. Crankshaft rear slinger
5. Rocker arm shaft assembly 33. Spacer rubber
6. Valve cap 34. Oil pan
7. Camshaft bearing cap 35. Oil pump strainer
8. Camshaft bearing upper 36. Water pump pulley
9. Camshaft assembly 37. Water pump
10. Camshaft bearing lower 38. Front cover
11. Cylinder head assembly 39. Oil thermo valve
12. Cylinder head gasket 40. Power steering pump idle gear cover
13. Clutch pressure plate assembly 41. Power steering pump idle gear
14. Clutch disc 42. Flywheel housing
15. Engine control wire 43. Idle gear A
16. Engine control lever assembly 44. Oil pump assembly
17. Oil pipe 45. Connecting rod cap assembly
18. Oil filter assembly 46. Connecting rod lower bearing
19. Vacuum pump oil pipe 47. Piston and connecting rod assembly
20. Vacuum pump rubber hose 48. Crankcase
21. Fan belt 49. Thrust bearing lower
22. Generator 50. Crankshaft bearing lower
23. Engine foot 51. Crankshaft assembly
24. Injection pump assembly 52. Thrust bearing upper
25. Fan belt adjust plate 53. Crankshaft bearing upper
26. Generator bracket 54. Crankshaft gear
27. Crankshaft pulley 55. Crankshaft
28. Crankshaft front oil seal
N6A0631E
N6A0426E
N6A0630E
Legend
1. Vacuum pump oil pipe
2. Vacuum pump rubber hose
LNW21BSH058801 LNW21BSH007701
26. Generator Bracket 2) Loosen the damper pulley bolts and remove
the damper pulley.
28. Crankshaft Front Oil Seal
29. Crankshaft Front Slinger
Above works refer to ““CRANKSHAFT FRONT OIL
SEAL” section in this manual.
30. Tachometer sensor
31. Flywheel
1) Use the crankshaft stopper to prevent the
crankshaft from turning
Crankshaft Stopper: 5-8840-2230-0
N6A0293E
LNW21BSH007701
N6A6504E N6A0639E
N6A0640E
LNW21BSH023801
Disassembly
1. Crankshaft Gear
1) Use the crankshaft gear remover to remove the
crankshaft gear.
LNW21BSH023601
Crankshaft Gear Remover: 8-9439-6818-0
49. Thrust Bearing Lower
50. Crankshaft Bearing Lower
LNW21BSH023901
LNW21BSH054801
Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit, the
bearing must be replaced.
LNW21BSH024001 Bearing Spread mm (in)
N6A0206E
LNW91BSH000801
LNW21BSH025201
LG4HG-WE-0871.book 164 ページ 2008年9月25日 木曜日 午後5時58分
Example:
1 2 1 1 2
LNW21BSH024801
↑ ↑ ↑ ↑ ↑
No.1 No. 2 No. 3 No. 4 No. 5
Bearing Bearing Bearing Bearing Bearing
Housing Housing Housing Housing Housing
LNW21BSH024701
N6A0211E
Crankpin and Connecting Rod Bearing Clearance 5. Tighten the bearing cap to the specified torque.
1. Clean the crankshaft, the connecting rod, the bear- Tighten:
ing cap, and the bearings. Connecting rod bearing cap bolt to
2. Install the bearing to the connecting rod and the • 1st step: 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
bearing cap.
• 2nd step: 60°
3. Apply a coat of molybdenum disulfide grease to the
• 3rd step: 30°
bearing cap bolt threads and setting faces.
6. Use the dial indicator to measure the connecting
4. Prevent the connecting rod from moving.
rod bearing inside diameter.
LG4HG-WE-0871.book 166 ページ 2008年9月25日 木曜日 午後5時58分
N6A0212E N6A0213E
N6A0214E
LNW21BSH024101 LNW21BSH024301
5. Place the Plastigage (arrow) over the crankshaft 7. Tighten the crankcase to the specified torque in the
journal across the full width of the bearing. numerical order shown in the illustration.
Tighten:
Crankcase bolt (M14: (1) — (10)) to
• 1st step: 98 N⋅m (10 kg⋅m / 72 lb⋅ft)
• 2nd step: 132 N⋅m (13.5 kg⋅m / 98 lb⋅ft)
• 3rd step: 30 — 60°
LNW21BSH024201
N6A1415E
Tighten:
Crankcase bolt (M10: (1) — (17)) to 3.9 N⋅m (28 kg⋅m /
38 lb⋅ft)
LG4HG-WE-0871.book 168 ページ 2008年9月25日 木曜日 午後5時58分
Tighten:
Connecting rod bearing cap bolt to
• 1st step: 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
• 2nd step: 60°
• 3rd step: 30°
7. Remove the bearing cap.
8. Compare the width of the Plastigate attached to ei-
ther the crankshaft or the bearing against the scale
printed on the Plastigage container.
N6A0219E
Legend
1. Alignment mark
Installation
1. Crankshaft Bearing Upper
When replacing the crankshaft or the crankshaft
bearing with a new one, select the crankshaft bear-
ing according to the respective grades stamped on
the crankshaft and the cylinder block.
Refer to the “CRANKSHAFT”.
All upper bearings have oil grooves.
N6A0223E
Reassembly
1. Crankshaft
2. Crankshaft Gear
1) Use a piston heater to heat the crankshaft gear
to 170 — 250°C (338 — 482°F).
2) With the alignment mark “S” on the side of the
crankshaft gear turned outward, align the
groove on the gear side with the crankshaft pin
position and hammer it in with a crankshaft
gear installer until it hits the bottom.
Caution: LNW21BSH025201
When hammered in with the gear slanted, the crank-
shaft gear may be caught in the middle and cannot be 1) Carefully wipe any foreign material from the up-
hammered in fully. Hammer it inquickly enough not to al- per bearing.
low a shaft line along the gear and the crankshaft to Caution:
slant. Do not apply engine oil to the bearing back faces and
Crankshaft Gear Installer: 8-9439-6819-0 the cylinder block bearing fitting surfaces.
2) Locate the position mark applied at disassem-
bly if the removed upper bearings are to be re-
used.
2. Thrust Bearing Upper
Install the thrust bearing upper to the front side of
the cylinder block No.5 journal. At this time, the
thrust bearing upper may be pasted to the cylinder
block with grease.
However, be sure to wipe off any excessive
grease.
Caution:
The thrust bearing oil grooves must be facing the sliding
faces.
LNW21BSH025101
LG4HG-WE-0871.book 171 ページ 2008年9月25日 木曜日 午後5時58分
Caution:
The thrust bearing oil grooves must be facing the sliding
faces.
LNW21BSH025301
3. Crankshaft Assembly
Apply an ample coat of engine oil to the crankshaft
journals and the crankshaft bearing surfaces be-
fore installing the crankshaft with timing gear.
• While pressing on the installed crankshaft to-
ward the rear side, insert the thrust bearing up-
per into the rear side of the cylinder block No.5
journal.
Caution: N6A0650E
LNW21BSH025401
N6A1622E
Legend
1. Liquid gasket
N6A1415E
LG4HG-WE-0871.book 173 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH000801 N6A1623E
N6A0657E
LNW21BSH026101
Legend
1. Pulley
2. Set plate
Legend
1. Washer
2. Pilot bearing
LNW21BSH013501
LNW91BSH002301
Tighten:
Fan belt adjust plate bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
LG4HG-WE-0871.book 176 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH058801
N6A0631E
32. Generator
Note:
When tightening the generator, tighten in advance the
fan belt temporarily after its adjustment.
• Insert through the lower fixing bolt from the rear
side as shown in the illustration, and tighten it LNW21CSH000101
with a nut on the front side.
33. Fan Belt 34. Vacuum Pump Rubber Hose (12)
Check the drive belt tension. 35. Vacuum Pump Oil Pipe (11)
Depress the drive belt mid-portion with a 98 N Tighten:
(10 kg/22 lb) force or measure the drive belt vibra- Vacuum pump oil pipe to
tion frequency.
• Cylinder block side: 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
• Generator side: 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
LG4HG-WE-0871.book 177 ページ 2008年9月25日 木曜日 午後5時58分
N6A0286E N6A0448E
LNW21HSH000301
N6A0449E
37. Oil Pipe
Tighten: 40. Clutch Disc
Oil pipe joint bolt to 17 N⋅m (1.7 kg⋅m/12 lb⋅ft) 41. Clutch Pressure Plate Assembly
Above works refer to “FLYWHEEL AND PILOT
BEARING” section in this manual.
42. Cylinder Head Gasket
Above works refer to “CYLINDER HEAD” section
in this manual.
43. Cylinder Head Assembly
Above works refer to “CYLINDER HEAD” section
in this manual.
44. Camshaft Bearing Lower
45. Camshaft Assembly
46. Camshaft Bearing Upper
47. Camshaft Bearing Cap
48. Valve Cap
LG4HG-WE-0871.book 178 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BLF001201
(a) 1st: 39 N⋅m (4.0 kg⋅m/ 29 lb⋅ft) (d) 200 N⋅m (20.4 kg⋅m/ 148 lb⋅ft)
2nd: 60° (e) M14 1st: 98 N⋅m (10 kg⋅m/ 72 lb⋅ft)
3rd: 30° 2nd: 132 N⋅m (13.5 kg⋅m/ 98 lb⋅ft)
(b) 21 N⋅m (2.1 kg⋅m/ 15 lb⋅ft) 3rd: 30 - 60°
(c) 1st: 78 N⋅m (8.0 kg⋅m/ 58 lb⋅ft) (f) M10 37 N⋅m (3.8 kg⋅m/ 27 lb⋅ft)
2nd: 90 - 120° (g) 11 N⋅m (1.1 kg⋅m/ 95 lb⋅in)
LG4HG-WE-0871.book 180 ページ 2008年9月25日 木曜日 午後5時58分
CYLINDER BLOCK
Component
N6A1641E
LG4HG-WE-0871.book 181 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. Engine assembly 34. Cover
2. Nozzle cover 35. Crankshaft pulley
3. Cylinder head cover 36. Crankshaft front oil seal
4. Cylinder head cover gasket 37. Crankshaft front slinger
5. Rocker arm shaft assembly 38. Flywheel assembly
6. Valve cap 39. Crankshaft rear oil seal
7. Camshaft bearing cap 40. Crankshaft rear slinger
8. Camshaft bearing upper 41. Spacer rubber
9. Camshaft assembly 42. Oil pan
10. Camshaft bearing lower 43. Oil pump strainer
11. Cylinder head assembly 44. Water pump pulley
12. Cylinder head gasket 45. Water pump
13. Clutch pressure plate assembly 46. Front cover
14. Clutch disc 47. Oil thermo valve
15. Engine control wire 48. Power steering pump idle gear cover
16. Engine control lever assembly 49. Power steering pump idle gear
17. Oil pipe 50. Flywheel housing
18. Oil filter assembly 51. Idle gear A
19. Tachometer sensor 52. Idle gear B
20. Fuel pipe bracket 53. Idle gear B shaft
21. Vacuum pump oil pipe 54. Oil pump assembly
22. Vacuum pump rubber hose 55. Connecting rod cap
23. Fan belt 56. Connecting rod lower bearing
24. Generator 57. Piston and connecting
25. Engine foot 58. Crankcase
26. Injection pump assembly 59. Thrust bearing lower
27. Injection pump rubber spacer 60. Crankshaft bearing lower
28. Idle pulley bracket 61. Crankshaft assembly
29. Heater pipe 62. Thrust bearing upper
30. Water suction pipe 63. Crankshaft bearing upper
31. Oil cooler assembly 64. Piston oil jet
32. Fan belt adjust plate 65. Cylinder block
33. Generator bracket
LNW21BSH002501 N6A0425E
LNW21HSH000301
N6A0630E N6A0426E
LNW21HSH000701
N6A0631E
LNW21BSH058801
LNW21HSH001001
32. Generator Bracket
29. Water Suction Pipe
30. Oil Cooler Assembly
1) Remove the oil cooler bolts.
