INTRODUCTION

GENERAL
This section has the description and the repair proce-
dures for the engine and the fuel system. Removal, dis-
assembly, cleaning, assembly, installation, specifica-
tions and troubleshooting procedures are included.
The fuel injection pump has one plunger assembly that
supplies fuel to the four fuel injectors. A mechanical
governor controls the maximum engine speed. The op-
eration of this governor is described in the Fuel System
later in this section.

DESCRIPTION
The Isuzu 4JG2 diesel engine is a four–cylinder engine
with a displacement of 3059 cm3 (186.7 in3). The firing
order is 1–3–4–2. The No. 1 cylinder is toward the end
of the engine with the fan. The serial number of the en-
gine is on the side of the cylinder block near the No. 4
cylinder location.
This diesel engine has direct fuel injection. Diesel fuel is
injected into the cylinder at the end of the compression
stroke of the piston. A glow plug is also installed in the
cylinder head for each cylinder. These glow plugs are
cold start aids to make the diesel engine easier to start
when the engine is cold.
The crankshaft has five main bearings. The main bear-
ing in the center of the crankshaft is also the thrust bear-
ing and has thrust washers (thrust bearings) on each side
of the main bearing. The bearing journals have had a
special process called “tufftrided” and can not be re-
paired by grinding.
The pistons have three piston rings. Each of the two
compression rings have a special shape designed for its
position on the piston. The third piston ring is the oil
control ring. The cylinder liners are chrome plated.
The valves, valve guides, and valves seats can be re-
placed during engine repairs.

2 3 4
1
5

10 6

1. COOLING FAN
2. THERMOSTAT HOUSING
3. ENGINE OIL DIPSTICK
4. FILL CAP FOR ENGINE OIL
5. FUEL INJECTOR
6. SERIAL NUNBER
LOCATION
7. FLYWHEEL
8. DRAIN PLUG, ENGINE OIL
9. FUEL INJECTION PUMP
10. INTAKE MANIFOLD

FIGURE 1. ISUZU 4JG2 DIESEL ENGINE

1
 REPAIRS
WARNING
Disconnect the battery cables before doing any
disassembly and repair to the engine or parts of the
electrical system. Put a “DO NOT OPERATE” tag in
the operator’s area and on the battery connectors.
The diodes and resistors in the electrical system can
be damaged if the following cautions are not
followed:
• Do not disconnect the battery when the engine
is running. The voltage surge can damage the
electronic devices in the circuit.
• Do not disconnect an electric wire before the
engine is stopped and the switches are “OFF”.
• Do not cause a short circuit by connection of
the electric wires to the wrong terminals.
Make sure a correct identification is made of
the wire before it is connected.
• Make sure a battery is the correct voltage and
polarity before it is connected.
• Do not check for current flow by making a
spark because the electronic devices in the cir-
cuit can be damaged.
REMOVAL AND INSTALLATION OF THE
ENGINE
NOTE: The removal and installation procedures for the
engine are not included in this section. See the section,
THE FRAME for the procedures to remove and install
the engine.
CYLINDER HEAD AND VALVE
MECHANISM (See FIGURE 2.)
Removal
NOTE: The following procedure is for removal of the
cylinder head when the engine is in the lift truck. If the
2
engine has been removed from the lift truck, many of the
following disconnections and removals will already be
done.
1. Disconnect the battery cables at the battery.
2. Drain the cooling system.
3. Disconnect the air filter from the intake manifold. Re-
move the air filter and air duct.
4. Remove the fan guard from the radiator. Loosen the
alternator support bracket and remove the drive belt.
5. Remove the cooling fan and spacer. Remove the
pulley for the cooling fan and the drive belt.
6. Remove the alternator and its mount.
7. Remove the fuel lines between the fuel injectors and
the fuel injection pump. If the engine must be complete-
ly disassembled for repairs, remove fuel injection pump
as described in the procedure FUEL INJECTION
PUMP, Removal.
8. Disconnect the exhaust manifold from the cylinder
head.
9. Disconnect the hoses at the thermostat housing. Re-
move the clamps for the engine wiring that are on the
thermostat housing and the side of the cylinder head.
10. Remove the glow plug connectors. Remove the
glow plugs from the cylinder head.
11. Disconnect the fuel lines and remove the fuel injec-
tors.
12. Remove the intake manifold.
13. Remove the rocker arm cover.
14. Remove the rocker arm assembly. Remove the push
rods. Keep the push rods in the correct order so that they
will be installed in the same positions.
 1. VALVE COVER 5
2. GROMMET
3. CAPSCREW 4
4. OIL FILL CAP
5. BREATHER 3
6. PCV VALVE
7. HOSE 2 6
8. CAPSCREW
9. VALVE STEM SEAL
10. WASHER
11. VALVE GUIDE 1
12. LIFTING EYE
13. CYLINDER HEAD 7
14. GLOW PLUG CONNECTOR
15. GLOW PLUG

1
8
9
19 18 13
17 10

12 11

14

15

16

16. HEAD GASKET

17. COMBUSTION CHAMBER INSERT
18. VALVE SEAT, INTAKE
19. VALVE SEAT, EXHAUST

FIGURE 2. CYLINDER HEAD ASSEMBLY

15. Loosen and remove the cylinder head bolts in sever-

al steps in the sequence shown in FIGURE 3.
6 14 15 7
2 10 18 11 3
16. Remove the cylinder head from the cylinder block.
Remove the gasket.
1 9 17 12 4
5 13 16 8
NOTE: Keep all valve parts together so that they can be
installed in the same positions. FRONT OF ENGINE

FIGURE 3. LOOSENING SEQUENCE FOR

REMOVAL OF THE CYLINDER HEAD

3
17. Put the cylinder head on a flat work surface. Use a 3. Check the surface of the cylinder head for distortion at
wood surface or a pad to prevent damage to the cylinder the location for the intake and the exhaust manifold. If
head. Use a valve spring compressor to compress the the amount of distortion is more an 0.20 mm (0.008 in),
valve springs and remove the retainers. See FIGURE 4. the cylinder head needs repair.
Release the valve spring compressor. Remove the valve
spring cap, valve spring, seal, and seat washer. Remove
the valve from the cylinder head. If the valve will be
used again, make a mark on the valve head so that it can
be installed again in the same position.

1. VALVE SPRING COMPRESSOR

1
9742

A
E F
C D

FIGURE 4. VALVES, REMOVAL AND B

INSTALLATION
FIGURE 5. CHECK THE CYLINDER HEAD FOR
18. Repeat step 17 to remove the other valves. DISTORTION

Cleaning 4. Use a straight edge and a thickness gauge to check the

1. Clean the surfaces of the cylinder head where the gas-
kets fit.
2. Clean the carbon from the combustion chambers and
the valve ports. Be careful not to damage the combus-
tion chamber inserts.
Inspection And Repairs
depth of the combustion chamber inserts. If the depth is
more than 0.02 mm (0.008 in), the insert(s) must be re-
placed. An insert with cracks or other damage must also
be replaced. Replace the combustion chamber inserts as
follows:
a. Use a hammer and rod to hit the insert and remove
it from the cylinder head. See FIGURE 6.

CYLINDER HEAD 1. COMBUSTION

CHAMBER INSERT
1. Inspect the cylinder head for cracks in the exhaust
ports, combustion chambers, combustion chamber in-
serts and external surfaces. If there are any cracks in the
cylinder head, it must be replaced.

2. Check the surface of the cylinder head for distortion. 1

Use a straight edge and a thickness gauge as shown in
FIGURE 5. Do the measurement in the positions
shown. If the amount of distortion is more than 0.2 mm
(0.008 in), the cylinder head needs repair. If the height of
the cylinder head is less than 91.55 mm (3.604 in), re- FIGURE 6. REMOVE THE COMBUSTION
place the cylinder head. CHAMBER INSERT

4
 b. Make sure the bore in the cylinder head is clean.
Put the insert in the seat in the cylinder head and
hit it with a plastic hammer.
c. See FIGURE 7. Put a piece of metal on top of the
combustion chamber insert. With a press, use
4500 to 5500 kg (9923 to 12,128 lb) of pressure to
install the inserts.
d. After installation, check that the insert is not
loose. Hit the insert with a plastic hammer to
check for looseness. See FIGURE 7. If the insert
is above the surface of the cylinder head, grind
the surface of the insert. The insert must not be
above the surface of the cylinder head.
1. PRESS 1
2. COMBUSTION
CHAMBER
INSERT
2
FIGURE 7. INSTALL THE COMBUSTION
CHAMBER INSERT
ROCKER SHAFT ASSEMBLY
1. Check the rocker arm shaft as shown in FIGURE 8.
Rotate the shaft and make a note of the highest and the
lowest reading on the dial indicator. If the difference be-
tween the readings is less very small, use a press to
straighten the shaft. Do not apply heat to the shaft. If the
difference between the readings is greater than 0.2 mm
(0.008 inch), replace the shaft.
2. Check the rocker arm shaft for wear. Use a microme-
ter and measure the diameter of the shaft at the locations
for the rocker arms. See FIGURE 8. The standard size of
the rocker arm shaft is 18.98 to 19.00 mm (0.747 to
0.748 in). When the diameter at any of the locations is
less than 18.9 mm (0.744 inch), replace the rocker arm
shaft.
9724
FIGURE 8. CHECK THE ROCKER ARM SHAFT
3. Inspect the rocker arms for wear. The standard inside
diameter of the rocker arm is 19.036 to 19.060 mm
(0.7494 to 0.7503 in). Replace the rocker arm when the
inside diameter is more than 19.100 mm (0.7519 in).
Find the clearance between the rocker arm and the rock-
er arm shaft. The standard clearance is 0.01 to 0.05 mm
(0.0004 to 0.002 in). When the clearance is more than
0.2 mm (0.008 inch), replace the rocker arm or the rock-
er arm shaft. Make sure the oil ports are clean. See
FIGURE 9.
1
1
1. OIL PORT
FIGURE 9. CHECK THE ROCKER ARM
4. Make sure the surfaces are not worn or damaged
where the rocker arm pushes on the valve stem. Use an
oil stone to remove minor wear patterns. A badly worn
or damaged rocker arm must be replaced.
VALVES AND GUIDES
1. Inspect the valves for burned or damaged areas in the
seat surfaces. The correct valve face angle is 45°. In-
spect for cracks and damaged or worn valve stems.
2. Check the diameter of the valve stems and inside di-
ameter of the valve guides. Check the clearance of each
valve stem in its valve guide. Use the following proce-
dure:
5
 a. Use a micrometer to measure the diameter of the
9727
valve stem in three places: top, center, and bot-
tom. The correct measurements are shown in
TABLE 1.

TABLE 1. VALVE STEM SIZES

VALVE STANDARD LIMIT
Intake 7.946–7.961 mm 7.880 mm
(0.3128–0.3134 in) (0.3102 in) FIGURE 10. VALVE GUIDES, REMOVAL
Exhaust 7.946–7.961 mm 7.850 mm
(0.3128–0.3134 in) (0.3091 in)

A
b. Use a hole gauge to measure the bore in the valve
guide. The correct measurements are shown in
TABLE 2.

TABLE 2. VALVE GUIDE CLEARANCE

VALVE STANDARD LIMIT
Intake 0.039–0.069 mm 0.200 mm
(0.0015–0.0027 in) (0.0079 in)
Exhaust 0.064–0.093 mm 0.250 mm 9743 DIMENSION “A” = 13 mm (0.512 in)
(0.0025–0.0037 in) (0.0098 in)
FIGURE 11. VALVE GUIDES, INSTALLATION
c. If the clearance between the valve stem and its VALVES AND VALVE SEATS
valve guide is greater than the specification, the
1. Check the valve seats for wear and damage. Before
valve and valve guide must be replaced as a set. any work is done on the valve seats, make sure the valve
guides are good.
Remove the valve guides with the special tool as shown 2. Check the depth of the valve below the face of the cyl-
in FIGURE 10. inder head. See TABLE 4. If the measurement of the
depth is more than the specification, replace the valve
Special Tools: Valve guide tool seat.
(HYSTER Part No. 320910)
3. Check the width of the contact area on the valve seat.
See FIGURE 13. and TABLE 3.
4. A correction for minimum wear and damage to the
Use the special tool to install the valve guides as shown
valve and valve seat can be done by a process called
in FIGURE 11. Apply clean engine oil to the valve “lapping”. When the valve seats are “lapped”, keep the
guide during installation. Install the valve guide so that valve seat as narrow as possible. Make sure all of the
it extends 13 mm (0.512 in) above the surface of the cyl- lapping compound is removed from the valve and valve
inder head. seat when the process is completed.

