1B (4HG1)

Engine = '16 Model 4HG1
WORKSHOP MANUAL
Mechanical
Mechanical (4HG1) 1B-1
Engine
Mechanical
(4HG1)
Table of Contents
Engine (tilt cab model)....................................................1B-3 removal...................................................................1B-103
removal.......................................................................1B-3 installation...............................................................1B-106
installation...................................................................1B-8 Flywheel......................................................................1B-109
Engine (non tilt cab model)...........................................1B-14 removal...................................................................1B-109
removal.....................................................................1B-14 disassembly.............................................................1B-111
installation.................................................................1B-20 inspection................................................................1B-112
Engine mounting...........................................................1B-26 reassembly..............................................................1B-113
removal.....................................................................1B-26 installation...............................................................1B-114
installation.................................................................1B-28 Flywheel housing........................................................1B-117
Inlet cover......................................................................1B-29 removal...................................................................1B-117
installation.................................................................1B-32 Crankshaft front oil seal..............................................1B-126
Cylinder head cover.......................................................1B-35 removal...................................................................1B-126
installation.................................................................1B-37 Crankshaft rear oil seal................................................1B-131
Rocker arm shaft...........................................................1B-39 removal...................................................................1B-131
disassembly...............................................................1B-41 Piston...........................................................................1B-137
inspection..................................................................1B-42 removal...................................................................1B-137
reassembly................................................................1B-44 disassembly.............................................................1B-139
Camshaft........................................................................1B-49 reassembly..............................................................1B-146
disassembly...............................................................1B-51 Crankshaft...................................................................1B-152
inspection..................................................................1B-53 removal...................................................................1B-152
reassembly................................................................1B-55 disassembly.............................................................1B-166
Idle gear.........................................................................1B-58 reassembly..............................................................1B-170
inspection..................................................................1B-60 Cylinder block.............................................................1B-201
installation.................................................................1B-61 removal...................................................................1B-201
Cylinder head................................................................1B-64 disassembly.............................................................1B-203
removal.....................................................................1B-64 inspection................................................................1B-206
disassembly...............................................................1B-70 reassembly..............................................................1B-207
inspection..................................................................1B-74 installation...............................................................1B-209
reassembly................................................................1B-79 Intake throttle control solenoid valve..........................1B-212
installation.................................................................1B-85 removal...................................................................1B-212
Front cover....................................................................1B-95 inspection................................................................1B-213
installation.................................................................1B-98 Engine speed sensor....................................................1B-215
Crankshaft pulley........................................................1B-103 removal...................................................................1B-215
1B-2 Mechanical (4HG1)
inspection................................................................1B-216
installation...............................................................1B-217
Supplementary Information.........................................1B-218
Engine (tilt cab model)
removal
1. Engine safety information
Caution：
・ Make sure to place chock blocks to the
wheels.
・ Select an engine hoist that is able to withstand
the weight of the engine.
・ Do not get under the engine while the engine
is hoisted.
・ Do not put your hands where they can get
easily caught.
・ Because heavy objects are being dealt with,
be careful of pinching, dropping, interference,
and breakage.
2. Preliminary and post procedures
1. Preliminary procedures 1. Radiator cap
1) Disconnect the battery cable from the battery 2) Loosen the radiator side drain plug, and drain the
negative terminal. coolant into a pan.
2) Raise the vehicle.
3) Tilt the cab.
3. Coolant drain
1. Coolant discharge
Warning：
・ Do not loosen the radiator cap or reserve tank
cap when coolant is hot, as doing so may
result in burns caused by the release of steam
or hot water.
1) Remove the radiator cap from the radiator.
Caution：
・ The radiator cap opens and closes using a
double action mechanism.
・ Do not damage the radiator cap or filler neck.
1. Drain plug
3) Loosen the drain plug on the cylinder block side,

and drain the coolant into a pan.
6. Vacuum hose disconnect

1) Disconnect the vacuum hose from the throttle
chamber.
1. Drain plug
4) Drain coolant from the radiator reserve tank.