N6A0293E
33. Cover
LNW21HSH005701
N6A0294E
LG4HG-WE-0871.book 185 ページ 2008年9月25日 木曜日 午後5時58分
N6A6504E
Legend
1. Washer
LNW21BSH007701 2. Pilot bearing
2) Loosen the damper pulley bolts and remove 39. Crankshaft Rear Seal
the damper pulley.
40. Crankshaft Rear Slinger
35. Crankshaft Front Oil Seal Above works refer to “CRANKSHAFT REAR OIL
36. Crankshaft Front Slinger SEAL” section in this manual.
Above works refer to “CRANKSHAFT FRONT OIL 41. Oil Pan
SEAL” section in this manual. 42. Oil Pump Strainer
37. Tachometer sensor
38. Flywheel Assembly
1) Use the crankshaft stopper to prevent the
crankshaft from turning
Crankshaft Stopper: 5-8840-2230-0
N6A0193E
N6A0639E LNW91BSH000401
LNW21BSH070601
N6A0177E
N6A0562E
54. Connecting Rod Cap
51. Idle Gear B 55. Connecting Rod Lower Bearing
52. Idle Gear B Shaft 56. Piston and Connecting Rod Assembly
Above works refer to “PISTON AND CONNECT-
ING ROD” section in this manual.
57. Crankcase
1) Loosen the crankcase bolts in numerical order
a little at a time.
2) Install the three crankcase fixing bolts (See ar-
row marks) to the crankcase replacer holes as
shown in the illustration, and tighten the bolts
alternate a little at a time.
Note:
When removing the crankcase, be sure to remove the oil
pump and the generator bracket before that.
N6A0695E
LNW21BSH023601
LNW21BSH023701 LNW21BSH026401
LNW21BSH023801
LNW21BSH026701
LG4HG-WE-0871.book 189 ページ 2008年9月25日 木曜日 午後5時58分
N6A0299E
Note:
The inside of the dry type cylinder liner is made of thin
cast iron. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or scorched,
the cylinder liner must be replaced.
Cylinder Liner Projection Inspection
Use a dial gauge to measure the projection of each cyl-
inder.
5. Reinstall the cylinder liner. The difference in the cylinder liner projection height be-
Refer to the “Cylinder Block Bore Measurement”. tween any two adjacent cylinders must not exceed 0.03
6. Reinstall the cylinder block dowel. mm (0.0012 in).
LNW21BSH026801
Caution:
All foreign material must be carefully removed from the
cylinder liner and the cylinder bore before installation.
3. Install the cylinder liner perpendicularly to the cyl-
inder bore. Do not give any excessive force such
as knocking while inserting cylinder liner into the
cylinder bore.
N6A0306E
Caution:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will result
in engine failure. Always measure the cylinder bore and
select the correct piston grade.
2. Measure the piston outside diameter (Reference).
LNW21BSH027101
Piston Measuring Point (4): 82 mm (3.23 in)
Piston Grade Selection
Cylinder Liner and Piston mm (in)
Measure the cylinder liner bore after installing the cylin- Clearance
der liner. Then select the appropriate piston grade for
the installed cylinder liner. 0.081 — 0.116 (0.0032 — 0.0046)
1. Measure the cylinder liner bore.
Refer to the “Cylinder Liner Bore Measurement”.
Measuring Point (1) 20 mm (0.79 in)
Measuring Point (2) 90 mm (3.54 in)
Measuring Point (3) 160 mm (6.30 in)
N6A0307E
Piston Grade
Cylinder Liner Bore Piston Piston Outside
Diameter Service Diameter
mm (in) Grade mm (in)
115.041 — 114.944 —
115.060 (4.5292 — — 114.959 (4.5253
4.5299) — 4.5259)
Caution:
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in slight
decreases in cylinder liner clearances. Always measure
the cylinder liner clearance after installation to be sure
that it is correct.
Installation LNW21BSH025201
1. Cylinder Block
Use compressed air to thoroughly clean the inside 1) Carefully wipe any foreign material from the up-
and outside surfaces of the cylinder block, the oil per bearing.
holes, and the water jackets.
Caution:
2. Oiling Jet Do not apply engine oil to the bearing back faces and
1) Install the oiling jets together with the check the cylinder block bearing fitting surface.
valves.
Take care not to damage the oiling jet nozzles. 2) Locate the position mark applied at disassem-
bly if the removed upper bearings are to be re-
2) Tighten the check valves and oiling jets to the
used.
specified torque.
4. Thrust Bearing Upper
Tighten: Install the thrust bearing upper to the front side of
Check valve and oiling jet to 21 N⋅m (2.1 kg⋅m/15 lb⋅ft) the cylinder block No.5 journal. At this time, the
thrust bearing upper may be pasted to the cylinder
block with grease.
However, be sure to wipe off nay excessive
grease.
Caution:
The thrust bearing oil grooves must be facing the sliding
faces.
LNW21BSH026401
5. Crankshaft Assembly
LG4HG-WE-0871.book 193 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH025401
Caution:
The thrust bearing oil grooves must be facing the sliding
faces.
N6A0650E
LG4HG-WE-0871.book 194 ページ 2008年9月25日 木曜日 午後5時58分
N6A1622E
Legend
1. Liquid gasket
N6A1415E
LG4HG-WE-0871.book 195 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH000801 LNW21BSH003801
LNW21BSH003701
LNW21BSH007801
14. Idle Gear B
The face of the idle gear B with longer boss should
be positioned toward the rear side shown in the il-
lustration
Tighten:
Idle gear B bolt to 110 N⋅m (11.2 kg⋅m/81 lb⋅ft)
LG4HG-WE-0871.book 196 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH000501 LNW91BSH000601
16. Flywheel Housing • Tighten the bolts marked with “d” from the injec-
1) Carefully wipe any foreign material from the cyl- tion pump side, and those with “c” from the cyl-
inder block rear face. inder block side.
2) As shown in the diagram, uniformly apply liquid 17. Power Steering Pump Idle Gear
gasket (ThreeBond 1207C) to the inside of the 1) Apply the engine oil to the idle gear shaft.
bolt hole (excluding the bolt hole at the arrow). 2) Install the idle gear shaft with the idle gear to
the cylinder block portion as shown in the illus-
tration.
Tighten:
Idle gear shaft bolt to 133 N⋅m (13.6 kg⋅m/98 lb⋅ft)
LNW21BSH072401
Tighten:
Flywheel housing bolt to
• (a): 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
• (b): 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
• (c): 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
• (d): 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
• (e): 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
LG4HG-WE-0871.book 197 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH004301 LNW21BSH070601
18. Power Steering Pump Idle Gear Cover 20. Front Cover
Install the gear cover with the O-ring. 1) Carefully wipe any foreign material from the cyl-
inder block front face.
Tighten:
Gear cover bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft) 2) Apply a 2.5 — 3.5 mm (0.10 — 0.14 in) bead of
the recommended liquid gasket (ThreeBond
1207C) or its equivalent on the groove of the
front cover fitting surface shown in the illustra-
tion.
3) Install the O-rings (2 pieces) to the front cover.
• Install the front cover within 7 minutes after ap-
plication of the liquid gasket.
• For the dislocation of liquid gasket, refer to the
illustration.
4) Align the cylinder block knock pins with the
front cover knock pin holes.
Tighten:
Front cover bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
LNW91BSH000701
N6A1623E
LG4HG-WE-0871.book 198 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. O-ring
2. Liquid gasket
N6A1625E
Legend
1. Liquid gasket
LNW21BSH059001
22. Water Pump Pulley
21. Water Pump Assembly Tighten:
1) Apply 3 — 4 mm (0.12 — 0.16 in) bead of the Water pump pulley bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
recommended liquid gasket (ThreeBond
1207C) or its equivalent on the water pump fit-
ting surface.
2) Install the water pump to the front cover.
Tighten:
Water pump bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
• Install the water pump within 7 minutes after
application of liquid gasket.
• For the dislocation of liquid gasket, refer to the
illustration.
Caution:
The water pump clamping bolt is also used to tighten the
front cover. So, install the water pump before liquid gas-
ket gets dry immediately after installation of the front
cover.
LNW21BSH026101
Legend
1. Pulley
2. Set plate
Tighten:
Oil pump strainer bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
LG4HG-WE-0871.book 199 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. Washer
2. Pilot bearing
N6A0657E
N6A6504E
LG4HG-WE-0871.book 200 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH013501 N6A0293E
LNW21BSH058801
N6A0294E
35. Oil Cooler Assembly
33. Generator Bracket
1) Apply 2 — 3 mm (0.08 — 0.12 in) bead of the
Tighten: recommended liquid gasket (ThreeBond
Generator bracket bolt to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) 1207C) or its equivalent on the oil cooler fitting
surface.
2) Apply a coat of engine oil to the O-rings (2 piec-
es) and install the O-rings to the oil cooler.
LG4HG-WE-0871.book 201 ページ 2008年9月25日 木曜日 午後5時58分
N6A1626E
Legend
1. O-ring
2. Liquid gasket
N6A1627E
Note:
Take care that the O-ring does not get smeared with liq- Legend
uid gasket. 1. Liquid gasket
• Install the oil cooler within 7 minutes after appli-
cation of the liquid gasket. Tighten:
• For the dislocation of the liquid gasket, refer to Water suction pipe bolt and nuts to 24 N⋅m (2.4 kg⋅m/17
the illustration. lb⋅ft)
3) Tighten the oil cooler bolts and nut to the spec-
ified torque a little at a time in the sequence Note:
shown in the illustration. Install the water suction pipe immediately after the in-
stallation of the oil cooler.
Tighten:
Oil cooler bolt and nut to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
N6A0322E
Tighten:
Heater pipe bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
N6A0631E
42. Generator
LNW21HSH001001
Note:
When tightening the generator, tighten in advance the
38. Idle Pulley Bracket (If equipped with A/C)
fan belt temporarily after its adjustment.
Tighten:
• Insert through the lower fixing bolt from the rear
Idle pulley bracket bolt to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
side as shown in the illustration, and tighten it
with a nut on the front side.
LNW21HSH000701
LNW21ESH000601
39. Injection Pump Rubber Spacer
40. Injection Pump Assembly 43. Fan Belt
Above works refer to “INJECTION PUMP ASSEM- Check the drive belt tension.
BLY” section in this manual. Depress the drive belt mid-portion with a 98 N
41. Engine Foot (10 kg/22 lb) force or measure the drive belt vibra-
Tighten: tion frequency.