6
5. Damaged valve seats can be repaired with a cutter TABLE 3. VALVE CONTACT WIDTH
tool. See FIGURE 12. Repair the seats as follows:
VALVE STANDARD LIMIT
a. Use a cutter with 15°, 45°, and 75° blades. Install Intake 1.70 mm (0.067in) 2.2 mm (0.087 in)
the correct cutter into the valve seat that is to be Exhaust 2.0 mm (0.079 in) 2.5 mm (0.098 in)
repaired. See FIGURE 12. Carefully turn the cut-
ter in a clockwise direction. Remove only the e. Check the valve depth. The correct valve depth is
minimum metal to repair the valve seat. Keep the shown in TABLE 4. If the valve seat is badly
valve seat as narrow as possible. damaged or worn, replace the valve seat as de-
scribed in the following paragraphs.

TABLE 4. VALVE DEPTH

VALVE STANDARD LIMIT
1. CUTTER 1 Intake 1.1 mm (0.043 in) 1.6 mm (0.083 in)
Exhaust 1.1 mm (0.043 in) 1.6 mm (0.063 in)

6. If the valve seat can not be repaired so that the valve

depth is within the specifications, the valve seat must be
replaced. Replace the valve seat as follows:
a. Use an electric welder and weld a small bead on
the circumference of the valve seat. See
FIGURE 14. Make sure that you do not weld be-
FIGURE 12. CUTTER FOR VALVE SEATS tween the valve seat and the cylinder head.
b. Let the cylinder head cool for 5 to 15 minutes,
then use a small prybar or a screwdriver to re-
b. When the valve seat has been cut, remove the cut- move the valve seat.
ter and pilot. Clean the valve port area and re-
move any particles.
3 1
1 2
1
2
15 0
0
45

1. CYLINDER HEAD 75 0
2. VALVE SEAT
3. VALVE CONTACT 3
WIDTH 1. WELD BEAD 1. USE A SCREWDRIVER
2. VALVE SEAT TO REMOVE THE
FIGURE 13. VALVE SEAT SPECIFICATIONS 3. CYLINDER HEAD VALVE SEAT
FIGURE 14. VALVE SEAT REMOVAL
c. Use the “lapping” process to make sure the valve
and valve seat fit tightly together. c. Clean the bore for the valve seat.
d. Use a press to install a new valve seat. See
d. Check the width of the valve contact area on the
FIGURE 15.
valve seat. See FIGURE 13. The correct contact
width is shown in TABLE 3. Replace the valve e. Check the fit of the valve as described in the pro-
seat when the width is more than specifications. cedures above.

7

1
4 3
1. PRESS
2. ADAPTER 4. CYLINDER
3. VALVE SEAT HEAD
FIGURE 15. VALVE SEAT INSTALLATION
VALVE SPRINGS
1. Check the valve springs for damage.
2. Measure the free length of the valve springs. See
FIGURE 16. The standard length is 48.0 mm (1.89 in).
Replace the valve spring when the length is less than
47.1 mm (1.86 in).
3. Check the valve springs for being straight. Put the
spring against a square as shown in FIGURE 16. Re-
place the valve spring when the measurement is more
than 1.7 mm (0.067 in).
MEASURE
HERE
FIGURE 16. INSPECT THE VALVE SPRINGS
4. Use a valve spring tester to check the valve springs. A
typical tester is shown in FIGURE 17. Check the ten-
sion at the installed height of 38.9 mm (1.5 in). The cor-
8
rect tension is 296 N (67 lbf). Replace the valve spring
when the tension is less than 258 N (58 lbf).
FIGURE 17. CHECK VALVE SPRING TENSION
PUSH RODS
Put the push rod on a flat plate as shown in FIGURE 18.
Roll the push rod on the flat plate and check the variation
with a spacer gauge. If a push rod is more than 0.3 mm
(0.012 in) from straight, it must be straightened or re-
placed.
Check the ends of the push rod for wear and damage. Re-
place a worn or damaged push rod.
FIGURE 18. CHECK FOR A BENT PUSH ROD
Assembly
1. Use engine oil to lubricate the inner surface of the oil
seal for the valve stem. A special tool is available to in-
stall the oil seal on the valve guide. Install the oil seal on
the valve guide. See FIGURE 19.
2. Lubricate the valve stems with engine oil. Install the
valves in their correct positions in the cylinder head.

1. VALVE SEAL INSTALLATION TOOL
ISUZU PART NO. 5–8840–2033–0
FIGURE 19. INSTALLATION, OIL SEAL FOR
THE VALVE STEM
3. Install the seat washer, valve spring, and valve spring
cap on a valve stem. One end of the valve spring has a
spot of paint. See FIGURE 20. This end of the valve
spring must be installed next to the cylinder head.
1. PAINT SPOT
1
FIGURE 20. VALVE SPRING
4. Use the spring compressor to compress the valve
spring. See FIGURE 21. Install the retainers that hold
the valve spring assembly to the valve stem. Repeat step
2 through step 4 for all of the valves.
FIGURE 21. INSTALL THE RETAINERS FOR
THE VALVE SPRING
5. Assemble the parts of the rocker arm assembly as
shown in FIGURE 22. Make sure the largest oil hole in
the rocker arm shaft goes toward the fan end of the en-
gine. Apply engine oil to the parts during assembly.
Installation
1. Clean the surface of the cylinder head and the surface
of the cylinder block. Clean the top of the pistons.
2. The correct head gasket is determined by measuring
the fit of the piston to the cylinder block. Use the follow-
ing procedures to choose the correct head gasket:
9
 14

9
13

12

6 8 10

5
7

4
11 1. CAM FOLLOWER (TAPPET)
3 2. PUSH ROD
15 3. END PLUG
4. SNAP RING
16 5. ADJUSTMENT SCREW
6. JAM NUT
17 7. MOUNT, ROCKER SHAFT
8. WASHER
9. STUD
10. ROCKER ARM
2
11. WASHER
12. SPRING
18
13. ROCKER ARM SHAFT
14. CAPSCREW
15. VALVE KEEPER
16. RETAINER
1 19 17. VALVE SPRING
18. EXHAUST VALVE
19. INTAKE VALVE

FIGURE 22. ROCKER SHAFT AND VALVE ASSEMBLY

a. Use a dial indicator to measure the distance that
the piston extends above the cylinder block.
Make four measurements at each bore as shown
in FIGURE 23.
b. Use the difference between the measurements (1
minus 2), and (3 minus 4) to calculate the average
distance that the piston extends. Do these mea-
surements for all four cylinders to obtain the
maximum dimension.

10
 the top. Carefully align the cylinder head gasket and cyl-
1 inder head.

4. Lubricate the threads of the cylinder head bolts with

engine oil. Install and tighten the bolts in three steps.
Tighten the bolts to 49 N.m (36 lbf ft) in the sequence
shown in FIGURE 24. Use the sequence again and
2 tighten the bolts 60 to 75° more. Use the sequence a third
2 time and tighten the bolts 60 to 75° more.

17 13 5 4 12
1 16
9 8

1. DIAL INDICATOR
2. MEASURING 6 7 15
14
POINTS 2
18 10 3 11

12842 FRONT OF ENGINE

FIGURE 23. MEASURE THE PISTON HEIGHT FIGURE 24. TIGHTENING SEQUENCE FOR
THE CYLINDER HEAD BOLTS
c. Three different thicknesses or grades of head gas- 5. Lubricate the push rods with engine oil and then in-
kets are available. To determine the correct gas- stall them in the engine.
ket, use the specifications in TABLE 5.
6. Install the rocker arm assembly. Loosen the screws for
TABLE 5. CYLINDER HEAD THICKNESS adjusting the valve clearance. Tighten the bolts for the
GRADE AVERAGE PISTON GASKET rocker shaft mounts to 54 N.m (40 lbf ft). Tighten the
MARK HEIGHT THICKNESS bolts for the inner mounts first.
0 0.658–0.713 mm 1.60 mm 7. Install the glow plugs in the cylinder head. Tighten the
(0.026–0.028 in) (0.063 in)
glow plugs to 23 N.m (17 lbf ft). Install the glow plug
00 0.713–0.759 mm 1.65 mm connector.
(0.028–0.030 in) (0.065 in)
000 0.759–0.814 mm 1.70 mm 8. Install the fuel injectors in the cylinder head. Tighten
(0.030–0.032 in) (0.067 in) the injectors to 64 N.m (47 lbf ft).

9. Install a new gasket for the intake manifold. Install the

gasket so that the end with the sharp corners is toward
the fan end of the engine. Install the intake manifold.

10. Install a new gasket for the exhaust manifold. Install

the exhaust manifold. Tighten the capscrews for the ex-
haust manifold. Connect the exhaust pipe to the exhaust
GRADE MARKS 12842
manifold.

NOTE: The difference between the highest and lowest
measurements in piston heights must not be more than
1.00 mm (0.039 in).
3. Install the dowel pin in the cylinder block. Install the
cylinder head on to the cylinder block, with the marks at
11. Install the fuel lines. See FIGURE 25. Connect the
fuel injection lines to the fuel injectors.
NOTE: If the fuel injection pump is installed at this
step, install the fuel lines. If the fuel injection pump is
not installed, do this step after the fuel injection pump is
installed.

11
Install the support clips in their original positions so that
there is no stress on the fuel injection lines. A stress on
the fuel injection line can cause a break during opera-
tion.
13. Install the coolant pump. Tighten the capscrews for
the coolant pump to 19 N.m (14 lbf ft).
14. Install the coolant hoses to the thermostat housing
and coolant pump.

15. Adjust the valves as described in CHECKS AND

ADJUSTMENTS.

16. Install the rocker arm cover.

17. Install the front and rear engine lifting eyes.

18. Install the oil pipe from the fuel injection pump to the
cylinder block.
FIGURE 25. INSTALLATION OF THE FUEL
INJECTION LINES 19. Install the alternator and its adjustment bracket.
12. Install the thermostat housing to the cylinder head.
See FIGURE 26. 20. Install a new engine oil filter.

1. COVER 21. Install the oil pressure switch if it was removed.

2. GASKET
3. THERMOSTAT
4. GASKET 22. Connect the coolant hoses. Fill the cooling system
5. HOUSING with coolant.
6. COOLANT
TEMPERATURE 1
SENDING UNIT 23. Install the pulley for the cooling fan and the drive
7. TEMPERATURE belt. Install the cooling fan. Adjust the drive belt to the
SENSOR,
QUICK START 2 correct tension.

3 24. Install and connect the air cleaner.

4
TIMING GEAR CASE
6

Removal (See FIGURE 27.)

7 The engine is normally removed from the lift truck to re-

5 move the timing gear case. There are separate covers on
the timing gear case that can be removed to check the
FIGURE 26. THERMOSTAT HOUSING timing indicators.

12
 5
3
4
2

1. OIL SEAL
2. TIMING GEAR COVER
3. SEAL
4. DOWEL PIN
5. TIMING GEAR CASE
6. GASKET 1
7. INSPECTION COVER
8. SHAFT, IDLER GEAR “A”
9. IDLER GEAR “A”
10. RETAINER
11. CAPSCREW
12. SHAFT, IDLER GEAR “B”
13. IDLER GEAR “B” AND BEARING 6
14. RETAINER 9 7
15. CAPSCREW
16. OIL PIPE 10 8
17. WASHER 17
18. SPECIAL CAPSCREW
17

18 12

16 11 13
15

14

FIGURE 27. TIMING GEAR ARRANGEMENT

1. Use a puller to remove the crankshaft pulley. See
FIGURE 28. Use a block of wood next to the flywheel to
prevent the crankshaft from turning.
2. Remove the capscrews that hold the timing gear cover
to the timing gear case. Remove the timing gear cover.
3. Remove the capscrew and retainer for idler gear “B”.
Remove the idler gear and its shaft.
4. Remove the oil pipe from the case and idler gear “A”.
5. Remove the capscrews and retainer for idler gear “A”.
Remove the idler gear and shaft.