5) Tighten the drain plug on the cylinder block side.
6) Tighten the radiator side drain plug. 1. Vacuum hose
Caution： 7. Oil level gauge guide tube removal

・ Do not start the engine without coolant in the 1) Remove the oil level gauge from the oil level gauge
radiator. guide tube.
・ Doing so might cause overheating and prevent
2) Remove the oil level gauge guide tube from the
the engine from running.
crankcase and cylinder head.
4. Clutch removal
Refer to "5.Transmission, Transaxle 5E.Clutch
System(MYY) Clutch removal".
5. Inlet pipe removal
1) Remove the inlet hose and inlet pipe as a set from
the turbocharger intake pipe and intake pipe.
1. Oil level gauge guide tube
8. Engine control cable disconnect

1) Disconnect the engine stop cable from the injection
pump.
1. Inlet pipe
2) Disconnect the engine control cable from the engine 10. Fuel hose disconnect
controllever.
1) Disconnect the fuel return hose from the fuel return
pipe.
2) Disconnect the fuel feed hose from the fuel feed
pipe.
Note：
・ Plug to prevent fuel from coming out, and tie
upward.
11. Radiator removal
Refer to "1.Engine 1D.Cooling(4HG1)
Radiator removal".
12. Cooling fan removal
1) Remove the cooling fan from the set plate.
Note：
・ When removing the set plate, also loosen the
4 collective tightening bolts for the water pump
9. Engine controllever removal pulley and the set plate.
1) Remove the engine control wire from the injection
pump and engine control lever.
2) Remove the engine control lever from the flywheel
housing and injection pump.
13. Air duct removal 15. Power steering oil pump disconnect
1) Remove the air duct from the turbocharger and air 1) Disconnect the power steering oil pump from the
cleaner. flywheel housing.
Note：
・ Remove it with the bracket, and fasten it
together with the hoses to a suitable position
with a wire.
16. Generator disconnect
1) Disconnect the vacuum hose from the vacuum
pump.
2) Disconnect the B-terminal cable from the generator.
3) Disconnect the connector from the generator.
17. Engine removal
1) Install the wire to the engine hanger and hoist, and
hold the engine.
2) Remove the mounting bolts on the chassis frame
side of the engine mounting.
1. Air duct 3) Slowly operate the hoist to raise the engine to the
top surface of the chassis frame.
14. Exhaust brake valve removal
1) Remove the clamp from the tailpipe.
2) Remove the tailpipe from the exhaust silencer.
3) Remove the exhaust silencer from front exhaust
pipe B and the mount bracket.
4) Disconnect the vacuum hose from the exhaust brake
valve.
5) Remove front exhaust pipe B and the exhaust brake
valve as a set from front exhaust pipe A.
6) Remove the clamp from front exhaust pipe A.
7) Remove front exhaust pipe A from the exhaust pipe
adapter.
4) Rotate the engine by 90 degrees.
5) Move from the chassis frame top surface, and

remove the engine.
6) Remove the wire from the engine hanger and hoist.
Caution：
・ Pay careful attention to the interference from
various parts when performing the procedure.
・ Never go under the engine while it is hoisted.
installation 3) Connect the vacuum hose to the vacuum pump.

3. Power steering oil pump connect
1. Engine installation
1) Connect the power steering oil pump to the
1) Install the wire to the engine hanger and hoist.
flywheel housing.
2) Operate the hoist to move the engine to the
Tightening torque： 48 N・m { 4.9 kgf・m / 35 lb・ft }
installation position.
Flywheel housing section bolt
Cylinder block section

4) Slowly lower it to the engine installation position.
1. Flywheel housing section bolt
2. Cylinder block section bolt
4. Exhaust brake valve installation