Engine foot bolt to 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
Drive Belt Deflection mm (in) / Hz
New belt 7 — 9 (0.28 — 0.35) / 140 — 170
Reuse belt 9 — 10 (0.35 — 0.39) / 121 — 139
LNW21ESH000501 N6A0286E
LNW21HSH000301
N6A0449E LNW21BSH002501
LNW91BMH000101
Legend
1. Mounting rubber
2. Nut
3. Bolt
4. Stud bolt
5. Gasket
6. Head cover
MEMO
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LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Engine Cooling
(4HG1)
TABLE OF CONTENTS
GENERAL DESCRIPTION ...................................1C-2
Water Pump.......................................................1C-3
Thermostat ........................................................1C-3
Radiator .............................................................1C-4
Specified Coolant Solution ................................1C-4
WATER PUMP......................................................1C-6
Component ........................................................1C-6
Removal ............................................................1C-6
Inspection ..........................................................1C-7
Installation .........................................................1C-7
THERMOSTAT .....................................................1C-9
Component ........................................................1C-9
Removal ............................................................1C-9
Inspection ..........................................................1C-9
Installation .......................................................1C-10
RADIATOR..........................................................1C-11
Component ......................................................1C-11
Removal ..........................................................1C-11
Inspection ........................................................1C-12
Installation .......................................................1C-13
DRIVE BELT ADJUSTMENT ..............................1C-14
Component ......................................................1C-14
Inspection ........................................................1C-14
List of Tightening Torques ...............................1C-16
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
GENERAL DESCRIPTION
LNW91CLF000101
Legend
1. Radiator cap 8. Water jacket
2. Heater core 9. Drain plug
3. Reserve tank 10. Oil cooler
4. Air bleeding 11. Water pump
5. Water outlet pipe 12. Cooling fan
6. Thermostat 13. Drain plug
7. Thermometer unit 14. Radiator
The engine cooling system consists of the radiator, the now circulating through the radiator for effective engine
water pump, the cooling fan, and the thermostats. cooling.
To quickly increase cold engine coolant temperature for Engine coolant change procedure.
smooth engine operation, the coolant is circulated by the 1. To change engine coolant, make sure that the en-
water pump and thermostats through the by-pass hose gine is cool.
and back to the cylinder block. The coolant does not cir-
culate through the radiator. WARNING:
Warning:
When the coolant temperature reaches 82°C (180°F), WHEN THE COOLANT IS HEATED TO A HIGH TEM-
the thermostat will begin to open and a gradually in- PERATURE, BE SURE NOT TO LOOSEN OR RE-
creasing amount of coolant will circulate through the ra- MOVE THE RADIATOR CAP. OTHERWISE YOU
diator. MIGHT GET SCALDED BY HOT VAPOR OR BOILING
The thermostats will be fully open when the coolant tem- WATER. TO OPEN THE RADIATOR CAP, PUT A
perature reaches 100°C (212°F). All of the coolant is PIECE OF THICK CLOTH ON THE CAP AND LOOS-
LG4HG-WE-0871.book 3 ページ 2008年9月25日 木曜日 午後5時58分
Caution:
A failure to correctly fill the engine cooling system in
changing or topping up coolant may sometimes cause
the coolant to overflow from the filler neck even before
the engine and radiator are completely full.
If the engine runs under this condition, shortage of cool-
ant may possibly result in engine overheating. To avoid
such trouble, the following precautions should be taken
in filling the system.
3. To refill engine coolant, pour coolant up to filler
neck using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between
the filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Fill the coolant slowly to avoid it from flowing out.
And also, the coolant overflow will increase, mak- N6A0790E
N6A0792E
Legend
A. With jiggle valve
Radiator
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of coolant a pressurized radia-
tor is attached. LNW91CSH000101
Mixing ratio
Specified coolant solution (Lit/qt.)
=
Specified coolant solution (Lit/qt.) + water (Lit/qt.)
Note:
Specified coolant solution + Water = Total cooling sys-
tem capacity.
LNW91CSH000201
LNW46BSH001001
LNW91CMH000101
WATER PUMP
Component
LNW91CMF000101
Legend
1. Radiator lower hose 4. Fan belt
2. Fan guide 5. Water pump pulley
3. Fan 6. Water pump assembly
Removal
Preparation
• Disconnect battery ground cable.
• Drain coolant.
• Tilt the cab.
LNW91CSH000301
LNW21BSH012201
4. Fan Belt
5. Water Pump Pulley
6. Water Pump Assembly LNW21CSH001001
Inspection Installation
Make the necessary adjustments, repairs, and part re- 1. Water Pump Assembly
placements if excessive wear or damage is discovered
1) Apply 3 — 4 mm (0.12 — 0.16 in) bead of the
during inspection.
recommended liquid gasket (ThreeBond
Water Pump Assembly 1207C) or its equivalent on the water pump fit-
ting surface.
1. Check the pump body for crack and damage.
2) Install the water pump to the front cover.
2. Check the impeller for crack and corrosion.
3. Check the seal unit leakage. Tighten:
4. If there is any abnormal condition, replace the wa- Water pump bolt to 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
ter pump as an assembly. • Install the water pump within 7 minutes after appli-
cation of liquid gasket.
• For the dislocation of liquid gasket, refer to the il-
lustration.
LNW21CSH000901
N6A1625E
LG4HG-WE-0871.book 8 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. Liquid gasket
Caution:
The water pump clamping bolt is also used to tighten the
front cover. So, install the water pump before liquid gas-
ket gets dry immediately after installation of the front
cover.
2. Water Pump Pulley
Tighten:
Water pump pulley bolt to 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
LNW21ESH000501
LNW21BSH026101
Legend
1. Pulley
2. Set plate
3. Fan Belt
Check the drive belt tension.
Depress the drive belt mid-portion with a 98 N
(10 kg / 22 lb) force or measure the drive belt vibra-
tion frequency.
THERMOSTAT
Component
LNW91CLF000201
Legend
1. Radiator upper hose 3. Thermostat
2. Water outlet pipe
Removal Inspection
Preparation Make the necessary adjustments, repairs, and part re-
• Disconnect battery ground cable placements if excessive wear or damage is discovered
during inspection.
• Drain coolant
Operating Test
1. Radiator Upper Hose
1. Completely submerge the thermostat in water.
Disconnect radiator upper hose from radiator.
2. Heat the water.
2. Water Outlet Pipe
Stir the water constantly to avoid direct heat being
Remove mounting bolt and remove outlet pipe to-
applied to the thermostat.
gether with radiator upper hose.
3. Check the valve initial opening temperature.
3. Thermostat
LG4HG-WE-0871.book 10 ページ 2008年9月25日 木曜日 午後5時58分
Legend
1. With jiggle valve
2. Without jiggle valve
Tighten:
Water outlet pipe bolt to 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
N6A0806E
Legend
1. Thermometer
2. Agitating rod
3. Wooden piece
4. Thermostat
5. Heat
Installation
1. Thermostat
Install the gaskets to the thermostats and the ther- LNW21BSH022001
mostats to the cylinder head as shown in the illus-
tration. 3. Radiator Upper
• Connect battery ground cable.
• Pour coolant
• Start the engine and check coolant leakage.
LG4HG-WE-0871.book 11 ページ 2008年9月25日 木曜日 午後5時58分
RADIATOR
Component
LNW91CLF000301
Legend
1. Radiator upper hose 4. Fan guide
2. Coolant reserve tank hose 5. Radiator lower hose
3. Radiator
Removal
• Disconnect battery ground cable.
• Tilt the cab.
• Loosen drain plug to drain coolant.
LG4HG-WE-0871.book 12 ページ 2008年9月25日 木曜日 午後5時58分
LNW91CSH000401 LNW21BSH000201
1. Radiator Upper Hose 2. Check the state of the negative pressure valve sit-
2. Radiator Lower Hose uated at the center on the valve seat side of the
Disconnect upper hose and lower hose from the ra- cap. If the valve seat does not function smoothly
diator. due to rust or dirt, clean or replace the radiator cap.
3. Coolant Reserve Tank Hose Coolant Leaks Inspection
4. Fan Guide • Add 200kPa (2.0 kg/cm2 /28 psi) pressure using
the radiator cap tester to inspect for leaks in the fol-
5. Radiator
lowing locations.
1) Remove upward the radiator assembly with
hose, taking care not to damage the radiator – Radiator assembly
core by fan blade. – Water pump assembly
– Radiator hose
– Heater hose
• Inspect the radiator hose and heater hose for dam-
age or wear. Check that the hose clamps are not
loose.
LNW91CSH000501
Inspection
Radiator cap
1. Check the valve opening pressure using the radia-
tor cap tester. If the valve opening pressure devi- LNW41CSH000101
ates from the standard value, replace the radiator
cap. Radiator Core
Valve opening pressure = 1. Deformed radiator fins could reduce radiation ef-
108 ± 14.7 kPa (1.1 ± 0.15 kg/cm2 / 15.7 ± 2.1 psi) fects, resulting in overheat. Straighten the fins. In
such a case, take care not to damage the fin roots.
2. Remove dust and other foreign materials.
LG4HG-WE-0871.book 13 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH000101
Legend
1. Stud bolt
2. Rubber
3. Washer
4. Flange nut
5. Flame side bracket
6. Radiator side bracket
LNW46BSH000101
LG4HG-WE-0871.book 14 ページ 2008年9月25日 木曜日 午後5時58分
LNW21CMF000501
Legend
1. Crank pulley 8. Adjust plate
2. Generator drive belt 9. A/C compressor drive belt
3. Generator fixing bolt 10. Water pump pulley
4. Generator 11. Tension pulley lock nut
5. Adjusting bolt 12. Tension pulley
6. A/C compressor 13. Adjusting bolt
7. Adjust plate lock nut
Inspection
A/C Drive Belt Deflection mm (in)
Check drive belts for wear or damage, and replace with
new ones as necessary. Check belts for tension, and New belt 16 — 20 (0.63 — 0.79)
adjust as necessary. Reuse belt 18 — 22 (0.71 — 0.87)
1. Check drive belts tension
2. Push the middle of belts with a force of 98 N (10 kg
/ 22 lb) and check each belt for deflection or vibra-
tion frequency.
LNW21BSH028101
Legend
1. Belt deflection
Tension Adjustment
(Refer to the illustration on the previous page.)
1. Generator & Water Pump Pulley Drive Belt
1) Loosen the Air Conditioning (A/C) drive belt
tension pulley adjust bolt and lock nut (11).
Then free the A/C drive belt.
2) Loosen the adjust plate lock nut (7), the fixing
bolt, and the fixing bolts (3) on the lower side of
the generator.
3) Rotate the adjust bolt to adjust the belt.
4) After adjustment, tighten each section to the
specified torque.
Tighten:
Bolt and nut to
• (7): 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
• (3): 40 N⋅m (4.1 kg⋅m /30 lb⋅ft)
5) Adjust the A/C drive belt tension.
2. A/C Compressor Drive Belt
1) Loosen the tension pulley lock nut (11), and ro-
tate the adjust bolt to adjust the belt.
When finishing the fan drive belt adjustment,
then adjust the A/C drive belt.
After adjustment, tighten the lock nut (11) to the
specified torque.