CAUTION
Do not turn the camshaft or the crankshaft when the
idler gears are removed and the valve mechanism is
installed. If either shaft is turned, damage will occur
to the valve mechanism. To prevent damage to the
valve mechanism, remove the rocker arm assembly
when working on the timing gears.
FIGURE 28. REMOVE THE CRANKSHAFT
NOTE: Before removing the camshaft, the oil pump
DAMPER PULLEY
must be removed. See the procedures for the Oil Pump

13
6. Remove the capscrew for the the camshaft gear. Care-
fully pull the camshaft timing gear from the camshaft.
Remove the capscrews and thrust plate from the cylin-
der block. Make sure the camshaft journal, lobes, and
bearing surfaces are not damaged during disassembly.
See the procedures for the Camshaft for additional in-
formation.
8. Remove the capscrews that hold the timing gear case
to the cylinder block. Remove the timing gear case and
gasket.
9. Remove the oil seal from the timing gear cover. See
FIGURE 30.
Installation

5 6 1. See FIGURE 27. Install the timing gear case (12) to

the cylinder block. Use a new gasket during installation.
Tighten the capscrews evenly to 20 N.m (15 lbf ft).

2. Install the key and the gear on the crankshaft. Make

4
sure the timing marks “XX” are showing. Use a piece of
tubing to push the gear completely against the shoulder.

3. See Camshaft, Installation procedures to install the

3 camshaft into the cylinder block. Install the thrust plate
and tighten the capscrews to 18 N.m (13 lbf ft). Install
the key and the camshaft timing gear. Make sure the tim-
1 2 ing marks “YY” are showing. Tighten the capscrew for
1. CRANKSHAFT GEAR the camshaft gear to 64 N.m (47 lbf ft).Check that the
2. IDLER GEAR “A” camshaft turns smoothly. Rotate the camshaft so that the
3. IDLER GEAR “B” “YY” mark on the camshaft timing gear is toward the
4. CAMSHAFT TIMING GEAR center axis of idler gear “A”.
5. CAVITY FOR COOLANT PUMP
6. OPENING FOR FUEL INJECTION PUMP
4. Install the idler gear shaft for idler gear “A”. Make
FIGURE 29. TIMING GEAR ARRANGEMENT sure the oil port is toward the top of the engine.

5. Turn the crankshaft so that the “XX” mark on the

7. If the crankshaft gear must be removed, use a puller to
crankshaft gear is toward the top of the engine.
remove the crankshaft gear. Remove the woodruff key
from the crankshaft.
6. Lubricate idler gear “A” with engine oil. Install idler
gear “A” so that the “X” and “Y” marks can be seen. As
idler gear “A” is installed, align the “X” mark with the
“XX” mark on the crankshaft gear, and align the “Y”
mark with the “YY” mark on the camshaft timing gear.
See FIGURE 31.

7. Install the retainer plate and the two capscrews for

idler gear “A”. Tighten the capscrews to 20 N.m (15 lbf
ft).

8. See FIGURE 31. Lubricate idler gear “B” with en-

gine oil. Install idler gear “B” on its shaft so that the “Z”
and “ZZ” marks on both timing gears are aligned. In-
stall the washer and capscrew on tining gear “B”. Tight-
FIGURE 30. REMOVE THE OIL SEAL
en the capscrew to 76 N.m (56 lbf ft).

14

YY
4
3
7
6 2
XX
1 5
1. CRANKSHAFT GEAR
2. IDLER GEAR “A”
3. IDLER GEAR “B”
4. CAMSHAFT GEAR
5. ALIGN X ON IDLER GEAR “A” WITH XX
ON THE CRANKSHAFT TIMING GEAR
6. ALIGN Y ON IDLER GEAR “A” WITH YY
ON THE CAMSHAFT TIMING GEAR
7. ALIGN Z ON IDLER GEAR “B” WITH ZZ
ON IDLER GEAR “A”
FIGURE 31. ALIGNMENT OF THE TIMING
GEARS
9. Install the oil pipe for the timing gear. Install the spe-
cial capscrew and pipe to the retainer for idler gear “A”
See FIGURE 27. Tighten the special capscrew to 13
N.m (9 lbf ft).
10. Install the crankshaft oil seal in the timing gear cov-
er. Lubricate the lip of the oil seal with engine oil. Use
the installation tool (Isuzu Part No. 5–8840–2061–0) to
install the oil seal in the timing gear cover. Install the oil
seal 1 mm (0.039 in) into the front of the timing gear
cover. See FIGURE 32.
1 1. CASE
2. OIL SEAL
2
1.0 mm
(0.039 in)
2
FIGURE 32. INSTALL THE CRANKSHAFT OIL
SEAL
11. Install the O–ring in the groove in the timing case
cover. Align the cover with the dowel pins, then install
the cover. Tighten the capscrews to 19 N.m (14 lbf ft)..
12. Align the crankshaft damper pulley with the key and
install the pulley. Be careful not to damage the seal. Use
a block to prevent the crankshaft from turning. Install
the capscrew and washer. Tighten the capscrew to 275
N.m (203 lbf ft).
CAMSHAFT AND CAM FOLLOWERS
Removal
See TIMING GEAR CASE, REMOVAL for informa-
tion about removal of the camshaft from the cylinder
block.
Inspection And Repairs
1. Before the camshaft is removed, use a dial indicator to
measure the amount of movement at the end of the cam-
shaft. The standard clearance is 0.08 mm (0.0032 in).
Replace the thrust plate when the movement is more
than 0.20 mm (0.0079 in).
2. Remove the camshaft timing gear. Remove the caps-
crew and washer. Use a puller to remove the camshaft
timing gear from the camshaft.
15
 1

2
3

6 1. CAMSHAFT
2. WOODRUFF KEY
3. CAPSCREW (2)
7
4. THRUST PLATE
5. CAMSHAFT TIMING GEAR
6. WASHER
7. CAPSCREW

FIGURE 33. CAMSHAFT ASSEMBLY

3. Remove the capscrews and the thrust plate. place the camshaft when the height of a lobe is less than
41.65 mm (1.6398 in).

1 5. Check the “run out” of the camshaft as shown in

FIGURE 35. Rotate the camshaft and look at the dial in-
dicator. The standard measurement for “run out” is 0.02
mm (0.008 in) or less. Replace the camshaft when the
“run out” is more than 0.10 mm (0.004 in).
1. CAMSHAFT
2. LOBE
3. JOURNAL
A 9740

2
B B

3 A
12631

FIGURE 34. CAMSHAFT MEASUREMENTS

9748

4. See FIGURE 34. Use a micrometer to measure the

camshaft journals. The correct measurement is 49.945
to 49.975 mm (1.9663 to 1.9675 in). Replace the cam-
shaft when any of the journals are less than 49.60 mm
(1.953 in). Measure the height of the camshaft lobes.
The correct measurement is 42.02 mm (1.6543 in). Re-
FIGURE 35. CAMSHAFT INSPECTION
6. See FIGURE 36. Measure the inside diameter of the
camshaft bearings. The standard measurement is 50.00
to 50.03 mm (1.9685 to 1.9696 in). Replace camshaft

16
bearings when the inside diameter is 50.08 mm (1.9716
in) or more. The maximum clearance between the bear-
ings and the camshaft is 0,12 mm (0.005 in). See
FIGURE 37. Replace the camshaft or bearings as neces-
sary.
FIGURE 36. CAMSHAFT BEARING
INSPECTION
CAUTION
During installation of the camshaft bearings, the oil
ports in the bearing must be aligned with the oil ports
in the cylinder block. If the ports are not correctly
aligned, the bearing surfaces will not be lubricated
and will fail.
1. CAMSHAFT BEARING TOOL
ISUZU PART NO. 5–8840–2038–0)
FIGURE 37. CAMSHAFT BEARING
REPLACEMENT
CAM FOLLOWERS (TAPPETS)
1. Keep the cam followers in an arrangement so that they
will be installed again in the same position in the cylin-
der block. Inspect the contact surface of the cam follow-
er for damage and wear. A cam follower will have a
smooth ring where it rubs on the camshaft lobe. A cam
follower with a damaged surface must be replaced. Re-
place a cam follower as necessary.
2. Measure the outside diameter of the cam followers as
shown in FIGURE 38. The correct measurement is
12.97 to 12.99 mm (0.510 to 0.511 in). Replace a cam
follower that has specifications less than 12.95 mm
(0.0509 in).
3. Check the clearance between the cam follower and
the bore in the cylinder block. Measure the diameter of
the hole for the cam follower in the cylinder block as
shown in FIGURE 39. The standard clearance is 0.03
mm (0.001 in). Install a new cam follower or cylinder
block if the clearance is more than 0.10 mm (0.004 in).
FIGURE 38. CAM FOLLOWER INSPECTION
FIGURE 39. CAM FOLLOWER BORE
INSPECTION
Installation
1. Lubricate the cam followers with engine oil and
install them in the cylinder block.
2. Lubricate the camshaft and bearings and carefully
install the camshaft.
3. Install the thrust plate fro the camshaft. Tighten the
capscrews for the thrust plate to 18 N.m (13 lbf ft).
Check that the camshaft rotates freely.
4. Align the camshaft timing gear with the woodruff key
and install the timing gear on the camshaft. Make sure
the timing marks (Y–Y) on the timing gear are showing.
Tighten the capscrew to 64 N.m (47 lbf ft).
17
5. Check the alignment of the timing marks as described
in the procedures for the Timing Case.
LUBRICATION SYSTEM
Oil Pump, Removal And Disassembly
(See FIGURE 40.)
1. Remove the dipstick. Drain the engine oil.
Oil Pump, Inspection
1. Remove the strainer assembly, the pump cover and
the outer rotor.
2. If the oil pump is worn so that the performance is de-
creased, the oil pump must be replaced. Check the end
clearance of the inner rotor. See FIGURE 41. If the
clearance is greater than 0.15 mm (0.006 in), replace the
rotor assembly.

2. Remove the oil sump.

3. Remove the oil pump with the oil tube from the cylin-
der block

2
4

5
FIGURE 41. CHECK THE END CLEARANCES
OF THE ROTOR
3

3. Check the clearances between the inner rotor and out-

er rotors. If the clearance is greater than 0.20 mm (.008
6 in), replace the rotor assembly. See FIGURE 42.

7
1

1. OIL TUBE 8
ASSEMBLY
2. O–RING
3. OIL PUMP BODY
4. PINION
5. ROLL PIN
6. INNER ROTOR
AND DRIVE
SHAFT 9
7. OUTER ROTOR FIGURE 42. CHECK THE CLEARANCE
8. COVER BETWEEN THE ROTORS
9. STRAINER
ASSEMBLY
4. Check the clearances between the outer rotor and the
FIGURE 40. OIL PUMP ASSEMBLY
pump body. See FIGURE 43. If the clearance is greater
than 0.40 mm (.016 in), replace the oil pump.

18

FIGURE 43. CHECK THE CLEARANCE
BETWEEN THE VANE AND PUMP BODY
5. Use a micrometer to measure the outer diameter of the
drive shaft as shown in FIGURE 44. Measure the inner
diameter of the pump body. If the clearance between the
drive shaft and the pump body is greater than 0.20 mm
(0.008 in), replace the oil pump.
FIGURE 44. CHECK THE ROTOR DRIVE
SHAFT
Oil Pump, Assembly And Installation
(See FIGURE 45.)
1. Install the drive shaft and rotor into the pump body.
2. Install the pinion on the drive shaft. Use a 5 mm (0.20
in) drill to make an aligned hole through the pinion and
drive shaft. Install the roll pin. Use a thread adhesive
(Hyster Part No. 226414 or Locktite 271) to help hold
the roll pin in the hole.
3. Install the cover.
4. Install the strainer assembly. Install the oil tube so
that it is loosely fastened to the oil pump.
FIGURE 45. INSTALLATION, OIL PUMP
5. Install the oil pump in the cylinder block. Use a new
O–ring on the oil tube. Connect the oil tube and tighten
the fittings.
6. Install the oil sump.
FIGURE 46. INSTALLATION, OIL SUMP
Oil Sump, Installation
1. Apply a liquid gasket to the arches of bearing cap No.
5 as shown FIGURE 46. Apply a liquid gasket to the
arches of the timing gear case as shown in FIGURE 46.
2. Install the gasket for the oil sump. Make sure the gas-
ket fits completely into the groove of bearing cap No. 5
and the corners where it joins the cylinder block. See
FIGURE 47.
3. Install the oil sump and tighten the capscrews. Tight-
en the capscrews in a sequence beginning at the middle
19
and working toward each end of the oil sump. Tighten
the capscrews to 19 N.m (14 lbf ft).
FIGURE 47. INSTALLATION, OIL SUMP
Oil Filter Assembly (See FIGURE 48.)
Replace the oil filter as described in the section, PERI-
ODIC MAINTENANCE. Change the oil filter at the
same time engine oil is changed. Use the correct oil ac-
cording to the specifications. Install a new filter car-
tridge. Apply clean oil to the gasket of the new filter car-
tridge. Turn the filter until the gasket touches, then
tighten 1/2 to 3/4 turn with your hand. Start the engine.
Check the area around the oil filter for leaks.
1
6 3. Use snap ring pliers to remove the snap rings at each
2 remove the piston pin as shown in FIGURE 49.
3
4
1. FILTER
CARTRIDGE
2. BODY, OIL FILTER 5. REGULATOR
3. O–RING VALVE
4. PLUG 6. GASKET
FIGURE 48. OIL FILTER ASSEMBLY
20
PISTONS AND CONNECTING RODS
(See FIGURE 50.)
NOTE: See the sections on Cylinder Liners for the se-
lection and fitting of pistons to new cylinder liners.
Removal
1. Remove the cylinder head as described in “Cylinder
Head, Removal”.
2. Remove the oil sump. Remove the piston cooling
pipe.
3. Clean the carbon from the top of each cylinder bore.
4. Remove the bearing caps from the connecting rods.
Keep the bearings in their order in which they were in-
stalled. Keep each bearing cap with its connecting rod.
5. Push the piston and connecting rod assembly from the
top of the cylinder. Keep the piston and connecting rod
assemblies in an arrangement so that they can be in-
stalled in the engine again in the same order from which
they were removed.
Disassembly (See FIGURE 50.)
1. During disassembly of the piston and connecting rod
assemblies, keep each set of parts with its assembly. Put
a piston and connecting rod assembly in a vise with soft
jaws. Be careful that the assembly is not damaged in the
vise.
2. Use a piston ring expander to remove the piston rings.
end of the piston pin. Use a hammer and a brass driver to
9736
FIGURE 49. PISTON PIN, REMOVAL
 NOTE: If the cylinder liner is worn or damaged, check
6 the clearance between the piston and the cylinder liner
5
after the cylinder liner has been replaced.
1
4 Piston Rings, Inspection