Caution：
・ Because vibrations and looseness of the
exhaust system can be caused by
mispositioning of exhaust system components
during assembly, temporarily tighten the bolts
until all components are in position, and final
tighten from the engine side in turn.
・ Do not reuse the removed bolt and nut.
・ Visually confirm that there is no foreign
material inside the exhaust pipe or silencer.
1) Install front exhaust pipe A to the exhaust pipe
adapter.
5) Connect the engine mounting aligned with the holes Tightening torque： 67 N・m { 6.8 kgf・m / 49 lb・ft }
on the engine mounting cross member. 2) Install the clamp to front exhaust pipe A.
Tightening torque： 48 N・m { 4.9 kgf・m / 35 lb・ft } Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
6) Remove the wire from the engine hanger and hoist. 3) Install front exhaust pipe B and the exhaust brake
2. Generator connect valve as a set to front exhaust pipe A.
1) Connect the connector to the generator. Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2) Connect the B-terminal cable to the generator. 4) Connect the vacuum hose to the exhaust brake
valve.
6. Cooling fan installation
1) Install the cooling fan to the set plate.
5) Install the exhaust silencer to front exhaust pipe B

and mount bracket.
Mounting bracket side
7. Radiator installation
Front exhaust pipe B side Refer to "1.Engine 1D.Cooling(4HG1)
Radiator installation".
6) Install the tailpipe to the exhaust silencer.
8. Fuel hose connect
1) Connect the fuel return hose to the fuel return pipe.
2) Connect the fuel feed hose to the fuel feed pipe.
9. Engine controllever installation
5. Air duct installation
1) Install the engine control lever to the flywheel
1) Install the air duct to the turbocharger and air
cleaner.
2) Install the engine control wire to the injection pump
Tightening torque： 6 N・m { 0.6 kgf・m / 53 lb・in }
and engine control lever.
1. Air duct
10. Engine control cable connect
1) Connect the engine control cable to the engine
controllever.
2) Install the oil level gauge to the oil level gauge

2) Connect the engine stop cable to the injection guide tube.
pump.
12. Vacuum hose connect
1) Connect the vacuum hose to the throttle chamber.
11. Oil level gauge guide tube installation

1) Install the oil level gauge guide tube to the
crankcase and cylinder head. 1. Vacuum hose
Tightening torque： 50 N・m { 5.1 kgf・m / 37 lb・ft } 13. Inlet pipe installation
1) Install the inlet hose and inlet pipe as a set to the
turbocharger intake pipe and intake pipe.
Inlet pipe bolt
Tightening torque： 23.5 N・m { 2.40 kgf・m / 17.3
lb・ft } Inlet pipe hanger bolt
1. Radiator cap
2. Air bleeding plug
2) Replenish the radiator with coolant.

Caution：
・ Fill slowly to prevent air from entering the
system.
3) Install the air bleeding plug to the water outlet pipe.
Tightening torque： 23.5 N・m { 2.4 kgf・m / 17 lb・
ft }
4) Press the radiator upper hose manually several
times to remove the air from the hose.
Caution：
・ Repeat the operation until the coolant level no
longer lowers.
1. Inlet pipe bolt 5) Install the radiator cap to the radiator.
2. Inlet pipe hanger bolt
6) Add coolant up to the MAX line of the radiator
14. Clutch installation reserve tank.

System(MYY) Clutch installation".
1. Post procedures
1) Lower the cab.
2) Lower the vehicle.
3) Connect the battery cable to the battery negative
terminal.
16. Coolant filling
1. Coolant refill
1) Remove the air bleeding plug from the water outlet
pipe.
1. Radiator reserve tank

2. MAX line
3. MIN line
7) Start and idle the engine for 5 minutes or more.

8) Stop the engine.
11) Install the radiator cap to the radiator.
12) Turn OFF the heater fan switch.
13) Start the engine.
14) Increase the engine speed.
Note：
・ Increase the engine speed to around 2000 rpm
and run the engine for 5 minutes once the
needle of the engine coolant temperature
gauge reaches the center.
15) Touch the radiator upper hose, and confirm that the
coolant in the hose has become warm.
Caution：
・ If the radiator upper hose has not become
warm, raise the engine speed to continue to
warm it up.
・ Do not try determining it by using only an
engine coolant temperature gauge and the hot
air coming out of the heater.
16) Idle the engine for 5 minutes.
17) Stop the engine. 1. Cap
18) Remove the radiator cap from the radiator. 2. Air bleeding plug
Warning： 3) Loosen the air bleeding plug of the fuel filter.
・ Do not loosen the radiator cap or reserve tank 4) Press the priming pump until air is no longer
cap when the coolant is hot, as doing so may discharged.
or hot water.
21) Repeat steps 13 to 20 until the coolant level no
longer lowers.
Caution：
・ If the coolant level of the radiator reserve tank
has lowered the next morning, add up to the
MAX line.
17. Fuel air bleed
1) Prepare the fuel pan.
2) Install the transparent hose to the air bleeding plug
on the fuel filter.
1. Priming pump
5) Tighten the air bleeding plug of the fuel filter.