Tighten:
Lock nut (11) to 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft).
LG4HG-WE-0871.book 16 ページ 2008年9月25日 木曜日 午後5時58分
LNW91CLF000401
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (d) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (e) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (f) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Engine Fuel
(4HG1)
TABLE OF CONTENTS
GENERAL DESCRIPTION ...................................1D-2
Fuel Flow ...........................................................1D-3
Injection Nozzle .................................................1D-5
Injection Nozzle .................................................1D-5
Fuel Filter and Water Separator ........................1D-5
FUEL FILTER ASSEMBLY........................................1D-6
Component ........................................................1D-6
Removal ............................................................1D-6
Installation .........................................................1D-6
Cartridge Replacement......................................1D-6
INJECTION NOZZLE ASSEMBLY........................1D-8
Component ........................................................1D-8
Removal ............................................................1D-8
Disassembly ....................................................1D-10
Reassembly.....................................................1D-11
Installation .......................................................1D-13
INJECTION PUMP ASSEMBLY....................................1D-15
Component ......................................................1D-15
Removal ..........................................................1D-15
Installation .......................................................1D-17
INJECTION TIMING ADJUSTMENT ..................1D-20
Injection Pump Notched Line Inspection .........1D-20
Injection Volume Adjustment ...........................1D-21
FUEL TANK ........................................................1D-24
Component ......................................................1D-24
Removal ..........................................................1D-24
Installation .......................................................1D-25
FUEL TANK UNIT ...............................................1D-26
Component ......................................................1D-26
Removal ..........................................................1D-26
Installation .......................................................1D-26
List of Tightening Torques ...............................1D-27
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
GENERAL DESCRIPTION
Caution
When working on the fuel system, there are several
things to keep in mind:
• Any time the fuel system is being worked on, dis-
connect the negative battery cable except for those
tests where battery voltage is required.
• Always keep a dry chemical (Class B) fire extin-
guisher near the work area.
• Replace all pipes with the same pipe and fittings
that were removed.
• Clean and inspect “O” rings. Replace where re-
quired.
• Always relieve the line pressure before servicing
any fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pic-
tures relating to that repair.
Description
Fuel Filters
The Purpose of the fuel filters is to clean the fuel of any
dirt particles that can cause wear on the fuel injection
nozzle’s sliding surface; and to separate any water from
the fuel, which is ever-present from the condensation in
the fuel tank. The pre-fuel filter (water separator) is lo-
cated between the fuel tank and the injection pump. The
secondary fuel filter is located between the fuel pump
and the injection pump.
Pre-Fuel Filter
When the condensed water in the pre-fuel filter (water
separator) comes to the warning level indicated on its
plastic body, drain the fluid immediately from the drain
plug located bottom of water separator.
Injection Pump
The fuel injection system includes a fuel tank, fuel hoses
and lines, a fuel/water separator, fuel filters, a fuel
pump, a Bosch-type in-line fuel injection pump with an
internal governor, delivery valves, fuel injection lines
and for fuel injection nozzles.
The fuel pump, injection pump and the nozzle are man-
ufactured by Bosch AS corporation, but serviced by
Bosch.
Remove the injection pump and governor assembly as
a unit to have it services. Do not open or break any seals
on the pump or the warranty is void. The injection pump
has an identification plate attached to the pump body.
LG4HG-WE-0871.book 3 ページ 2008年9月25日 木曜日 午後5時58分
N6A0817E
Legend
A. Feed 3. Fuel tank
B. Return 4. Fuel filter
1. Nozzle 5. Injection pump
2. Water separator
LG4HG-WE-0871.book 4 ページ 2008年9月25日 木曜日 午後5時58分
N6A0819E
Legend
1. Control rack 7. Full load set screw
2. Sensor lever 8. Boost compensator lever
3. U-shaped lever 9. Aneroid compensator spring
4. Torque cam 10. Bellows
5. Push rod B 11. Return spring
6. Cancel spring 12. Push rod C
LG4HG-WE-0871.book 5 ページ 2008年9月25日 木曜日 午後5時58分
N6A0825E
N6A0827E
Legend
1. Fuel pipe 2. Fuel filter
Removal Pump the primer pump until fuel flow is free of air
bubbles.
Preparation
• Lock the priming pump cap.
• Disconnect battery ground cable.
• Tilt the cab Note:
1. Fuel Pipe Check for fuel leakage from around the injection pump
and the fuel filter.
2. Fuel Filter Assembly
N6A0830E
Legend
1. Air bleeding plug
2. Pre-fuel filter
3. Drain level
4. Drain plug
N6A0014E
N6A0839E
Legend
1. Nozzle cover 3. Injection pipe
2. Leak off pipe 4. Injection nozzle assembly
N6A0841E N6A0843E
N6A0842E
Inspection
Before disassembling the injection nozzle assembly,
check nozzle opening pressure, spray pattern, chatter
and oil leakage.
N6A0029E
Opening Pressure
Use a nozzle tester to check the injection nozzle open-
Leakage
ing pressure.
Hold the tester handle to about 2,070 kPa (21 kg/cm2/
If the opening pressure is above or below the specified
300 psi) below the opening pressure. If no drops of fuel
value, the injection nozzle must be replaced or adjusted.
fall from the nozzle tip within 10 seconds, the nozzle is
Injection Nozzle Opening MPa (kg/cm2/psi) not leaking.
Pressure Chatter
An easily audible chatter at all pump lever speeds
4HG1 18.1 (185/2,631) should be heard.
WARNING:
Warning:
TEST FLUID FROM THE INJECTION NOZZLE WILL
SPRAY OUT UNDER GREAT PRESSURE. IT CAN
LG4HG-WE-0871.book 10 ページ 2008年9月25日 木曜日 午後5時58分
N6A0845E
Legend
1. Flange
2. Retaining nut
3. Injection nozzle
4. Spacer
5. Spring seat
6. Nozzle spring
7. Adjusting shim
8. Nozzle holder body
1. Flange
2. Retaining Nut N6A0847E
N6A0846E
LG4HG-WE-0871.book 11 ページ 2008年9月25日 木曜日 午後5時58分
N6A0847E
N6A0845E
Legend
1. Flange
2. Retaining nut
3. Injection nozzle
2. Carefully wash the needle valve and the nozzle 4. Spacer
body in clean diesel fuel after lapping. 5. Spring seat
Nozzle Body and Needle Valve 6. Nozzle spring
Check the nozzle body and the needle valve for damage 7. Adjusting shim
and deformation. 8. Nozzle holder body
The nozzle and body assembly must be replaced if ei-
ther of these two conditions are discovered during in- 1. Nozzle Holder Body
spection. 2. Adjusting Shim
3. Nozzle Spring
Note:
New nozzles must be cleaned in a solvent to remove 4. Spring Seat
protective coating. 5. Spacer
6. Injection Nozzle
LG4HG-WE-0871.book 12 ページ 2008年9月25日 木曜日 午後5時58分
N6A0852E
7. Retaining Nut
Clamp the injection nozzle holder in a vice.
Tighten the injection nozzle holder retaining nut to
the specified torque.
N6A0843E
Tighten:
Injection nozzle holder retaining nut to 34 N⋅m (3.5 kg⋅m Opening Pressure Adjustment
/ 25 lb⋅ft) 1. Clamp the injection nozzle holder (1) in a vise (2).
2. Use a wrench to remove the injection nozzle retain-
ing nut (3).
N6A0846E
N6A0856E N6A0029E
Spray Pattern
Check the spray condition.
Refer to the illustration.
N6A0889E
Spray Condition
• Correct (1) 2) Tighten the nozzle holder flange nuts to the
• Incorrect (Restrictions in orifice) (2) specified torque in the numerical order.
• Incorrect (Dripping) (3) Tighten:
If the spray condition is bad, the injection nozzle must be Nozzle holder flange nuts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
replaced or adjusted.
LG4HG-WE-0871.book 14 ページ 2008年9月25日 木曜日 午後5時58分
N6A0115E
N6A0893E
LG4HG-WE-0871.book 15 ページ 2008年9月25日 木曜日 午後5時58分
N6A0894E
Legend
1. Intake air duct 10. Fuel feed hose
2. Vacuum hose 11. Nozzle cover
3. Oil level guide tube 12. Leak off pipe
4. Engine stop cable 13. Fuel pipe
5. Accelerator control cable 14. Fuel filter assembly
6. Engine control wire 15. PCV hose
7. Engine control lever 16. Injection pipe
8. Oil pipe 17. Injection pump assembly
9. Fuel return hose 18. Injection rubber spacer
Removal
Preparation
• Disconnect the battery ground cable
• Drain coolant
1. Intake Air Duct
2. Vacuum Hose
3. Oil Level Guide Tube
• Remove the guide tube fixing bolt and pull out
the guide tube.
LG4HG-WE-0871.book 16 ページ 2008年9月25日 木曜日 午後5時58分
N6A0895E N6A0898E
N6A0930E
N6A0901E N6A0903E
N6A0904E
Installation
1. Injection Pump Rubber Spacer
1) Stick the rubber spacer to the location indicated
in the illustration with pressure sensitive adhe-
sive double coated tape.
N6A0902E
Legend
1. TDC
N6A0904E
Note: N6A0907E
N6A0906E
LG4HG-WE-0871.book 19 ページ 2008年9月25日 木曜日 午後5時58分
Caution:
Make absolutely sure that the clip is correctly positioned.
An improperly positioned clip will result in injection pipe
breakage and fuel pulsing noise.
Tighten:
Clip screw to 3 N⋅m (0.3 kg⋅m / 26 lb⋅in)
3) Tighten the injection pipe sleeve nuts to the
specified torque.
Tighten:
Injection pipe sleeve nut to 29 N⋅m (3 kg⋅m / 22 lb⋅ft)
4. PCV Hose
5. Fuel Filter
Tighten:
Fuel filter bracket bolt to 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
N6A0908E
6. Fuel Pipe
7. Leak Off Pipe
Legend
8. Nozzle Cover
1. Pointer
9. Fuel Feed Hose
2. Timer outside mark
10. Fuel Return Hose
3. Timing check hole
11. Oil Pipe
3. Fuel Injection Pipe 12. Engine Control Lever
1) Install the injection pipe assembly and tempo- 13. Engine Control Wire
rarily tighten the injection pipe sleeve nuts. 14. Accelerator Control Cable
2) Set the clips in the prescribed position shown in 15. Engine Stop Cable
the illustration. 16. Oil Level Guide Tube
17. Vacuum Hose
18. Intake Air Duct
N6A1631E
LG4HG-WE-0871.book 20 ページ 2008年9月25日 木曜日 午後5時58分
N6A0932E
N6A0933E
Item Condition
Injection nozzle and holder assembly Bosch AS Part No.: 105118-6041
Injection nozzle Bosch AS Part No.: 105017-1850
Nozzle holder Bosch AS Part No.: 105048-3673
Injection nozzle opening pressure kPa (kg/cm2 / psi) 18,142 (185 / 2,631)
Injection line dimensions
Inside diameter mm (in) 2.0 (0.079)
Outside diameter mm (in) 6.0 (0.236)
Length mm (in) 600 (23.6)
Fuel delivery pressure kPa (kg/cm2 / psi) 156.9 (1.6 / 22.75)
Test fuel SAE Standard Test Diesel Fuel (SAE J967d)
ISO Standard Test Diesel Fuel (ISO 4113)
Test fuel temperature °C (°F) 40 — 45 (104 — 113)
Identification numbers 101401-7430
101401-7440
LG4HG-WE-0871.book 22 ページ 2008年9月25日 木曜日 午後5時58分
Injection Volume
N6A1657E
LG4HG-WE-0871.book 24 ページ 2008年9月25日 木曜日 午後5時58分
FUEL TANK
Component
LNW91DLF000101
Legend
1. Fuel feed hose 7. Fuel tank bracket
2. Fuel return hose 8. Band
3. Fuel tank breather 9. Fill cap
4. Fuel tank unit 10. Fuel tank
5. Roll over valve 11. Drain plug
6. Frame
Installation
1. Fuel Tank
Note:
When the bracket was removed to take off the fuel tank,
install the bracket to the frame and tighten it to the spec-
ified torque.