1. Measure the end clearance of each piston ring as

shown in FIGURE 51. Install the piston ring into the
3
cylinder where it will be used. Use a thickness gauge to
2 measure the end clearance. Make sure the piston ring is
perpendicular to the cylinder wall when the end clear-
1 ance is measured. For the correct end clearance of the
piston rings, see TABLE 6. If the end clearance for any
of the piston rings is greater than the specifications, re-
place the piston ring.
7
TABLE 6. PISTON RING END CLEARANCE
8
RING STANDARD LIMIT
1st 0.20–0.35 mm 1.5 mm
(Top) (0.0079–0.0138 in) (0.0591 in)
2nd 0.37–0.52 mm 2.0 mm
(0.0146–0.0224 in) (0.0787 in)
3rd 0.20–0.40 mm 1.6 mm
(0.0079–0.0157 in) (0.0630 in)

9739

9 10 8
1. SNAP RING
2. PISTON PIN
3. PISTON
4. OIL CONTROL RING
5. COMPRESSION RING NO. 2
6. COMPRESSION RING NO. 1
7. CONNECTING ROD
8. BEARING HALF
9. BEARING CAP
10. NUT

FIGURE 50. PISTON AND CONNECTING ROD FIGURE 51. CHECK THE END CLEARANCE OF
ASSEMBLY THE PISTON RING

Pistons, Inspection And Repair 2. Measure the clearance between the piston ring and the
groove in the piston as shown in FIGURE 52. For the
Visually inspect the pistons for wear and cracks. Re- correct clearance of the piston rings in their grooves, see
place a piston that is worn or damaged. TABLE 7.

21
 TABLE 7. PISTON RING GROOVE Connecting Rods, Inspection And Repair
CLEARANCE 1. Clean and inspect the parts for wear and damage.
RING STANDARD LIMIT Check the alignment of the connecting rods (bend and
twist) with a test fixture. See TABLE 8.
1st 0.09–0.13 mm 0.15 mm
(Top) (0.003–0.005 in) (0.0059 in)
TABLE 8. CONNECTING ROD ALIGNMENT
2nd 0.03–0.07 mm 0.15 mm
(0.0012–0.0028 in) (0.0059 in) STANDARD LIMIT

3rd 0.03–0.07 mm 0.15 mm Bend per 0.08 mm 0.20 mm

(0.0012–0.0028 in) (0.0059 in) 100 mm (3.94 in) (0.0031 in) or less (0.0079 in)
Twist per 0.05 mm 0.15 mm
100 mm (3.94 in) (0.0020 in) or less (0.0059 in)

9738

FIGURE 52. CLEARANCE BETWEEN THE
PISTON RING AND THE GROOVE
Piston Pins, Inspection And Repair
1. Inspect the piston pins for cracks and wear. Measure
the diameter of the pin. The correct measurement is
33.995 to 34.000 mm (1.3384 to 1.3386 in). If the diam-
eter of the piston pin is less than 33.970 mm (1.3374 in)
replace the piston pin.
1. ALIGNMENT TOOL
2. Check the clearance between the bushing in the con-
necting rod and the piston pin as described in the proce-
dures for the Piston Pins. If the bushing is worn, use a
press to remove the bushing from the connecting rod.
Use the press to carefully install a new bushing. Use a
reamer to increase the inner diameter of the bushing to
the standard size for the piston pin.

2. Measure the inside diameter of the piston pin hole in

the connecting rod. The standard clearance is 0.008 to
0.020 in (0.0003 to 0.0008 in). If the clearance between
the piston pin and bushing is more than 0.05 mm (0.0020
in), replace the bushing or pin. If the bushing is worn,
use a press to remove the bushing from the connecting
rod. Use the press to carefully install a new bushing,
making sure the oil ports are aligned. Use a reamer to in-
crease the inner diameter of the bushing to the standard 9730

size for the piston pin.

3. Install the piston pin into the piston. If the pin rotates
smoothly, the clearance is normal. If there is resistance,
check the clearance. The standard clearance is 0.002 to
0.004 mm (0.0008 to 0.0016 in). If the clearance be-
tween the piston pin and piston is more than 0.04 mm
(0.0016 in), replace the worn parts.
FIGURE 53. CHECK THE CLEARANCE
BETWEEN THE CONNECTING ROD AND THE
CRANKSHAFT
3. Install the connecting rod in its position on the crank-
shaft. Check the axial clearance between the connecting
rod and the crankshaft as shown in FIGURE 53. The
standard clearance is 0.230 mm (0.0091 in). Replace the

22
connecting rod when the clearance is more than 0.35 Pistons And Connecting Rods, Assembly
mm (0.0144 in). And Installation
Special Tools: Piston ring expander
New Pistons, Selection Piston installation tool
(piston ring compressor)

CAUTION
The correct piston grade must be selected to keep the
clearances correct between the cylinder liner and
piston or the engine will be damaged.
If a new piston must be installed because of damage or a
new cylinder liner was installed, the following proce-
dure must be used to select the correct piston:
CAUTION
The engine will be damaged if the pistons and con-
necting rods are installed in the wrong direction.
1. Assemble the connecting rod and the piston. Make
sure that the connecting rod is installed in the piston as
shown in FIGURE 55. Hold the connecting rod in a vise
while the piston is installed.

a. Measure the outside diameter of the piston as

1
shown in FIGURE 54. The measurement is made
on the piston skirt approximately 71 mm (2.8 in)
1. THE PISTON MUST
below the top of the piston. The piston sizes are BE INSTALLED IN THE
shown in TABLE 9. ENGINE WITH THE
NOTCH MARK
TOWARD THE
COOLANT PUMP
2. THE “ISUZU” CAST
MARK MUST BE 2
INSTALLED IN THE
SAME DIRECTION AS
THE NOTCH MARK
ON THE PISTON.

FIGURE 55. PISTON AND CONNECTING ROD

71 mm ARRANGEMENT
(2.8 in)

FIGURE 54. MEASURE THE PISTON WARNING

TABLE 9. PISTON SIZES
GRADE OUTSIDE DIAMETER
MARK
A 95.365–95.374 mm (3.7545–3.7549 in)
B 95.375–95.384 mm (3.7549–3.7553 in)
C 95.385–95.394 mm (3.7553–3.7557 in)
D 95.395–95.404 mm (3.7557–3.7561 in)
b. See the procedures for Cylinder Liners to make
sure the piston is installed in the correct bore.
Hot parts. Wear protective clothing and gloves to
prevent burns.
2. Use snap ring pliers to install one of the snap rings in
the piston. Heat the piston in an oil bath to approximate-
ly 77°C (170°F) for easier installation of the piston pin.
Push the piston pin into the piston and connecting rod.
Install the other snap ring. Check that the connecting rod
moves smoothly on the piston pin.
3. Use a piston ring expander to install the piston rings as
shown in FIGURE 56. During installation, make sure
the mark on the piston rings is toward the top of the pis-
ton. Make sure there is no gap on either side of the ex-
pander coil before the oil control ring is installed. Make

23
sure the piston rings will move smoothly in their
grooves after they are installed. CAUTION
The number on the bearing cap must be the same
number as the connecting rod. The arrow marks of
all the bearing caps must point toward the fan end of
the engine.

NOTE: See the section “How To Check The Clearance

Between The Crankshaft Bearings And Their Journals”
when the bearing for the connecting rod is installed.

7. Install the bearing in the bearing cap for the connect-

ing rod. Apply clean engine oil to the bearing surface
and then install the bearing and bearing cap on the con-
1. OIL CONTROL RING
necting rod. Tighten the nuts 29 N.m (22 lbf ft). For the
2. COMPRESSION RING NO. 2
3. COMPRESSION RING NO.1 second step, rotate the nuts 45 to 60° more. Rotate the
crankshaft to make sure it moves freely.
FIGURE 56. ASSEMBLY OF THE PISTON
RINGS 8. Install the piston cooling pipe. See FIGURE 58.
Tighten the relief valve to 29 N.m (22 lbf ft). Tighten the
4. Apply clean engine oil to the piston rings and the jour- M8 capscrews to 19 N.m (14 lbf ft). Tighten the M6 cap-
nals for the connecting rods. When a piston is installed screws to 8 N.m (69 lbf in).
into its cylinder, arrange the gaps in the piston rings so
that they are 120° part from each other. See FIGURE 57. CAUTION
After installation of the oil pipes, check that there is
FAN END OF ENGINE clearance between the oil pipes and the pistons. Ro-
tate the crankshaft slowly to check the clearances

C A
1
2
4 3

B
A = GAP FOR OIL CONTROL RING
B = GAP FOR COMPRESSION RING NO. 2
C = GAP FOR COMPRESSION RING NO.1
4
FIGURE 57. ARRANGEMENT OF THE PISTON
RINGS ON THE PISTON

5. Install the upper half of the bearing in the connecting

rod. Make sure the parts are clean. Rotate the crankshaft
so that the bearing journal for piston being installed is at
BDC.
1. RELIEF VALVE
6. Apply a thin coat of molybdenum disulfide grease to 2. OIL PIPE
the piston skirts. Use a piston ring compressor and in- 3. CYLINDER BLOCK
stall the piston assemblies into their correct cylinders. 4. CAPSCREW
During installation, the small mark on the top of the pis-
ton must be toward the end of the engine with the cool- FIGURE 58. ARRANGEMENT FOR COOLING
ing fan. See FIGURE 55. or FIGURE 57. OIL PIPES

24
9. Install the oil pump. See “Oil Pump, Assembly And
Installation” and FIGURE 45.
10. Install the oil sump. See “Oil Sump, Installation”
and FIGURE 46.
4. Remove the bearing caps for the connecting rods.
5. Remove the capscrews for the main bearings caps as
shown in the sequence in FIGURE 60.

11. Install the cylinder head as described in “Cylinder

Head, Installation”. 3 2
7 10 6

CRANKSHAFT AND MAIN BEARINGS

(See FIGURE 59.)
4 8 9 5 1

Crankshaft, Removal

1. Remove the flywheel and flywheel housing. See FIGURE 60. REMOVE THE CRANKSHAFT
“Flywheel, Removal”.
6. Before removing the crankshaft, measure the clear-
2. Remove the timing gear case as described in “Timing
ance between the crankshaft and thrust bearings at the
Gear Case, Removal”.
middle main bearing location. See FIGURE 61. Move
the crankshaft fully forward before making the mea-
surement. The standard clearance is 0.10 mm (0.0039
7 in). The maximum amount of clearance (axial clear-
6
ance) is 0.30 mm (0.0118 in). If the amount of axial
8
clearance is greater than the specification, install new
5
thrust bearings.
3
4
1 2

10 9749
1. CAPSCREW
2. WASHER
3. PULLEY FIGURE 61. CHECK THE CLEARANCE
4. TIMING GEAR 8. CRANKSHAFT BETWEEN THE CRANKSHAFT AND THRUST
5. KEY 9. MAIN BEARING BEARINGS
6. MAIN BEARING (LOWER)
(UPPER) 10. MAIN BEARING
7. THRUST BEARING CAP
7. Remove the crankshaft. Keep the main bearings for
FIGURE 59. CRANKSHAFT ARRANGEMENT the crankshaft in their correct order.