Tighten:
Fuel tank bracket to 54 N⋅m (5.5 kg⋅m / 40 lb⋅ft)
Also, when mounting the fuel tank to the bracket, place
the packing section attached to the fuel tank securely on
the bracket.
2. Band
• Tighten the band to 13 N⋅m (1.3 kg⋅m /113 lb⋅in)
3. Fuel Tank Unit Connector
• Connect the fuel tank unit connector.
4. Fuel Return Hose
5. Fuel Feed Hose
• Set the hose to the pipe more than 25 mm (0.98
in) deep.
6. Breathose Fuel Hose
• Fill the fuel to the fuel tank.
• Connect battery ground cable.
LG4HG-WE-0871.book 26 ページ 2008年9月25日 木曜日 午後5時58分
LNW91DMF000101
Legend
1. Frame 3. Fuel tank unit connector
2. Fuel tank unit 4. Fuel tank
Removal
Preparation
Disconnect the Battery ground cable.
1. Fuel Tank Unit Connector
• Disconnect the fuel tank unit connector from
the fuel tank unit.
2. Fuel Tank Unit
• Remove the fuel tank unit fixing screw and fuel
tank unit.
Note:
After removing fuel tank unit, cover fuel tank with waste
to prevent any dust entering
Installation
1. Fuel Tank Unit
2. Fuel Tank Unit Connector
• Connect the wiring connector to the fuel tank
unit.
LG4HG-WE-0871.book 27 ページ 2008年9月25日 木曜日 午後5時58分
LNW91DLF000201
(a) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft) (i) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(b) 3 N⋅m (0.3 kg⋅m/26 lb⋅in) (j) 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
(c) 23 N⋅m (2.3 kg⋅m/17 lb⋅ft) (k) 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
(d) 34 N⋅m (3.5 kg⋅m/25 lb⋅ft) (l) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(e) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft) (m) 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
(f) 42 N⋅m (4.3 kg⋅m/31 lb⋅ft) (n) 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
(g) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) (o) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(h) 14 N⋅m (1.4 kg⋅m/122 lb⋅in) (p) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
MEMO
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LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Engine Electrical
(4HG1)
TABLE OF CONTENTS
BATTERY.............................................................. 1E-2
General Description........................................... 1E-2
Diagnosis........................................................... 1E-2
On-vehicle Service ............................................ 1E-3
Main Data and Specifications ............................ 1E-4
STARTING SYSTEM ............................................ 1E-5
Component ........................................................ 1E-5
ON-VEHICLE SERVICE ....................................... 1E-9
Component ........................................................ 1E-9
Removal ............................................................ 1E-9
Installation ....................................................... 1E-10
STARTER MOTOR ............................................. 1E-11
Component ...................................................... 1E-11
Disassembly .................................................... 1E-13
Inspection and Repair...................................... 1E-15
Reassembly..................................................... 1E-19
CHARGING SYSTEM ......................................... 1E-22
Component ...................................................... 1E-22
DIAGNOSIS ........................................................ 1E-23
ON-VEHICLE SERVICE ..................................... 1E-26
Component ...................................................... 1E-26
Removal .......................................................... 1E-26
Installation ....................................................... 1E-26
GENERATOR ..................................................... 1E-29
Component ...................................................... 1E-29
Disassembly .................................................... 1E-30
Inspection and Repair...................................... 1E-31
Reassembly..................................................... 1E-37
Inspection ........................................................ 1E-39
List of Tightening Torques ............................... 1E-42
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
BATTERY
General Description
There are six battery fluid caps at the top of the battery.
The battery is completely sealed except for the six small
vent holes at the side. These vent holes permit the es-
cape of small amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire ser-
vice life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an excessive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery flu-
id.)
3. The battery is much less vulnerable to self-dis-
charge than a conventional type battery. N6A0983E
Diagnosis
Legend
Visual Inspection 1. Battery
Inspect the battery for obvious physical damage, such 2. Upper level
as a cracked or broken case, which would permit elec- 3. Lower level
trolyte loss.
Replace the battery if obvious physical damage is dis-
covered during inspection. Voltage Check
Check for any other physical damage and correct it as 1. Put voltmeter test leads to battery terminals.
necessary. If not, proceed to “Hydrometer check”. a. VOLTAGE IS 12.4V OR ABOVE - Go to “Load
test”.
Hydrometer Check
b. VOLTAGE IS UNDER 12.4V - Go to procedure
There is a built-in hydrometer (Charge test indicator) at 2 below.
the top of the battery. It is designed to be used during di-
2. Determine fast charge amperage from specifica-
agnostic procedures.
tion.
Before trying to read the hydrometer, carefully clean the
(See Main Data and Specifications in this section).
upper battery surface.
If your work area is poorly lit, additional light may be nec- Fast charge battery for 30 minutes at amperage
essary to read the hydrometer. rate no higher than specified value.
a. BLUE RING OR DOT VISIBLE - Go to “Voltage Take voltage and amperage readings after charge.
check”. a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
b. BLUE RING OR DOT NOT VISIBLE - Go to AMPERAGE RATE - Replace battery.
“Fluid level check”. b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE - Drop charging voltage to
Fluid Level Check 15V and charge for 10 — 15 hours.
The fluid level should be between the upper level line Then go to “Load test”.
and lower level line on side of the battery. c. VOLTAGE IS BETWEEN 12V AND 16V - Con-
a. CORRECT FLUID LEVEL - Charge the battery. tinue charging at the same rate for an additional
b. BELOW LOWER LEVEL - Replace battery. 3-1/2 hours. Then go to “Load test”.
d. VOLTAGE IS BELOW 12V - Replace battery.
Load Test
1. Connect a voltmeter and a battery load tester
across the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery.
Remove load.
LG4HG-WE-0871.book 3 ページ 2008年9月25日 木曜日 午後5時58分
WARNING:
Warning:
NEVER ATTACH THE END OF THE JUMPER CABLE
DIRECTLY TO THE NEGATIVE TERMINAL OF THE
DEAD BATTERY.
5. Start the engine of the vehicle with the good bat-
tery.
Make sure that all unnecessary electrical accesso-
ries have been turned “OFF”.
N6A0984E
6. Start the engine of the vehicle with the dead bat-
tery. Installation
7. To remove the jumper cables, follow the above di-
To install the battery, follow the removal procedure in
rections in the reverse order.
the reverse order, noting the following points:
1. Make sure that the rod is hooked on the body side.
STARTING SYSTEM
Component
Starting Circuit
The cranking system consists of a battery, starter, starter switch, starter relay, etc. and these main components are
connected as shown in figure. For details of the starting circuit.
LNW21EMF001901
Legend
1. Pinion clutch 6. “B” terminal
2. Ring gear 7. Starter relay
3. Shift lever 8. Starter switch
4. Magnetic switch 9. Battery
5. “S” terminal 10. Starter
Starter
The starting system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts
of magnetic switch are closed, and the armature rotates.
At the same time, the plunger is attracted, and the pinion
is pushed forward by the shift lever to mesh with ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from ring gear,
and the armature stops rotation. When the engine speed
is higher than the pinion, the pinion idles, so that the ar-
mature is not driven.
LG4HG-WE-0871.book 6 ページ 2008年9月25日 木曜日 午後5時58分
LNW91ELF000501
LG4HG-WE-0871.book 7 ページ 2008年9月25日 木曜日 午後5時58分
LNW21EMF000901
Legend
1. Brush 5. Clutch
2. Yoke 6. Pinion
3. Magnetic switch 7. Armature
4. Torsion spring
LG4HG-WE-0871.book 8 ページ 2008年9月25日 木曜日 午後5時58分
ON-VEHICLE SERVICE
Component
Starter
LNW91EMF000101
Legend
1. Starter earth cable 3. Terminal B
2. Starter assembly 4. Terminal S
Removal
Preparation
• Disconnect the battery ground cable (both batter-
ies).
1. Starter Earth Cable
LNW21ESH001501
LNW21ESH001001
Installation
1. Starter Wiring Connector
LNW21ESH001401
Legend
1. Terminal B
2. Terminal S
2. Starter Assembly
LG4HG-WE-0871.book 11 ページ 2008年9月25日 木曜日 午後5時58分
STARTER MOTOR
Component
S25-501B
LNW91ELF000101
Legend
1. Bearing retainer 14. Torsion spring
2. Pinion 15. Magnetic switch assembly
3. Ball bearing 16. Terminal cover
4. Pinion clutch 17. Shift lever
5. Ball bearing 18. Through bolt
6. Return spring 19. Rear cover
7. Pinion stopper 20. Brush holder
8. Pinion stopper clip 21. O-ring
9. Ball bearing 22. Yoke
10. Bearing holder 23. Armature ball bearing
11. Bolt 24. Armature
12. Gear case 25. Armature ball bearing
13. Dust cover
LG4HG-WE-0871.book 12 ページ 2008年9月25日 木曜日 午後5時58分
LNW91ELF000201
Legend
1. Bearing retainer 15. Gear case
2. Clip 16. Dust cover
3. Pinion stopper 17. Torsion spring
4. Pinion 18. Magnetic switch assembly
5. Cushion spring 19. Terminal cover
6. Sleeve cover 20. Shift lever
7. Stopper washer 21. Through bolt
8. Ball bearing 22. Rear cover
9. Pinion clutch 23. Brush holder
10. Return spring 24. O-ring
11. Pinion stopper 25. Yoke
12. Pinion stopper clip 26. O-ring
13. Ball bearing 27. Armature ball bearing
14. Bearing holder 28. Armature
LG4HG-WE-0871.book 13 ページ 2008年9月25日 木曜日 午後5時58分
RTW46DSH003201
5. Armature
6. Yoke
RTW46DSH002601 Remove the brush holder and pull the armature as-
sembly from the yoke.
2. Through Bolt
Remove the four brushes from the brush holders.
3. Rear Cover
Remove the through bolts, then remove the rear
cover.
RTW46DSH003001
N6A0998E RTW46DSH002801
RTW46DSH003401
N6A1002E
Armature
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
RTW56DSH000701
Commutator Run-Out mm (in)
Standard Limit Legend
0.05 (0.002) or less 0.2 (0.008) 1. Insulator
2. 0.5 to 0.8 mm (0.020 to 0.031 in)
3. Commutator segments
4. Correct
5. Incorrect
RTW46DSH003501
RTW46DSH003701
RTW46DSH003801
RTW46DSH003601
LG4HG-WE-0871.book 17 ページ 2008年9月25日 木曜日 午後5時58分
RTW46DSH003901
RTW46DSH004001
LG4HG-WE-0871.book 18 ページ 2008年9月25日 木曜日 午後5時58分
N6A1014E N6A1016E
2) File away any foreign material clinging to the 10) Repeat the procedure for each of the brushes.
edge of the lead wire.
3) Remove the brushes from the brush holder.
Overrunning Clutch
4) Install the new brushes. 1. Inspect the overrunning clutch gear teeth for ex-
cessive wear and damage.
5) Straighten the bent portion of the clip.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
N6A1015E
RTW46DSH004401 RTW46DSH005901
RTW46DSH004701
Reassembly
1. Gear Case
2. Magnetic Switch Assembly
3. Torsion Spring
4. Shift Lever
1) Attach the torsion spring to the hole in the mag-
netic switch as illustrated.
RTW46DSH004601
RTW46DSH005601 LNW61DSH002801
2) Insert the shift lever into the plunger hole of the 9. Return Spring
magnetic switch. 10. Pinion Stopper
5. Dust Cover 11. Pinion Stopper Clip
Install the dust cover. 12. Ball Bearing
6. Bolt 13. Bearing Holder
Install the magnetic switch assembly in the gear
14. Clutch Assembly
case and tighten the bolt to the specified torque.
15. Bearing Retainer
16. Armature
17. Yoke
18. Brush Holder
RTW46DSH005701
Tighten:
Gear case bolt to 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
RTW46DSH004501
7. Pinion Clutch
8. Pinion Shaft 1) Twist the holder spring and hold it.
Apply a coat of grease to the pinion clutch gear and 2) Install the brush to the brush holder.
install the pinion assembly to the armature shaft. 3) Repeat step 1 and 2 for the reaming holders.
4) Install the brush holder assembly to the yoke.
LG4HG-WE-0871.book 21 ページ 2008年9月25日 木曜日 午後5時58分
N6A1027E RTW46DSH002601
LNW61DSH002901
MFW81ESH000201
Tighten:
Through bolt to 6 N⋅m (0.6 kg⋅m / 52 lb⋅in) In measuring the dimension, pull the pinion out a little in
21. Lead Wire Nut the arrow direction.
Connect the lead wire in the magnetic switch and
tighten the terminal nut to the specified torque. mm (in)
Dimension Standard
a 0.3 — 0.1 (0.01 — 0.004)
CHARGING SYSTEM
The charging system is the IC integral regulator charging system and its main components are connected as shown
in figure.
The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator in-
stalled on the rear end cover.
The generator does not require particular maintenance such as voltage adjustment. The rectifier connected to the
stator coil has nine diodes to transform A.C. voltage into D.C. voltage. This D.C. voltage is connected to the output
terminal of generator.
Component
LNW21EMF000201
Legend
1. Pulley 8. Ball bearing
2. Ball bearing 9. Oil seal
3. Fan 10. Vacuum pump
4. Stator 11. Rear cover
5. Rotor 12. Slip ring
6. Brush 13. Through bolt
7. IC regulator 14. Front cover
LG4HG-WE-0871.book 23 ページ 2008年9月25日 木曜日 午後5時58分
DIAGNOSIS
General On-Vehicle Inspection
The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on
when the starter switch is turned to “ON” position. The charging system operates normally if the lamp goes off when
the engine starts. If the warning lamp shows abnormality or if undercharged or overcharged battery condition is sus-
pected, perform diagnosis by checking the charging system as follows:
1. Check visually the belt and wiring connector.
2. With the engine in stop status, turn the starter
switch to “ON” position and observe the warning
lamp.
• If lamp does not come on:
Disconnect wiring connector from generator,
and ground the terminal “L” on connector side.
• If lamp comes on:
Repair or replace the generator.
LG4HG-WE-0871.book 24 ページ 2008年9月25日 木曜日 午後5時58分
LNW71EMF001101
Legend
1. Stator 6. Charge warning light (LED)
2. Rotor 7. Heater relay
3. Charge relay 8. IC Regulator
4. Key switch 9. Generator
5. Batteries
LG4HG-WE-0871.book 25 ページ 2008年9月25日 木曜日 午後5時58分
LNW71EMF001201
Legend
1. Stator 6. Charge warning light (LED)
2. Rotor 7. Heater relay
3. Charge relay 8. IC Regulator
4. Key switch 9. Generator
5. Batteries
Primary Specifications
ON-VEHICLE SERVICE
Component
Generator
LNW41ELF000101
Legend
1. A/C compressor 5. ACG harness
2. A/C compressor drive belt 6. Fan belt
3. Vacuum pump oil pipe 7. Adjust plate
4. Vacuum hose 8. Generator
LNW21ESH000601 LNW21CSH000101
N6A1040E
Tighten:
Vacuum pump oil pipe to
• Cylinder block side: 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
• Generator side: 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)
LNW21ESH000501
Note:
When installing the compressor fixing bolts, tighten first
the 2 bolts on the rear side, and then the remaining 2 on
the front side.
LNW21BSH028101
LNW21BSH055101
Tighten:
Locking nut to 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
• Connect the negative battery cable.
• Lower the cab.
LG4HG-WE-0871.book 29 ページ 2008年9月25日 木曜日 午後5時58分
GENERATOR
Component
LNW91ELF000301
Legend
1. Pulley nut 15. IC regulator
2. Pulley 16. Terminal nut and bolt
3. Fan 17. Rectifier
4. Front cover 18. Oil seal
5. Front ball bearing 19. Rear cover
6. Bearing retainer 20. Through bolt
7. Spacer 21. Vacuum pump body
8. Rotor 22. Vane
9. Stator 23. Rotor
10. Brush guide 24. O-ring
11. Ball bearing 25. Vacuum pump rear cover
12. Fan guide 26. Vacuum pump assembly
13. Condenser 27. Rear cover assembly
14. Brush holder
LG4HG-WE-0871.book 30 ページ 2008年9月25日 木曜日 午後5時58分
N6A1044E
N6A1047E
Legend
1. Taping
LG4HG-WE-0871.book 31 ページ 2008年9月25日 木曜日 午後5時58分
N6A1048E N6A1050E
RTW46DSH000401
N6A1051E
Note:
Hold the lead wire between the solder and the rectifier
with a pair of long nose pliers. Slip Ring Diameter mm (in)
This will prevent heat transfer and resultant dam- Standard Limit
age to the rectifier. 37.6 (1.480) 36.6 (1.441)
Refer to “INSPECTION AND REPAIR” for the IC
regulator, the rectifier, the brush holder, and the If the slip ring diameter is less than the specified limit,
condenser replacement procedures. the slip rings must be replaced.
LG4HG-WE-0871.book 32 ページ 2008年9月25日 木曜日 午後5時58分
N6A1054E
N6A1052E
Legend
Rotor Coil Resistance at ohms 1. Ball bearing
20°C (68°F)
• Check to see if the ball bearings rotate lightly
Standard 12.6 with no noise heard.
• As the result of inspection, it is found that the
4. Check for continuity between the slip rings and the
ball bearing do not rotate lightly or any noises
rotor core or shaft.
are heard, replace them with new ones.
Stator
1. Check for continuity across the stator coils.
N6A1053E
LNW76DSH000701
HCW31ESH004401
2. Rectifier
N6A1050E
N6A1060E
Oil Seal
Check the rear cover oil seal bore for oil leakage.
Oil Seal Replacement
1. Use a screwdriver to remove the oil seal from the
rear cover side.
Take care not to damage the oil seal bore.
2. Discard the used oil seal.
3. Use the oil seal installer to install the new oil seal.
N6A1063E
N6A1065E
Legend
1. Oil seal installer
2. Oil seal
N6A1050E
1. Install the brush holder and the stud bolts to the ter-
minal plate.
Check that the stud bolts fit properly.
2. Attach the IC regulator to the terminal plate.
3. Solder the IC regulator, the brush holder and the
condenser.
LG4HG-WE-0871.book 36 ページ 2008年9月25日 木曜日 午後5時58分
2. Vane
LNW91ESH000101
3. Rotor
1) Inspect the rotor for excessive wear, abrasion,
and scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2) Inspect the generator rotor shaft splines for
backlash.
Replace the rotor if backlash is present.
4. Check Valve
LNW91ESH000401 1) Carefully force the valve from the “B” side as
shown in the illustration.
Inspect the vacuum pump housing and the center
plate for excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum
pump housing and center plate must be replaced.
Inspect the vacuum pump housing inside for wear
and damage.
If the measured inside diameter is outside the
specified range, replace the vacuum pump hous-
ing.
LG4HG-WE-0871.book 37 ページ 2008年9月25日 木曜日 午後5時58分
N6A1069E LNW91ESH000401
N6A1074E
N6A1077E
Legend
1. Brush holding wire or pin
2. Brush
RTW46DSH002101
4) Bend the wire end to hold the brushes.
3) Tighten the pulley to the specified torque. If the holding wire does not hold the brushes
properly, the brushes will be damaged.
Tighten:
5) Tape the rotor shaft spline.
Pulley nut to 98 N⋅m (10.0 kg⋅m / 72 lb⋅ft)
Note:
Take care not to damage the rotor when clamping it in a
vise.
16. Stator and Rear Cover Assembly
N6A1078E
Legend
1. Taping
N6A1079E
Legend
1. Retainer ring
2. Bearing outer race N6A1081E
Inspection
Performance Test
1. Generator
• Connect the generator as shown in the illustra-
tion.
N6A1080E
Tighten:
Through bolt to 4 N⋅m (0.4 kg⋅m / 35 lb⋅in)
LG4HG-WE-0871.book 40 ページ 2008年9月25日 木曜日 午後5時58分
N6A1082E
N6A1082E
N6A1090E
Legend
1. Vacuum pump tester
N6A1662E
2. Intake
LNW91ELF000401
(a) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft) (d) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (e) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(c) 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Engine Exhaust
(4HG1)
TABLE OF CONTENTS
EXHAUST SYSTEM .............................................1G-2
Maintenance Precautions ..................................1G-2
Description of Function and Operation ..............1G-2
Functional Inspection:........................................1G-4
EXHAUST PIPE ....................................................1G-5
Component ........................................................1G-5
Removal ............................................................1G-5
Inspection ..........................................................1G-5
Installation .........................................................1G-6
EXHAUST BRAKE ................................................1G-7
Component ........................................................1G-7
Functional inspection:........................................1G-7
Removal ............................................................1G-7
Disassembly ......................................................1G-8
Inspection ..........................................................1G-8
Reassembly.......................................................1G-8
Installation .........................................................1G-9
List of Tightening Torques ...............................1G-10
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
EXHAUST SYSTEM
Maintenance Precautions Description of Function and Operation
Vibrations and looseness of the exhaust system are The exhaust brake includes a valve inside the exhaust
caused by mis-positioning when assembling. Tempo- pipe, and closing this valve increases resistance in the
rarily install all bolts and nuts until all components are exhaust stroke, to raise the effect of the engine brake.
positioned. After positioning is completed, tighten them Also, by adjusting the exhaust pressure, quick warm-up
from the engine side to the rear side. system (QWS) is executed.