8. If necessary. use a puller to remove the crankshaft

3. Remove the oil sump. Remove the oil pump. Remove timing gear as shown in FIGURE 62. Remove the
the cooling oil pipes. woodruff key from the crankshaft.

25
 d. Wait approximately 30 to 40 seconds. If the test
area becomes the color of copper, the nitrided
surface is worn and the crankshaft must be re-
placed. If the test surface does not change color,
the nitrided surface is good.

1. Carefully apply a drop of the test solution to the

surface of the bearing journal or other surface to
be inspected.
2. Do not apply the test solution to any surface
within approximately 10 mm (0.4 in) of an oil port.

1
FIGURE 62. CRANKSHAFT TIMING GEAR, 2
REMOVAL

Crankshaft, Inspection And Repair

1. Carefully clean the crankshaft. There must not be any
oil on the surfaces to be inspected.
2. Visually inspect the crankshaft for wear, cracks or
other damage. Replace the crankshaft if it has cracks. In- FIGURE 63. CHECK THE NITRIDED SURFACE
spect the oil seal surfaces for wear and damage OF THE CRANKSHAFT
NOTE: The surface of the crankshaft has been hard- e. Use steam to clean the test solution immediately
ened by a process called “tufftrided” (a nitriding treat- after the test. The test solution will cause corro-
ment) to increase its surface strength. Worn or damaged sion and damage the crankshaft if it is not re-
journal surfaces of the crankshaft can not be repaired by moved immediately after the test.
grinding. 4. Check the crankshaft as shown in FIGURE 64. Rotate
the crankshaft one turn and check the reading on the dial
3. The following procedure can be used to check the ni-
indicator. The standard reading is 0.05 mm (0.002 in). If
trided surface of the crankshaft:
the difference between the highest and the lowest read-
a. Prepare a test solution of 5 to 10% solution of am- ing is more than 0.08 mm (0.0031 inch), repair or re-
monium cuprous chloride dissolved in distilled place the crankshaft.
water.
b. This procedure will not give correct results if
there is any oil on the surfaces to be inspected.
Hold the surface to be tested as level as possible
to prevent the test solution from flowing from the
small test area.
c. See FIGURE 63. Carefully apply a drop of the
test solution to the surface to be inspected. Do not 9734

apply the test solution to any surface within ap-

proximately 10 mm (0.4 in) of an oil port. FIGURE 64. CRANKSHAFT INSPECTION

26
 Crankshaft Bearing Selection
No. 1 No. 2 No.3 No.4 No.5
1. When installing new main bearings for the crank-
shaft, be sure to check the size marks. There are size
marks on the cylinder block that indicate the bore size
for the main bearings. There are also size marks on the
crankshaft to indicate the bearing journal diameters. For
the location of these marks, see FIGURE 65. For the di-
mensions of the size marks, see TABLE 11.
1 2 1 1 2
2. Use a micrometer to measure the journals for the bear-
MAIN BEARING BORE SIZE MARKS
ings of the crankshaft. Make the measurements at the
positions shown in FIGURE 66. The correct measure-
No. 1 No. 2 No.5 ments are shown in TABLE 10.

TABLE 10. CRANKSHAFT JOURNAL SIZES

1 2 2 1 3 ITEM STANDARD LIMIT
MAIN 69.917–69.932 mm 69.91 mm
JOURNAL (2.7526–2.7532 in) (2.7524in)
No.3 No.4
ROD 52.915–52.930 mm 52.90 mm
MAIN JOURNAL DIAMETER JOURNAL (2.0833–2.0839 in) (2.0843 in)
SIZE MARKS
WEAR 0.05 mm (0.0020 in) 0.08 mm
FIGURE 65. CRANKSHAFT SIZE MARKS LIMIT (0.0031 in)

TABLE 11. CRANKSHAFT SIZE MARKS

MAIN BEARING MAIN BEARING CRANKSHAFT CLEARANCE
BORE DIAMETER JOURNAL SIZE BEARING
G SIZE
S BETWEEN BEARING
G
MARK AND JOURNAL
SIZE INSIDE DIAMETER SIZE OUTSIDE
MARK MARK DIAMETER
1 or 69.927–69.932 mm BLACK 0.035–0.061 mm
(2.7530–2.7532 in) (0.0014–0.0024 in)
1 73.987–74.000 mm 2 or 69.922–69.927 mm 0.032–0.058 mm
(2.9129–2.9134 in) (2.7528–2.7530 in) BLUE 0.0013–0.0023 in)
3 or 69.917–69.922 mm 0.037–0.063 mm
(2.7526–2.7528 in) 0.0015–0.0025 in)
1 or 69.927–69.932 mm 0.031–0.056 mm
(2.7530–2.7532 in) GREEN (0.0012–0.0022 in)
2 73.975–73.987 mm 2 or 69.922–69.927 mm 0.036–0.048 mm
(2.9124–2.9129 in) (2.7528–2.7530 in) 0.0014–0.0019 in)

3 or 69.917–69.922 mm BLACK 0.033–0.058 mm

(2.7526–2.7528 in) 0.0013–0.0023 in)

27
 ened to their final torque or there will be an error in the
measurement.

6. Remove the main bearing cap. The Plastigage will be

compressed and wider and will adhere to either the main
bearing or its journal. See FIGURE 68. Use the scale on
the envelope for the Plastigage to measure the width of
the plastic at its widest point. The scale will indicate the
clearance in millimetres or thousandths of an inch.

1
1. MEASURING
1 POINTS
1

1 1

1
FIGURE 67. PLASTIGAGE ON A BEARING
JOURNAL
FIGURE 66. CRANKSHAFT MEASUREMENTS
7. If the clearance is greater than the specifications, se-
How To Check The Clearance Between The lect a new a bearing set and install it. Measure the clear-
Crankshaft Bearings And Their Journals ance again. If the clearance can not meet specifications
the crankshaft must be replaced.
1. Use Plastigage or equivalent to check the clearance.
The procedure is similar for both connecting rod bear-
ings and main bearings. If the engine has been removed
from the lift truck put the engine so that the crankshaft is
up. The weight of the crankshaft must be against the up-
per bearing half so that the total clearance can be mea-
sured correctly. If the engine is still in the lift truck, the
crankshaft must have a support to remove any additional
clearance between the upper bearing half and its journal.

2. All main bearing caps must be installed and their

capscrews tightened to the specifications.
3. Check the rear main bearing first. Remove the cap for
the rear main bearing. The procedure for checking the
clearance of the other bearings is similar.
4. Clean the oil from the bearing half and journal to be
checked. Put a piece of Plastigage across the full width
of the bearing journal as shown in FIGURE 67. Do not
rotate the crankshaft when the Plastigage is between the
main bearing and its journal.
5. Install the main bearing cap and tighten the capscrews
to 167 N.m (123 lbf ft). The capscrews must be tight-
FIGURE 68. MEASURE THE PLASTIGAGE
ON A BEARING JOURNAL
8. See TABLE 11. If the clearance is within specifica-
tions, lubricate the bearing with engine oil and install the
main bearings and bearing caps. Tighten the capscrews
on the main bearing caps to the correct specifications.
9. Turn the crankshaft to make sure it rotates smoothly.
Crankshaft, Installation
1. Before installation of the crankshaft, make sure all the
passages for oil in the crankshaft are clean.

28
NOTE: See the following section “How To Check The
Clearance Between The Crankshaft Bearings And Their
Journals” when the crankshaft is installed.
2. Clean the main bearings. Install the main bearings in
the cylinder block. The upper main bearings have an oil
passage and an oil groove. The lower bearing half has a
smooth surface. Apply clean engine oil to the surface of
the bearings.
3. Carefully install the crankshaft.
4. Install the thrust bearings at the No. 3 main bearing
location. Make sure that the oil grooves in the thrust
bearings are toward the crankshaft. See FIGURE 69.
Push one end of the thrust bearing until both ends are
even with the surface of the crankcase.
2
2 bearing cap must be even with the surface of the cylinder
1 block. Tighten the capscrews in several steps in the se-
1. THRUST BEARING
2. OIL GROOVES (THE OIL GROOVES
MUST BE INSTALLED TOWARD THE
THRUST SURFACE OF THE
CRANKSHAFT)
FIGURE 69. INSTALLATION OF THE THRUST
WASHERS
CAUTION
It is very important that the thrust bearings are in-
stalled correctly. If they are installed wrong, the
crankshaft will be damaged because it will not re-
ceive correct lubrication. Install the thrust bearings
so that the oil grooves are toward the thrust surface
of the crankshaft.
5. Install the main bearings into the bearing caps. Apply
clean engine oil to the surface of the bearings and install
the bearing caps. The arrow marks of all the bearing
caps must point toward the fan end of the engine.
6. Install the gasket and apply silicon adhesive to the
cylinder block at the No. 5 main bearing as shown in
FIGURE 70.
FIGURE 70. APPLY SEALANT FOR THE NO. 5
MAIN BEARING
7. During installation, adjust the position of the No. 1
and No. 5 main bearing caps. The outer surface of each
quence shown in FIGURE 71. Tighten the capscrews
for the bearing caps to 167 N.m (123 lbf ft).
8 9
4 1 5
7 3 2 6 10
FIGURE 71. INSTALL THE CRANKSHAFT
8. Install the oil seal in the groove of the No. 5 main bear-
ing cap. Use a tool to push the seal into position as
shown in FIGURE 72. After installation, check that the
seal is fully against its seat.
9. Install the key in the crankshaft. Align the slot in
crankshaft timing gear with the key. Install the crank-
shaft timing gear. Make sure the timing marks X–X are
toward the outside.
29
 2. Remove the flywheel housing and the braces.
12.2–12.8 mm
(0.480–504 in)
4 Ring Gear, Replacement

WARNING
Wear eye protection for this operation to prevent eye
injury from metal chips. You will be using a hammer
and chisel to break the ring gear.
3
2. CRANKSHAFT
1 2
3. ADAPTER Before the ring gear is removed, check the position of
1. OIL SEAL 4. TOOL the chamfer on the teeth.
FIGURE 72. INSTALL REAR SEAL
1. See FIGURE 73. Use a hammer and chisel to break
10. Install the timing gear case as described in “Timing
the ring gear. Make sure that you do not damage the fly-
Gear Case, Installation”.
wheel.
11. Install the connecting rods as described in “Connect-
ing Rods, Assembly And Installation”.
12. Install the oil pump as described in “Oil Pump, As-
sembly And Installation”. Install the oil sump as de-
scribed in “Oil Sump, Installation”.
13. Install the flywheel housing and the flywheel.

FLYWHEEL AND RING GEAR

Flywheel, Removal (See FIGURE 74.)
1. Remove the capscrews for the flywheel, then remove FIGURE 73. RING GEAR REMOVAL
the flywheel.

2
5
3

1. FLYWHEEL HOUSING
2. FLYWHEEL
5 3. SUPPORT PLATE
4. DRIVE PLATE
5. BRACE

FIGURE 74. FLYWHEEL AND HOUSING

30
 4 1. FLYWHEEL HOUSING
3 3 2. SPECIAL BOLT AND NUT,
1
2 46 N.m (34 lbf ft)
4 3. CAPSCREWS TO cylinder block
4 (M10), 55 N.m (41 lbf ft)
4. CAPSCREWS TO cylinder block
(M12), 94 N.m (69 lbf ft)

TIGHTENING SEQUENCE

12767

5 5. CAPSCREWS TO BRACES,
5 98 N.m (72 lbf ft)
5 5 6. FLYWHEEL CAPSCREWS,
120 N.m (89 lbf ft)
6

FIGURE 75. FLYWHEEL AND HOUSING

2. The ring gear must be heated before it can be installed en the capscrews to 120 N.m (89 lbf ft) as shown
on the flywheel. Use an oven that has a temperature con- in the sequence in FIGURE 75.
trol. Make sure that the ring gear is not heated to more
than 200°C (390°F). CYLINDER BLOCK AND CYLINDER
LINERS (See FIGURE 76.)
WARNING
Hot parts. Wear protective clothing and gloves to
Cylinder Liners, Inspection
prevent burns.