This diagram shows a vehicle with a wheel base of 3,300 mm(129.9 in)
LNW91GSF000101
Legend
1. Front exhaust pipe A 3. Front exhaust pipe B
2. Exhaust brake assembly 4. Silencer
LG4HG-WE-0871.book 3 ページ 2008年9月25日 木曜日 午後5時58分
LNW91GSF000201
Legend
1. Front exhaust pipe A 4. Silencer
2. Exhaust brake assembly 5. Extension exhaust pipe
3. Front exhaust pipe B 6. Exhaust tail pipe
LNW91GSF000301
Legend
1. Front exhaust pipe A 3. Extension exhaust pipe
2. Silencer 4. Exhaust tail pipe
LG4HG-WE-0871.book 4 ページ 2008年9月25日 木曜日 午後5時58分
EXHAUST PIPE
Component
This diagram shows a vehicle with a wheel base of 3,300 mm (129.9 in)
LNW91GLF000101
Legend
1. Front exhaust pipe A 4. Silencer
2. Exhaust brake assembly 5. Exhaust tail pipe
3. Front exhaust pipe B 6. Extension exhaust pipe (wheel base 3,300 mm
(129.9 in) / 3,800 mm (149.6 in) vehicles)
• Remove the clamps and exhaust tail pipe. • Remove the clamp, and remove the front exhaust
pipe.
2. Remove the extension exhaust pipe.
(wheel base for 3,300 mm (129.9 in) / 3,800 mm Inspection
(149.6 in) vehicles)
1. Externally inspect the exhaust pipe components.
3. Remove the silencer.
• Damage caused by heat from the body panel or vi-
4. Remove the front exhaust pipe B.
brations can cause exhaust gas to enter the cabin.
5. Remove the exhaust brake assembly. Be careful.
LG4HG-WE-0871.book 6 ページ 2008年9月25日 木曜日 午後5時58分
Note:
• Do not reuse the removed gasket and nut.
• Visually check that there is no foreign material in
the exhaust pipe.
1. Temporarily tighten the front exhaust pipe A, ex-
haust brake assembly, and front exhaust pipe B.
Note:
Uniformly tighten the front exhaust pipe so that there is
no exhaust gas leak.
2. Install the exhaust brake vacuum hose.
3. Temporarily tighten the silencer.
4. Temporarily install the extension exhaust pipe.
(wheel base 3,300 mm (129.9 in) / 3,800 mm
(149.6 in) vehicles)
5. Temporarily install the exhaust tail pipe.
After temporary installation, securely tighten it.
6. Exhaust manifold from the front exhaust pipe A.
Tighten:
Exhaust manifold side nuts to 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
7. Transmission right side bracket from the clamp of
the front exhaust pipe A.
Tighten:
Exhaust pipe clamp bolts to 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
8. Exhaust brake.
Tighten:
Exhaust brake side nuts to 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
9. Silencer from the front exhaust pipe B.
Tighten:
Silencer side nuts and bolts to 50 N⋅m (5.1 kg⋅m / 37
lb⋅ft)
10. Silencer mounting bracket.
Tighten:
Silencer mounting bracket nuts and bolts to 19 N⋅m (1.9
kg⋅m / 14 lb⋅ft)
11. Front side of extension exhaust pipe
(wheel base 3,300 mm (129.9 in) / 3,800 mm
(149.6 in) vehicles).
Tighten:
Extension exhaust pipe nuts to 50 N⋅m (5.1 kg⋅m / 37
lb⋅ft)
12. Exhaust tail pipe.
LG4HG-WE-0871.book 7 ページ 2008年9月25日 木曜日 午後5時58分
EXHAUST BRAKE
Component
LNW91GLF000201
Legend
1. Exhaust brake assembly 8. Bearing
2. Bolt 9. Nut
3. Cover 10. Pin
4. Power chamber 11. Gasket
5. Gasket 12. Exhaust brake valve
6. Clevis joint 13. Nut
7. Cotter pin
LNW21GSH000401
Reassembly
1. Install the power chamber.
Tighten:
LG91GSH000101 Power chamber nut to 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)
Disassembly
1. Remove the cotter pin.
2. Remove the lock nut.
3. Remove the clevis joint.
4. Remove the power chamber.
Inspection
Inspect the following parts for damage and degradation.
• Exhaust brake valve
• Exhaust brake shaft
• Butterfly valve
• Bushing
• Power chamber
Individual inspections
• When negative pressure is actuated from the vac- LNW41GSH001101
uum pump to the power chamber at 66.7 - 93.3
kPa(0.680 - 0.951 kg/cm2/ 9.670 - 13.523 psi), the 2. Install the lock nut.
exhaust brake valve should open and close 3. After installing the clevis joint, tighten the lock nut
smoothly. at the specified torque.
Tighten:
Clevis joint lock nut to 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
LG4HG-WE-0871.book 9 ページ 2008年9月25日 木曜日 午後5時58分
LNW21GSH002201
Installation
1. Install and temporarily tighten the front exhaust
pipe A and exhaust brake assembly.
LNW91GSH000101
LNW91GLF000301
(a) 67 N⋅m (6.8 kg⋅m/49 lb⋅ft) (f) 50 N⋅m (5.1 kg⋅m/37 lb⋅ft)
(b) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft) (g) 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft) (h) 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
(d) 50 N⋅m (5.1 kg⋅m/37 lb⋅ft) (i) 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
(e) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Engine Lubrication
(4HG1)
TABLE OF CONTENTS
LUBRICATING SYSTEM ......................................1H-2
General Description...........................................1H-2
OIL FILTER ASSEMBLY.......................................1H-3
Component ........................................................1H-3
Removal ............................................................1H-3
Inspection ..........................................................1H-3
Installation .........................................................1H-4
OIL FILTER CARTRIDGE.....................................1H-5
Component ........................................................1H-5
Removal ............................................................1H-5
Installation .........................................................1H-5
OIL COOLER ........................................................1H-7
Component ........................................................1H-7
Removal ............................................................1H-8
Disassembly ....................................................1H-10
Reassembly.....................................................1H-10
Installation .......................................................1H-10
OIL PAN ..............................................................1H-14
Component ......................................................1H-14
Removal ..........................................................1H-14
Installation .......................................................1H-14
OIL PUMP ASSEMBLY.......................................1H-16
Component ......................................................1H-16
Removal ..........................................................1H-17
Oil Pump Component ......................................1H-19
Disassembly ....................................................1H-19
Inspection and Repair......................................1H-21
Reassembly.....................................................1H-22
Installation .......................................................1H-24
OIL RELIEF VALVE ............................................1H-27
Removal ..........................................................1H-27
Inspection and Repair......................................1H-27
Installation .......................................................1H-27
List of Tightening Torques ...............................1H-28
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
LUBRICATING SYSTEM
General Description
Lubricating Oil Flow
4HG1 Model
LNW91HMF000101
N6A0515E
Legend
1. Oil pipe 3. Oil filter
2. Oil pressure switch 4. O-ring
Removal
Preparation
• Disconnect battery ground cable.
• Place a receptacle beneath the oil filter to contain
the drained oil.
1. Oil Pipe
2. Oil Pressure Switch
3. Oil Filter
4. O-ring
Inspection
Oil Filter Cover
1. Check the partial filter orifice for any clogging.
2. Send air into the arrow-marked hole in the illustra-
tion, and check to see if the air blows out from the
small holes in the center sleeve (1). N6A0516E
LG4HG-WE-0871.book 4 ページ 2008年9月25日 木曜日 午後5時58分
LNW21HSH000401
4. Oil Pipe
Tighten:
Oil pipe joint bolt to 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
MFW51HSH000201
• Connect battery ground cable.
2. Oil Filter
• Start engine and check for oil leakage carefully.
Tighten:
Oil filter cover bolt to 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
LNW21HSH000301
LNW21HSH000101
Legend
1. Oil filter cartridge
Removal Installation
Preparation 1. Oil Filter Cartridge
• Disconnect battery ground cable. 1) Clean the oil filter fitting face.
• Place a receptacle beneath the oil filter to contain 2) Apply a light coat of engine oil to the O-ring.
the drained oil. 3) Turn in the new oil filter until the filter O-ring is
1. Oil Filter Cartridge fitted against the sealing face.
Use an oil filter wrench to remove the oil filter car- 4) Use an oil filter wrench to install the new oil filter
tridge. cartridge.
Oil Filter Wrench: 1-8522-1097-0 (2WD model) Oil Filter Wrench: 1-8522-1097-0 (2WD model)
5-8840-2094-0 (4WD model) 5-8840-2094-0 (4WD model)
Tighten:
2WD model: Oil filter to 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
4WD model: Oil filter to 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
LNW21HSH006001
LG4HG-WE-0871.book 6 ページ 2008年9月25日 木曜日 午後5時58分
LNW21HSH006001
LG4HG-WE-0871.book 7 ページ 2008年9月25日 木曜日 午後5時58分
OIL COOLER
Component
N6A0523E
Legend
1. Vacuum hose 14. PCV hose
2. Oil level guide tube 15. Water bypass hose
3. Intake air duct 16. Injection pipe
4. Engine stop cable 17. Injection pump assembly
5. Accelerator control cable 18. Injection pump rubber spacer
6. Engine control cable 19. A/C drive belt (If equipped with A/C)
7. Engine control lever assembly 20. Idle pulley bracket (If equipped with A/C)
8. Oil pipe 21. Heater hose
9. Fuel return hose 22. Radiator lower hose
10. Fuel feed hose 23. Heater pipe
11. Nozzle cover 24. Water suction pipe
12. Leak off pipe 25. Oil cooler assembly
13. Fuel pipe 26. O-ring
LG4HG-WE-0871.book 8 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BMF000601
Removal
Preparation
• Disconnect the battery ground cable
• Drain coolant
1. Vacuum Hose
2. Oil Level Guide Tube
Remove the guide tube fixing bolt and pull out the
guide tube.
3. Intake Air Duct
4. Engine Stop Cable
Loosen the locking nut at the bracket and discon-
nect engine stop cable from injection pump stop le-
ver.
N6A0525E
N6A0526E
N6A0425E
8. Oil Pipe
9. Fuel Return Hose
10. Fuel Feed Hose
Disconnect fuel hose from injection pump side and LNW21HSH001001
take care not to spill and enter dust.
11. Nozzle Cover 24. Water Suction Pipe
12. Leak Off Pipe 25. Oil Cooler Assembly
13. Fuel Pipe 1) Remove the oil cooler bolts.
14. Positive Crankcase Ventilation (PCV) Hose 26. O-Ring
15. Water Bypass Hose
16. Injection Pipe
17. Injection Pump Assembly
Above works refer to “INJECTION PUMP ASSEM-
BLY” section in this manual.
18. Injection Pump Rubber Spacer
19. Air Conditioning (A/C) Drive Belt (If equipped with
A/C)
LG4HG-WE-0871.book 10 ページ 2008年9月25日 木曜日 午後5時58分
LNW21HSH001201
Reassembly
1. O-Ring
Apply a coat of engine oil to the O-rings and install
the O-rings the oil cooler.