3. Install the ring gear on the flywheel. Make sure that NOTE: The cylinder block was marked at the factory to
the chamfer on the teeth is in the correct direction to- indicate the correct liner sizes. Check for the marks dur-
ward the starter. ing inspection.

Flywheel, Installation (See FIGURE 75.)
1. Install the flywheel housing and flywheel as follows:
a. If the flywheel housing was removed, install it
on the engine. Install the capscrews and bolt.
Tighten the special bolt (2) and nut first. Tighten
the nut to 46 N.m (34 lbf ft). Tighten the other
capscrews as shown in FIGURE 75.
b. Install the flywheel on the crankshaft. Apply an
adhesive sealant on the threads of the capscrews,
then install the capscrews for the flywheel. Tight-
Inspect the cylinder liner for wear and damage. Measure
the inside diameter of each cylinder liner to find the
amount of wear. Do the measurement of the liner at the
area that is approximately 20 mm (0.8 inch) below the
surface of the cylinder block. See FIGURE 77. Measure
the diameter in a minimum of two directions: (X—X)
perpendicular to the axis of the crankshaft and (Y—Y)
parallel to the axis of the crankshaft. The correct liner
sizes are shown in TABLE 13. If the inside diameter of
the cylinder liner is more than the specifications, replace
the cylinder liner.

31
 1. CYLINDER LINER 1
2. CYLINDER BLOCK
9732
FIGURE 76. CYLINDER BLOCK AND LINERS
Replacement Of A Cylinder Liner
NOTE: The cylinder liners have a chrome surface. Do
not try to repair a cylinder liner that has damage. A dam-
aged cylinder liner must be replaced.
20 mm
(0.80 in)
FIGURE 77. MEASURE THE BORE OF THE
CYLINDER LINER
Special Tools: Cylinder liner removal tool,
Isuzu Part No. 5–8840–2304–0
Cylinder liner installation tool,
Isuzu Part No. 5–8840–2313–0
1. To remove the cylinder liner, install the remover tool
as shown in FIGURE 78. Rotate the handle to pull the
liner from the cylinder block.
32
1. CYLINDER LINER REMOVER,
ISUZU PART NO. 5–8840–2304–0
FIGURE 78. CYLINDER LINER REMOVAL
2. Before installation of the cylinder liners, check the
surface of the cylinder block for distortion. Make the
measurements at the positions shown in FIGURE 79. If
the amount of distortion is more than 0.2 mm (0.008 in),
replace the cylinder block.
9744
A
E F
C D
B
FIGURE 79. CHECK THE SURFACE OF THE
CYLINDER BLOCK FOR DISTORTION
3. Measure the inside diameter of the cylinder block
where the replacement cylinder liner will be installed. A
grade of cylinder liner will be selected according to this
measurement. Measure the diameter at W—W, X—X,
Y—Y, and Z—Z as shown in FIGURE 80. Make the
measurements at approximately 98 mm (3.9 in) below
the surface of the cylinder block. Calculate the average
value of the four measurements to find the correct cylin-
der bore. This measurement will be used with the mea- 5. Carefully clean the bore in the cylinder block where
surement in step 4 to select the correct grade of cylinder the cylinder liner will be installed. Make sure the tools
liner. and press are ready before installation of the cylinder
liner is begun.

TABLE 12. CYLINDER LINER

LINER BORE DIAMETER LINER DIAMETER
GRADE (AVERAGE) (AVERAGE)
A 97.001–97.010 mm 97.011–97.020 mm
(3.8189–3.8193 in) (3.8193–3.8197 in)
B 97.011–97.020 mm 97.021–97.030 mm
(3.8193–3.8197 in) (3.8197–3.8201 in)
C 97.021–97.030 mm 97.031–97.040 mm
(3.8197–3.8201 in) (3.8201–3.8205 in)
D 97.031–97.040 mm 97.041–97.050 mm
FIGURE 80. MEASURE THE CYLINDER (3.8201–3.8205 in) (3.8205–3.8209 in)
BLOCK DIAMETER
6. Insert the cylinder liner in its bore in the cylinder
4. Make an X—X and Y—Y measurement at three block. Use a press and the special installation tool to in-
points on the cylinder liner as shown in FIGURE 81. stall the cylinder liner. See FIGURE 82. Make sure the
The following measuring points are below the upper alignment between the cylinder liner and the cylinder
surface of the cylinder liner: block is correct during installation. Use the press to ap-
point 1 = 20 mm (0.79 in) ply 4900 N (1100 lbf) to install the cylinder liner in the
point 2 = 90 mm (3.54 in) bore. Use the press to apply 24 500 N (5513 lbf) to finish
point 3 = 160 mm (6.30 in) installation of the cylinder liner in the cylinder block.

1. INSTALLATION TOOL, 9731

ISUZU PART NO. 5–8840–2313–0

FIGURE 82. CYLINDER LINER INSTALLATION

FIGURE 81. MEASURE THE OUTSIDE
DIAMETER OF THE CYLINDER LINER
Calculate the average value of the six measurements to
find the correct grade of cylinder liner. The grades of
cylinder liners are shown in TABLE 12.
7. Measure the position of the cylinder liner. The cylin-
der liner can extend 0.10 mm (0.004 in) above the sur-
face of the cylinder block. See FIGURE 83. The differ-
ence in the height of adjacent cylinder liners must be less
than 0.03 mm (0.0012 in).

33

9728
FIGURE 83. MEASURE THE CYLINDER LINER
POSITION
8. Measure the bore of the cylinder liner after it is
installed. Make the measurements at a point 20 mm
(0.80 in) from the top of the cylinder block. Make mea-
surements in two directions; in line with the crankshaft
and in the thrust direction. See FIGURE 77. Use these
measurements when choosing pistons.
TABLE 13. CYLINDER LINER SIZES
GRADE INSIDE DIAMETER
MARK (PISTON BORE)
A 95.421–95.430 mm (3.7567–3.7571 in)
B 95.431–95.440 mm (3.7571–3.7575 in)
C 95.441–95.450 mm (3.7575–3.7579 in)
D 95.451–95.460 mm (3.7579–3.7583 in)
COOLING SYSTEM (See FIGURE 84.)
Coolant Pump, Removal
1. Drain the cooling system
2. Remove the drive belt, the fan, and the pulley.
3. Remove the hoses from the coolant pump.
4. Remove the coolant pump from the engine.
34
Coolant Pump, Disassembly
(See FIGURE 84.)
CAUTION
Do not use a hammer to disassemble parts of the
coolant pump. Some parts are cast iron and can be
broken if they are hit with a hammer.
1. Remove the cover (10) and gasket (9) from the pump
body (5).
2. Use a press and adapter or a special puller (Hyster Part
No. 368758) to remove the hub (1).
3. Remove the set screw (7) that holds the bearing unit in
the pump body.
4. Use a press to push the shaft from the impeller (4) and
the seal (6).
Coolant Pump, Assembly And Installation
(See FIGURE 84.)
1. Install the bearing unit (2) so that the holes for the set
screw are aligned. Install the set screw (7).
2. Install the seal (4). Apply a thin coat of liquid sealant
to the outer circumference of the seal during installa-
tion.
3. Use a press to install the impeller (8). The clearance
between the impeller and the pump body must be 0.3 to
0.6 mm (0.012 to 0.024 inch).
4. Install the gasket and cover (10).
5. Install the hub (1). Use a press to push the hub on the
shaft.
6. Install the coolant pump and gasket on the cylinder
block. Tighten the capscrews to 20 N.m (15 lbf ft).
7. Adjust the tension of the drive belt as described in the
section PERIODIC MAINTENANCE.
Thermostat, Replacement (See FIGURE 84.)
1. Drain the cooling system so that the coolant level is
below the thermostat position and disconnect the top
hose from the outlet connection.
2. Remove the capscrews and remove the outlet connec-
tion.
3. Remove the thermostat.
 1. HUB
2. BEARING UNIT 11
12
3. DEFLECTOR 10
4. SEAL
5. PUMP BODY 7 8 9
6. WASHER 15
7. SETSCREW 6
8. IMPELLER 16
9. GASKET 5
10. COVER 17

3 4
2
13
1
18
19
14

11. SCREW 16. THERMOSTAT

12. GASKET 17. HOUSING
13. FITTING 18. DRIVE BELT 20
14. PLUG 19. PULLEY
15. OUTLET 20. SPACER

FIGURE 84. COOLING SYSTEM

4. Make sure that the surfaces for the joint in the outlet
are clean. Install a new thermostat in the housing.
5. Use a new gasket and install the outlet connection.
Tighten the capscrews to 20 N.m (15 lbf ft).
6. Connect the top hose and fill the cooling system.
FUEL SYSTEM
NOTE: Special tools and training are needed to repair
the fuel injection pump. A fuel injection pump is nor-
mally sent to an authorized repair station if repairs are
necessary. Fuel injectors also require special equipment
and training for repair. Most users have a special repair
service do this work. The repair of the fuel injection
pump and the fuel injectors is not described in this
section.
The solenoid valve is controlled by the ignition switch.
When the ignition switch is turned to ON, the coil in the
solenoid valve is energized. The solenoid valve opens to
permit fuel to flow into the pressure chamber for the
plunger (2). When the ignition switch is turned to OFF,
the solenoid valve closes and stops the flow of fuel. The
solenoid valve permits the engine to be stopped quickly
when the ignition switch is turned to OFF.
The drive shaft (2) is turned by the gear train in the en-
gine. The fuel pump (3) is a rotary vane pump that pulls
fuel from the fuel tank through the water separator. The
pressure of the fuel oil from the fuel pump increases
when the speed of the drive shaft increases. The regula-
tor valve controls the pressure of the fuel oil to the speci-
fications set by the manufacturer.

Description And Operation (See FIGURE 85.)

The parts of the fuel system include the fuel tank, injec-
tion pump and governor, fuel filter, and fuel injectors. A
basic diagram of the fuel system is shown in
FIGURE 85.
The overflow valve (6) in the injection pump is a by–
pass valve that permits some fuel oil to return to the fuel
tank. The overflow valve keeps the fuel oil at a constant
pressure in the plunger chamber so that the fuel flow to
the fuel injectors is even.

35
 5
6
4

1. FUEL INJECTION PUMP 8 7

2. DRIVE SHAFT
3. FUEL PUMP
(OUT OF POSITION) 3
4. FUEL FILTER
5. THROTTLE LEVER
6. OVERFLOW VALVE
7. FUEL INJECTOR
8. SOLENOID VALVE
9. FUEL TANK

2 1

9
12627

FIGURE 85. FUEL SYSTEM

A control sleeve slides on the plunger and partially from the timing gear case so that the drive gear is disen-
opens a passage in the plunger to control the amount of gaged from the timing gear train.
fuel oil sent to the fuel injectors. This control sleeve is
controlled by both the control lever (5) and the mechani- Installation
cal governor. The control lever (5) is connected to the
throttle pedal for the lift truck. NOTE: The timing gears must be correctly installed in
the engine before the fuel injection pump is installed. If
FUEL INJECTION PUMP the timing gear cover is removed, check the timing
marks as shown in FIGURE 86.
Removal
1. Disconnect the battery cables at the battery.
1
2. Remove clamps as necessary so that the fuel lines are
not bent. Remove the fuel line between the fuel filter and
the fuel injection pump.

3. Remove the fuel lines from the fuel injection pump

and the fuel injectors that returns fuel to the fuel tank.

4. Disconnect the throttle cable from the control lever on 2

the fuel injection pump.

5. See FIGURE 89. Remove the access cover for the

timing of the fuel injection pump on the timing gear cov-
er. Rotate the engine to align the “O” mark (2) on the
gear with the pointer (1). 1. TIMING GEAR, FUEL INJECTION PUMP
2. IDLER GEAR “B”
6. Remove the six capscrews that hold the fuel injection
pump to the engine. Move the fuel injection pump away FIGURE 86. ALIGNMENT OF TIMING GEARS

36
 CAUTION
Do not turn the crankshaft or the camshaft if the tim-
ing gears have been removed and the valve mecha-
nism is installed. If either shaft is turned, damage
will occur to the valve mechanism. To prevent dam-
age to the valve mechanism, remove the rocker arm
assembly when working on the timing gears.
1
NOTE: If the engine is installed in the lift truck, the let-
ters on the timing gears can be difficult to see to align the 3
position of the gears. Some service people use a light 2
and a mirror to see the letters on the timing gears.
1. ADAPTER PLATE
2. FUEL INJECTION PUMP
3. ALIGNMENT MARKS
1. See FIGURE 87. Remove the access cover for the
camshaft timing on the timing gear cover. Slowly turn FIGURE 88. FUEL INJECTION PUMP
the crankshaft clockwise. Align the pointer (1) with the ALIGNMENT
“O” mark (2) on the camshaft gear.
3. See FIGURE 89. Remove the access cover for the
timing of the fuel injection pump on the timing gear cov-
er. Put a thin coat of liquid sealant on both surfaces of the
1 2 gasket that is installed between the adapter for the fuel
injection pump and the timing gear case. Install the fuel
injection pump on the timing gear case. Align the “O”
mark (2) on the gear with the pointer (1) as the fuel injec-
tion pump is installed.