2. Element
N6A1626E
Legend
1. O-ring
2. Liquid gasket
LNW21HSH001201
Legend
1. Element
2. O-ring
LNW21HSH005801 N6A0322E
LNW21HSH001001
Legend
1. Liquid gasket
Tighten:
Water suction pipe bolt to 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Note:
Install the water suction pipe immediately after the in-
stallation of the oil cooler.
LG4HG-WE-0871.book 12 ページ 2008年9月25日 木曜日 午後5時58分
LNW21HSH000801 LNW21BSH028101
N6A0449E
LG4HG-WE-0871.book 13 ページ 2008年9月25日 木曜日 午後5時58分
N6A0525E
N6A0544E
24. Intake Air Duct
22. Accelerator Control Cable 25. Oil Level Gauge Guide Tube
1) Check to see if the idling control knob is turned 1) Install the O-rings to the guide tube lower por-
to the utmost limit to the left. tion and insert the guide tube completely to the
2) Install the end tip of the cable to the engine con- cylinder block.
trol lever. 2) Tighten the guide tube bolt to the specified
3) With the outer cable pulled toward the front of torque.
the vehicle, provide the engine control wire and Tighten:
the inner cable with the appropriate play. Then, Guide tube bolt to 13 N⋅m (1.3 kg⋅m/113 lb⋅in)
fasten the clamp with a nut.
N6A0390E
N6A0526E
26. Vacuum Hose
4) Check to see if the control lever of the injection
• Pour coolant into radiator.
pump is set at the idling position (with the lever
attached to the stopper bolt). • Connect battery ground cable.
23. Engine Stop Cable • Start engine and check for oil and water leak-
1) Install the end tip of the cable to the engine stop age carefully.
lever.
2) Pull the cable toward the rear of the vehicle,
and fasten the clamp with a nut at the position
where the lever stops.
LG4HG-WE-0871.book 14 ページ 2008年9月25日 木曜日 午後5時58分
OIL PAN
Component
LNW41HLF000201
Legend
1. Gasket 3. Rubber assembly
2. Oil pan 4. Drain plug
Removal Installation
Preparation 1. Oil Pan
• Disconnect battery ground cable 1) Apply a 3 mm (0.12 in) bead of recommended
• Lift up car liquid gasket (ThreeBond 1207C) or its equiva-
lent to the shaded areas shown in the illustra-
• Drain engine oil
tion.
Tighten:
Drain plug to 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
1. Oil Pan
LG4HG-WE-0871.book 15 ページ 2008年9月25日 木曜日 午後5時58分
N6A0551E LNW21BSH013801
LNW21BMH000101
Legend
1. Rubber assembly
2. Oil pan
3. Gasket
LNW91HLF000201
Legend
1. Engine assembly 15. Power steering pump idle gear
2. Nozzle cover 16. Flywheel housing
3. Cylinder head cover 17. Slinger
4. Head cover gasket 18. Rear oil seal
5. Rocker arm shaft assembly 19. Flywheel
6. Valve cap 20. Clutch disc
7. Camshaft bearing cap 21. Clutch pressure plate assembly
8. Camshaft bearing upper 22. Oil pump assembly
9. Camshaft assembly 23. Oil pipe
10. Camshaft bearing lower 24. Oil pan
11. Cylinder head assembly 25. Injection pump assembly
12. Cylinder head gasket 26. Engine control wire
13. Idle gear A 27. Engine control lever assembly
14. Power steering pump idle gear cover
LG4HG-WE-0871.book 17 ページ 2008年9月25日 木曜日 午後5時58分
N6A0426E
LNW21BSH072301
N6A0562E
N6A0177E
LG4HG-WE-0871.book 19 ページ 2008年9月25日 木曜日 午後5時58分
LNW91HLF000101
Legend
1. Idle gear A 6. Ball
2. Flywheel housing 7. Cotter pin
3. Power steering pump idle gear 8. Driven gear and shaft
4. Power steering pump idle gear cover 9. Gear and cose ASM
5. Spring 10. Oil pump ASM
Disassembly
1. Power Steering Pump Idle Gear Cover
2. Power Steering Pump Idle Gear
LG4HG-WE-0871.book 20 ページ 2008年9月25日 木曜日 午後5時58分
LNW91BSH000401 N6A0166E
N6A0167E
LNW21BSH072301
4. Idle Gear A
LNW21HSH002401
LG4HG-WE-0871.book 21 ページ 2008年9月25日 木曜日 午後5時58分
LNW21HSH001901
replaced.
2. Use an inside dial indicator or inside micrometer to
Gear and Cover Clear- mm (in) measure the pump cover bushing inside diameter
ance and the cylinder block inside diameter.
If clearance between the gear shaft and the bush-
Standard Limit ing exceeds the specified limit, the oil pump as-
0.064 — 0.109 sembly must be replaced.
0.2 (0.008)
(0.0025 — 0.0043)
LG4HG-WE-0871.book 22 ページ 2008年9月25日 木曜日 午後5時58分
LNW21HSH002401
LNW21HSH002501
N6A0177E LNW91BSH000501
LNW21BSH007801
LNW21BSH072401
2) Align the crankshaft gear with the engagement
mark of the idle gear and install the idle gear A. 3) Align the cylinder block knock pins with the fly-
Tighten: wheel housing knock pin holes.
Idle gear A bolt to 133 N⋅m (13.6 kg⋅m / 98 lb⋅ft)
LG4HG-WE-0871.book 24 ページ 2008年9月25日 木曜日 午後5時58分
LNW21BSH004301
Tighten:
Gear cover bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
LNW91BSH000601
LNW91BSH000701
Installation
1. Oil Pump Assembly
1) Carefully wipe any foreign material from the cyl-
inder block rear surface.
2) Apply the recommended liquid gasket (ThreeB-
ond 1141E) or its equivalent to the shaded ar-
eas shown in the illustration.
Caution:
Be careful that no liquid gasket gets into the holes in the
arrow-marked portion in the illustration and the inside of
the oil pump cover.
LNW21BSH072501
LG4HG-WE-0871.book 25 ページ 2008年9月25日 木曜日 午後5時58分
LNW21HSH002501 LNW21BSH007801
3) Install the oil pump to the cylinder block. 2) Align the crankshaft gear with the engagement
4) Tighten the oil pump to the specified torque. mark of the idle gear and install the idle gear A.
Tighten: Tighten:
Oil pump bolt to 31 N⋅m (3.2 kg⋅m/23 lb⋅ft) Idle gear A bolt to 133 N⋅m (13.6 kg⋅m/98 lb⋅ft)
N6A0177E LNW91BSH000501
LNW91BSH002301
N6A0568E
N6A0568E
N6A0569E
Installation
1. Oil Relief Valve
Tighten:
Oil relief valve to 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
LG4HG-WE-0871.book 28 ページ 2008年9月25日 木曜日 午後5時58分
LNW91HLF000301
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (g) 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
(b) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (h) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) (i) 31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
(d) 13 N⋅m (1.3 kg⋅m/113 lb⋅in) (j) 31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
(e) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(f) 64 N⋅m (6.5 kg⋅m/47 lb⋅ft) 2WD model
20 N⋅m (2.0 kg⋅m/14 lb⋅ft) 4WD model
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Engine Speed Control System
(4HG1)
TABLE OF CONTENTS
ACCELERATOR CONTROL CABLE ..................... 1I-2
Component ......................................................... 1I-2
Removal ............................................................. 1I-2
Inspection ........................................................... 1I-2
Installation .......................................................... 1I-2
ACCELERATOR PEDAL ....................................... 1I-4
Component ......................................................... 1I-4
Removal ............................................................. 1I-4
Installation .......................................................... 1I-4
IDLING CONTROL CABLE.................................... 1I-6
Component ......................................................... 1I-6
Removal ............................................................. 1I-6
Installation .......................................................... 1I-6
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
LNW91IMF000301
Legend
1. Adjust nut 3. Accelerator control wire (Accelerator pedal side)
2. Accelerator control wire (Injection pump side) 4. Accelerator control cable
ACCELERATOR PEDAL
Component
LNW91IMF000101
Legend
1. Accelerator control lever 4. Idling control cable assembly
2. Accelerator switch 5. Accele pedal bracket
3. Control cable
Installation
1. Accelerator Pedal Assembly
• Apply grease to the sliding portion, and install it
to the brake pedal bracket.
2. Idling Control Cable
LG4HG-WE-0871.book 5 ページ 2008年9月25日 木曜日 午後5時58分
LNU8Z0SH001201
LG4HG-WE-0871.book 6 ページ 2008年9月25日 木曜日 午後5時58分
LNW91IMF000201
Legend
1. Idling control knob 3. Idling control cable
2. Idling control cable nut
Removal • Insert the idling control knob into the cable, and
tighten the screw.
1. Idling Control Knob
Inspection:
• Loosen the idling control knob screw and re-
• With the idling control knob not in use, check to see
move the knob from cable.
if the injection pump lever is at the idle position
2. Idling Control Cable Nut (with the lever in contact with the stopper bolt).
3. Idling Control Cable
• With the idling control knob turned fully to the right,
• Remove control cable from accelerator pedal check to see if the number of the engine idling ro-
bracket. tations gets to 1,500 r/min or more.
Installation
1. Idling Control Cable
• Install control cable to Accelerator pedal brack-
et.
2. Idling Control Cable Nut
• Insert the idling control cable into the specified
hole of the instrument panel.
• It tightens with the nut.
3. Idling Control Knob
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
ENGINE
Induction
(4HG1)
TABLE OF CONTENTS
AIR CLEANER ELEMENT .....................................1J-2
Component .........................................................1J-2
Removal .............................................................1J-2
Installation ..........................................................1J-3
LG4HG-WE-0871.book 2 ページ 2008年9月25日 木曜日 午後5時58分
LNW91JSF000101
Legend
1. Body assembly 4. Air cleaner cover assembly
2. Air cleaner element 5. Vacuator valve
3. Gasket
Caution:
Do not bang the element against another object in an at-
tempt to clean it. Damage to the element will result.
N6A0978E
LG4HG-WE-0871.book 3 ページ 2008年9月25日 木曜日 午後5時58分
LNW21JSH000201 N6A0011E
Carbon and Dust Fouled Element 4. Dry the element in a well ventilated area.
1. Prepare a cleaning solution of Isuzu Genuine Ele- An electric fan will hasten drying.
ment Cleaner diluted with water.
Note:
2. Submerge the element in the solution for twenty Do not use compressed air or an open flame to dry the
minutes. element quickly. Damage to the element will result.
It will usually take two or three days for the element to
dry completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.
HCW31BSH057501
cm2/40 psi)
Installation
1. Air Cleaner Element
2. Air Cleaner Cover Assembly
LG4HG-WE-0871.book 1 ページ 2008年9月25日 木曜日 午後5時58分
MEMO
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LG4HG-WE-0871_57328_奥付 08.9.19 10:20 AM ページ 1
WORKSHOP MANUAL
ENGINE
(4HG1 model)
Issued by ISUZU MOTORS LIMITED
SERVICE MARKETING DEPARTMENT
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LG4HG-WE-0871_57328_奥付 08.9.19 10:20 AM ページ 2
WORKSHOP MANUAL
No.LG4HG-WE-0871