1. POINTER
2. MARK, CAMSHAFT
TIMING GEAR

FIGURE 87. ALIGNMENT, CAMSHAFT TIMING

GEAR 2

2. If removed, install the injection pump on the adapter 1. POINTER

plate. Make sure the marks are aligned. See 2. MARK, GEAR FOR FUEL INJECTION PUMP
FIGURE 88. Tighten the capscrews to 19 N.m (14 lbf FIGURE 89. ALIGNMENT, GEAR FOR THE
ft). FUEL INJECTION PUMP

37
4. Install the capscrews that fasten the adapter to the tim- 1. Carefully clean the parts of the fuel injector in a min-
ing gear case. Tighten the capscrews to 19 N.m (14 lbf eral oil solvent. The parts are specially fitted. Do not use
ft). an abrasive on the fitted areas of the nozzle.

5. Install the fuel lines from the fuel injection pump and
the fuel injectors that returns fuel to the fuel tank.
6. Install the clamps as necessary so that the fuel lines
are not bent. Install the fuel line between the fuel filter
and the fuel injection pump.
7. Connect the throttle cable to the control lever on the
fuel injection pump.
2. Carefully check all parts for wear and damage. See
FIGURE 90. The nozzle assembly (8) must be replaced
if there is any wear or damage. Hold the nozzle in a verti-
cal position. Pull the nozzle upward approximately 1/3
of its length and release it. The nozzle must lower
smoothly into its seat by its own weight. If the nozzle
does not pass this test, it must be replaced.

8. If installation and alignment of the timing gears is

complete, install the access covers for the camshaft gear 1
and the gear for the fuel injection pump.
2
9. See the procedure “Remove Air From The Fuel Sys- 8
tem” before starting the engine.

FUEL INJECTORS (See FIGURE 90.) 3

The engine will run roughly if a fuel injector is damaged 9

or dirty. To find which fuel injector has a problem, oper-
ate the engine at approximately 1000 rpm. Loosen and 4
tighten the connection to the inlet of each fuel injector in
a sequence. When the connection to the fuel injector 5
with a problem is loosened, there will not be a change in 6 10
the engine speed.
7
WARNING
Do not put your hands on fuel lines under pressure.
Fuel oil can be injected into your body by the hy-
draulic pressure. 1. RETAINING NUT 6. SPRING SEAT
2. GASKET 7. SPACER
3. NOZZLE HOLDER 8. NOZZLE
Removal 4. SHIM 9. ADJUSTER
5. SPRING 10. RETAINER
1. Disconnect the fuel lines at the fuel injector. Do not
bend the fuel lines. FIGURE 90. FUEL INJECTOR

2. Remove the fuel injectors. See FIGURE 90.

Inspection
NOTE: The inspection and repair of fuel injectors re-
quire special tools and training. Many users have a spe-
cial repair service make repairs on fuel injectors. Fuel
injector nozzles that have damage or are dirty will cause
black smoke in the exhaust, a decrease in engine power,
and an increase in engine noise.
3. The operation of the fuel injector must be checked
with an injection tester. See FIGURE 91. Follow the
instructions by the tester manufacturer.
4. Check the spray pattern of the nozzle. See
FIGURE 91. If the spray pattern is not correct, clean or
replace parts as required.

38

WARNING
Make sure that the nozzle of the injector is away
from the operator during a test. Test oil can be
injected into your body by the hydraulic pressure.
5. Use an injector tester to check the pressure at which
the nozzle operates. The correct pressure is 14.93 MPa
(2133 psi).
6. See FIGURE 90. To change the pressure at which the
nozzle operates, add or subtract shims (4). Shims are
available in thicknesses of 0.10 to 0.80 mm (0.004 to
0.031 in).
1. INJECTOR TESTER
2. FUEL INJECTOR
Installation
1. Install the fuel injector in the cylinder head. Tighten
the injector to 64 N.m (47 lbf ft).
2. Connect the fuel lines and tighten the fittings. Install
the line clamps if they were removed.
3. Remove the air from the fuel system. See “Remove
Air From The Fuel System”.
4. When the engine can be operated, check for fuel
leaks.
FUEL FILTER
NOTE: There is a water separator in the bottom of the
fuel filter. A sender unit in the bottom of the fuel filter
illuminates an indicator light on the instrument panel if
there is water in the water separator.

Filter Replacement
1. See FIGURE 92. Disconnect the two sender wires
from the bottom of the fuel filter. Remove the fuel filter
2
from its mount. Remove the parts that include the sender
unit from the bottom of the fuel filter.
1
2. Install the parts that include the sender unit in the new
fuel filter. Use a new O–ring between the fuel filter and
the sender unit. Lubricate the O–ring with diesel fuel
when it is installed. When the engine can be operated,
check for leaks.

PATTERN NOT CORRECT Remove Air from the Fuel System

NOTE: The fuel injection pump will normally remove
small amounts of air from the fuel system when the
engine is started. If the fuel pump, fuel injection pump,
or the fuel filter is empty, it is necessary to remove air
4° from tha system as described below.
1. See FIGURE 92. Loosen the vent screw on the fuel
filter housing. Use the hand pump to pump fuel from the
vent until there are no air bubbles in the fuel. Hold down
FIGURE 91. CHECK THE FUEL INJECTORS on the hand pump and close the vent screw.

39
 4. Start the engine and check for leaks.
1 1. HAND PUMP
2. HOUSING Check the Water Sensor (See FIGURE 93.)
2 3. VENT SCREW
4. INLET (FROM
FUEL TANK) 1. Check the operation of the sensor for the fuel filter as
4 5. OUTLET (TO follows:
5 3
INJECTION PUMP)
6. FILTER
7. CAP a. Drain the fuel from the filter. Disconnect the
8. SENSOR AND wires at the sensor. Remove the sensor and float
FLOAT assembly from the filter.
9. O–RING
10. WIRE
b. Connect a continuity tester between the two wires
CONNECTOR
11. DRAIN VALVE for the sensor. Lift on the float. There is continu-
6 9 AND HOSE ity when the float is raised. There is no continuity
when the float is lowered.
8

7
10

11

12609

FIGURE 92. FUEL FILTER WITH A WATER

SEPARATOR

2. Loosen the fitting for the return line on the injection

pump. Operate the hand pump until there is fuel at the
injection pump. Rotate the engine until the fuel at the fit-
ting is free of air bubbles. Tighten the fitting.

3. Loosen the supply line at each fuel injector. Rotate the

engine until the fuel at the fittings is free of air bubbles. FIGURE 93. TEST THE WATER SENSOR
Tighten the fittings.

CHECKS AND ADJUSTMENTS

VALVE CLEARANCE ADJUSTMENT INTAKE = 0.40 mm (0.016 in)

NOTE: Before you check the clearance of the valves,
check the torque of the bracket bolts for the rocker arm
assembly. The correct torque is 54 N.m (40 lbf ft).
Number 1 cylinder is at the end of the engine with the
cooling fan. An intake valve is the first valve in the se-
quence.
The valve clearance is measured between the top of the
valve stem and the rocker arm as shown in FIGURE 94.
Valve clearance (cold):
EXHAUST = 0.40 mm (0.016 in)
1. Remove the valve cover. Rotate the crankshaft until
the NO. 1 piston is at TDC on the compression stroke as
indicated by the timing marks on the crankshaft pulley.
See FIGURE 95. In this position, both rocker arms for
the number 1 cylinder will be loose.
2. Adjust the valves that are marked “A” in the table of
FIGURE 94. Do the adjustments when the engine is
cold. The correct valve clearance for all valves is 0.40
mm (0.016 in).

40
3. Rotate the crankshaft 360° until the TDC timing mark
is aligned again as shown in FIGURE 95. At this posi-
tion, the NO. 4 piston will be at TDC on the compression
stroke. Adjust the valves that are marked “B” in the table
of FIGURE 94. TDC

FIGURE 95. TIMING MARKS

9723

CYLINDER ARRANGEMENT
NO. 1 NO. 2 NO. 3 NO. 4
IN EX IN EX IN EX IN EX
A A A B B A B B
1
A – Adjust these valves when No. 1 piston is
at TDC on the compression stroke
1. DISTRIBUTOR HEAD 2
B – Adjust these valves when No. 4 piston is
2. PLUNGER
at TDC on the compression stroke
3. DIAL INDICATOR
FIGURE 94. VALVE CLEARANCE
ADJUSTMENT FIGURE 96. FUEL INJECTION PUMP

3. Rotate the crankshaft counterclockwise approximate-

CHECK THE TIMING OF THE FUEL
INJECTION PUMP
1. Remove the capscrew from the center of the distribu-
tor head (1). See FIGURE 96. Use a dial indicator so
that the movement of the plunger can be measured. The
movement of the plunger can be measured through the
hole in the distributor head where the capscrew was re-
moved.
2. Rotate the crankshaft until the number one piston is at
TDC on the compression stroke. Read the mark for tim-
ing on the crankshaft pulley that is aligned with the indi-
cator on the gear case shown in FIGURE 95. Rotate the
crankshaft before and after TDC to find the maximum
movement of the plunger toward the end of the distribu-
tor head.
ly 30°. Now rotate the crankshaft clockwise slowly.
4. Stop rotating the crankshaft when the plunger is 0.50
mm (0.020 in) less than its maximum movement found
in step 2.
5. Read the mark for timing on the crankshaft pulley that
is aligned with the indicator on the gear case. See
FIGURE 95. The correct timing for injection is 6°
BTDC.
6. If the timing is not correct, loosen the fuel injection
pump and rotate it as necessary. Repeat the procedure
described in step 5 until the timing is correct.
7. Remove the dial gauge and install the capscrew in the
distributor head.
8. Remove the air from the fuel system. The procedure is
described in “Remove the Air From the Fuel System”.

41
THROTTLE LINKAGE, ADJUSTMENT leased. Make sure the control lever is against the maxi-
(See FIGURE 97. and FIGURE 98.) mum speed screw when the pedal touches the floor.

NOTE: Each time the throttle linkage is disassembled, MONOTROL PEDAL

it is important to adjust the throttle cable. SHOWN

Adjust the throttle linkage when the engine is running at

2
idle speed and at normal operating temperature. 1

1. Disconnect the throttle cable at the control lever on

the injection pump.
2. Adjust the idle speed of the engine. The idle adjust- 3 4
5
ment screw on the injection pump controls the idle
speed. The correct idle speed is 725 ± 25 rpm. Be sure to 4
use a tachometer that will work for a diesel engine.
3. Check that the engine speed with the throttle wide
open and no load is 2100 to 2200 rpm. Use the maximum
speed screw on the injection pump for to set the engine
speed at wide open throttle.

1 2
3
4
4
6 4

1. PEDAL FRAME
6 2. PEDAL PAD
5 3. STOP
4. CORRECT HOLES FOR THE LINKAGE
5. LINK
12845
6. CRANK

FIGURE 98. THROTTLE PEDAL AND

1. RETURN SPRING 4. THROTTLE CABLE
2. CONTROL LEVER 5. INJECTION PUMP
3. IDLE ADJUSTMENT 6. MAXIMUM SPEED
SCREW SCREW
FIGURE 97. THROTTLE LINKAGE
4. Make sure the throttle linkage at the pedal assembly is
in the correct position. Hold the throttle pedal against
the floor plate. Hold the control lever in the wide open
position. Adjust the position of the cable by using the
jam nuts on the bracket at the intake manifold. Adjust
the cable so that the rod end fits into the control lever
5. Adjust the stop for the throttle pedal so that the control
lever is completely closed when the pedal is released.
6. Operate the throttle pedal. Make sure the control lever
is against the idle speed screw when the pedal is re-
LINKAGE
CHECK THE ELEMENTS FOR THE COLD
START AID SYSTEM
Check the condition of the glow plugs for the cold start
aid system. See the section THE ELECTRICAL SYS-
TEM for more information.
CHECK THE COMPRESSION PRESSURE
(See FIGURE 99.)
1. Operate the engine until it is at normal operating tem-
perature.
2. Remove the glow plugs from the cylinder head. Dis-
connect the wire at the fuel shut off solenoid on the in-
jection pump. Disconnect the wire for the temperature
switch at the thermostat housing.

42
3. Install a compression gauge in the number 1 cylinder.
Make sure the gauge has a minimum range of 3.5 MPa
(500 psi).
4. Use the starter to crank the engine at least six (6) revo-
lutions. Check the pressure reading and release the pres-
sure. Repeat the test again and make a note of the highest
pressure. Do this test for each cylinder.
5. The standard pressure reading is 3.0 MPa (427 psi).
The minimum reading is 2.7 MPa (384 psi). The maxi-
mum variation between cylinders is 0.3 MPa (43 psi).
6. If the readings are lower than the minimum reading,
there is a problem with the valves, piston rings or cylin-
der head gasket. Do the following tests to find the prob-
lem:
a. Add approximately 30 ml (1.0 oz) of engine oil to
each cylinder at the glow plug port.
b. Crank the engine approximately ten revolutions
to distribute the oil.
c. Install the compression gauge and do the same
tests as described in step 3.
d. If the compression pressure increases to a normal
reading, the low pressure was caused by worn or
damaged piston rings. The cylinder bore can also
be damaged.
e. If the compression reading does not increase, the
low pressure was caused by worn valves, valve
seats or valve guides.
f. If the low pressure readings are in two cylinders
next to each other, the cylinder head can be leak-
ing.
1. ADAPTER
1
FIGURE 99. CHECK THE COMPRESSION
PRESSURE
43
 ENGINE SPECIFICATIONS
ITEM SPECIFICATION
Engine Type In–Line, Four Cylinders
Bore x Stroke 95.4 mm x 107.0 mm (3.76 in x 4.21 in)
Firing Order 1–3–4–2
Displacement 3059 cm3 (186.7 in3)
Compression Ratio 20.5:1
Idle Speed 725 ± 25
Governed Speed (No Load) 2100–2200 rpm
Compression Pressure 2944 kPa (427 psi) @ 250 rpm
Injection Pump Timing 6° BTDC
Oil Pressure @ 2000 rpm 294 kPa (43 psi)
Thermostat
Starts to Open 76.5°C (170°F)
Fully Open 90°C (194°F)
Camshaft
Camshaft Lobes 42.02 mm (1.6543 in)
Camshaft Lobes – Minimum Height 41.65 mm (1.66398 in)
Bearing Journals 49.945–49.975 mm (1.9663–1.9675 in)
Service Limit 49.60 mm (1.953 in)
Clearance Between Journals and Bore 0.12 mm (0.005 in)
End Clearance (Maximum) 0.20 mm (0.0079 in)
Connecting Rods
Small End Bore 21.943–21.961 mm (0.8639–0.8646 in)
Clearance Between Piston Pin and Bore 0.012–0.039 mm (0.0005–0.0015 in)
Service Limit 0.05 mm (0.002 in)
Clearance Between Crankshaft Journals
and Rod Bearings 0.037–0.076 mm (0.0015–0.0030 in)
Crankshaft
Distortion 0.05 mm (0.002 in)
Service Limit 0.08 mm (0.0031 in)
Main Bearing Journal Diameter 69.917–69.932 mm (2.7526–2.7532 in)
Service Limit 69.91 mm (2.7524 in)
Clearance Between Journals and Main Bearings See TABLE 11
Connecting Rod Journal Diameter 52.915–52.930 mm (2.0833–2.0839 in)
Service Limit 52.90 mm (2.0843 in)
Thrust Bearing Clearance 0.10 mm (0.0039 in)
Service Limit 0.30 mm (0.0118 in)
Cylinder Block and Liners
Sizes See TABLES 12 and 13
Cylinder Head
Height 91.55 mm (3.604 in)
Distortion Limit 0.20 mm (0.008 in)

44
 ENGINE SPECIFICATIONS
ITEM ENGINE MODEL
Oil Pump
Clearance Between Shaft and Body (Maximum) 0.2 mm (0.008 in)
Clearance Between Inner and Outer Rotors (Maximum) 0.2 mm (0.008 in)
Clearance Between Outer Rotor and Body (Maximum) 0.4 mm (0.016 in)
End Clearance Between Rotors and Housing (Maximum) 0.15 mm (0.006 in)
Pistons
Diameter See TABLE 9
Clearance in Groove for Piston Rings See TABLE 7
Piston Ring End Clearance See TABLE 6
Piston Pins
Diameter 33.995–34.000 mm (1.3384–1.3386 in)
Service Limit 33.970 mm (1.3374 in)
Rocker Shaft Assembly
Rocker Shaft Diameter 18.98–19.00 mm (0.747–0.748 in)
Service Limit 18.90 mm (0.744 in)
Rocker Arm, Inside Diameter 19.036–19.060 mm (0.7494–0.7503 in)
Service Limit 19.100 mm (0.7519 in)
Valve Mechanism
Clearance in Guide (Intake) 0.039–0.069 mm (0.0015–0.0027 in)
Service Limit 0.200 mm (0.0079 in)
Clearance in Guide (Exhaust) 0.064–0.093 mm (0.0025–0.0037 in)
Service Limit 0.250 mm (0.0098 in)
Diameter of Valve Stem (Intake) 7.946–7.961 mm (0.3128–0.3134 in)
Service Limit 7.880 mm (0.3102 in)
Diameter of Valve Stem (Exhaust) 7.946–7.961 mm (0.3128–0.3134 in)
Service Limit 7.850 mm (0.3091 in)
Valve Seats See FIGURE 13
Valve Face Angle (Intake and Exhaust) 45°
Spring, Free Length 48.0 mm (1.89 in)
Service Limit 47.1 mm (1.86 in)

45
 TORQUE SPECIFICATIONS
ITEM SPECIFICATION
Camshaft Gear 64 N.m (47 lbf ft)
Camshaft Thrust Plate 18 N.m (13 lbf ft)
Cooling Fan 20 N.m (15 lbf ft)
Coolant Pump 19 N.m (14 lbf ft)
Connecting Rod Cap See Text
Crankshaft Pulley 275 N.m (203 lbf ft)
Cylinder Head See Text
Engine Mount to Engine 55 N.m (41 lbf ft)
Exhaust Manifold 18 to 22 N.m (13 to 16 lbf ft)
Flywheel 120 N.m (89 lbf ft)
Flywheel Housing See FIGURE 75
Fuel Injection Pump Drive Gear 64 N.m (47 lbf ft)
Fuel Injection Pump To Adapter Plate 19 N.m (14 lbf ft)
Fuel Injector 64 N.m (47 lbf ft)
Glow Plug 23 N.m (17 lbf ft)
Intake Manifold 16 to 24 N.m (12 to 17 lbf ft)
Main Bearing Cap 167 N.m (123 lbf ft)
Oil Pump 19 N.m (14 lbf ft)
Oil Sump 19 N.m (14 lbf ft)
Rocker Shaft Brackets 54 N.m (40 lbf ft)
Starter 88 N.m (65 lbf ft)
Thermostat Housing 19 N.m (14 lbf ft)
Timing Gear Case 20 N.m (15 lbf ft)
Timing Gear Cover 19 N.m (14 lbf ft)

46

PROBLEM
The engine will not start.
The engine rotates but will
not start.
The engine does not idle
smoothly.
The engine does not have
normal power.
The engine uses too much
fuel.
TROUBLESHOOTING
POSSIBLE CAUSE PROCEDURE OR ACTION
1. Fuel tank is empty. 1. Fill fuel tank.
2. Starter does not operate. 2. Check starter and circuit.
3. Cold start aid does not operate. 3. Check circuit for glow plugs.
4. Neutral start circuit does not oper- 4. Check wiring and switches.
ate correctly.
5. Engine has internal damage. 5. Check and repair.
6. Fuel shut–off solenoid does not op- 6. Check wiring and solenoid.
erate correctly.
7. Battery is not fully charged. 7. Charge the battery.
8. Battery cables dirty or loose. 8. Clean and tighten battery termi-
nals.
1. Fuel tank is empty. 1. Fill fuel tank.
2. Fuel injector(s), or fuel injection 2. Clean or repair.
pump does not operate correctly.
3. Cold start aid does not operate. 3. Check circuit for glow plugs.
4. Fuel lines have a restriction. 4. Repair fuel lines.
5. Fuel shut–off solenoid does not op- 5. Check wiring and solenoid.
erate correctly.
1. Air is in the fuel system. 1. Remove air.
2. Fuel injector(s), or fuel injection 2. Clean or repair.
pump does not operate correctly.
3. Fuel lines have a restriction. 3. Repair fuel lines.
4. Fuel filter has a restriction. 4. Install a new filter element.
5. Water in the fuel system. 5. Drain water from filter.
6. Valves are not adjusted correctly. 6. Adjust the valves.
7. Compression pressure is too low. 7. Repair engine.
1. Air filter has a restriction. 1. Clean or install a new filter.
2. Fuel injector(s), or fuel injection 2. Clean or repair.
pump does not operate correctly.
3. Fuel lines have a restriction. 3. Repair fuel lines.
4. Fuel filter has a restriction. 4. Install a new filter element.
5. Water in the fuel system. 5. Drain water from filter.
6. Valves are not adjusted correctly. 6. Adjust the valves.
7. Compression pressure is too low. 7. Repair engine.
8. Valve springs are worn or broken. 8. Replace springs.
9. Exhaust pipe has a restriction. 9. Clean exhaust pipe.
1. Air filter has a restriction. 1. Clean or install a new filter.
2. Fuel injector(s), or fuel injection 2. Clean or repair.
pump does not operate correctly.
3. Valves are not adjusted correctly. 3. Adjust the valves.
4. Compression pressure is too low. 4. Repair engine.
5. Valve springs are worn or broken. 5. Replace springs.
47
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Engine oil pressure is too 1. Too much oil in the engine, or the 1. Use correct amount and type of oil.
low. wrong type of oil.
2. Oil filter has a restriction. 2. Install a new oil filter.
3. Oil strainer has a restriction. 3. Clean oil strainer.
4. Oil pump is worn. 4. Install a new oil pump.
5. Rocker arm bushings are worn. 5. Install new bushings.
6. Camshaft or bearings are worn. 6. Install a new camshaft or bearings.
7. Crankshaft or bearings are worn. 7 Install a new crankshaft or bear-
ings.
The engine uses too much 1. Too much oil in the engine, or the 1. Use correct amount and type of oil.
oil. wrong type of oil.
2. Oil leaks from seals or gaskets. 2. Install new seals or gaskets.
3. Seals for valve guides are worn. 3. Install new valve guide seals.
4. Piston rings are worn or broken. 4. Install new piston rings.
5. Cylinder liners are worn or dam- 5. Install new liners.
aged.
6. Oil lines or oil filter is loose. 6. Check for loose fittings or filter.
The engine operating temper- 1. Coolant level is too low. 1. Check coolant level.
ature is too high. 2. Drive belt for fan and water pump 2. Install drive belt and adjust tension.
is loose or missing.
3. Radiator has a restriction. 3. Clean or repair radiator.
4. Water pump is worn or damaged. 4. Install a new water pump.
5. Cylinder head gasket leaks. 5. Install a new head gasket.
6. Thermostat does not operate. 6. Install a new thermostat.
7. Leaks in the cooling system. 7. Repair leaks.
8. Fuel injection timing is not correct. 8. Check and adjust timing.
White exhaust smoke. 1. There is water in the fuel. 1. Drain water at fuel filter.
2. Fuel injection timing is not correct. 2. Check and adjust timing.
3. Compression pressure is too low. 3. Repair engine.
4. Seals for valve guides are worn. 4. Install new valve guide seals.
5. Piston rings are worn or broken. 5. Install new piston rings.
6. Cylinder liners are worn or dam- 6. Install new liners.
aged.
Black exhaust smoke. 1. Air filter has a restriction. 1. Clean or install a new filter.
2. Fuel injector is dirty or pressure is 2. Clean and adjust injectors.
too low
3. Fuel injection timing is not correct. 3. Check and adjust timing.

TECHNICAL PUBLICATIONS

600 SRM 553 1/94 Litho in U.S.A.

48