Caution：
・ Fully remove any fuel around the air bleeding
plug.
6) Pump the priming pump further to send the air in
the fuel system to the injection pump.
7) Start the engine without depressing the accelerator
pedal and let it idle for 5 seconds or more.
8) Depress the accelerator pedal all the way to rev the
engine to its maximum speed and then release the
pedal. Repeat this step for several times.
Caution：
・ If air is insufficiently bled, this might result in
poor engine performance. So, be sure to
perform all processes properly.
18. Engine vehicle inspection
1. Inspection before starting the engine
1) Inspect for the following.
・ Engine oil level
・ Coolant level
・ Items around the engine that may get caught
2. Inspection after starting the engine
・ Abnormal noise
・ Abnormal vibration
・ Fuel leakage
・ Oil leakage
・ Coolant leakage
・ Air leakage
・ Exhaust gas leakage
・ Exhaust gas color
3. Inspection after stopping the engine
・ Coolant level
Engine (non tilt cab model)
removal
1. Engine safety information
Caution：
・ Make sure to place chock blocks to the
wheels.
・ Select an engine hoist that is able to withstand
the weight of the engine.
・ Do not get under the engine while the engine
is hoisted.
・ Do not put your hands where they can get
easily caught.
・ Because heavy objects are being dealt with,
be careful of pinching, dropping, interference,
and breakage.
1. Preliminary procedures 1. Radiator cap
1) Disconnect the battery cable from the battery 2) Loosen the radiator side drain plug, and drain the
negative terminal. coolant into a pan.
3) Tilt the cab.
3. Coolant drain
1. Engine coolant replacement period
Replace coolant every 2 years.
2. Coolant discharge
Warning：
cap when coolant is hot, as doing so may
or hot water.
Caution：
double action mechanism. 1. Drain plug
・ Do not damage the radiator cap or filler neck. 3) Loosen the drain plug on the cylinder block side,
ft }
Caution：
・ Repeat the operation until the water level no
longer drops.
6) Add tap water up to the MAX line of the radiator
reserve tank.
1. Drain plug

6) Tighten the radiator side drain plug.
Caution：
・ Do not start the engine without coolant in the
radiator.
3. Coolant passage cleaning
pipe.
2. MAX line
3. MIN line
7) Start and idle the engine for 20 minutes.

Caution：
・ Circulate the tap water in the heater water
passage system as well.
8) Stop the engine.
1. Radiator cap
2) Replenish the radiator with tap water.

1. Radiator cap 1. Drain plug
10) Loosen the radiator side drain plug, and drain the 12) Drain tap water from the radiator reserve tank.
tap water into a pan. 13) Tighten the drain plug on the cylinder block side.
4. Cab removal
Refer to "9.Body, Cab, Accessories 9M.Cab Mounting
Cab removal".
5. Clutch removal
1. Drain plug

and drain the tap water into a pan.
1. Inlet pipe

chamber.
2) Disconnect the engine control cable from the engine

controllever.
1. Vacuum hose
8. Oil level gauge guide tube removal

1) Remove the oil level gauge from the oil level gauge
guide tube.
10. Engine controllever removal


pump.
11. Fuel hose disconnect 14. Air duct removal

1) Disconnect the fuel return hose from the fuel return 1) Remove the air duct from the turbocharger and air
pipe. cleaner.
pipe.
Note：
・ Plug to prevent fuel from coming out, and tie
upward.
12. Radiator removal
Radiator removal".
Note：
pulley and the set plate.
1. Air duct

valve.
adapter.
16. Power steering oil pump disconnect

1) Disconnect the power steering oil pump from the
flywheel housing.
Note：
with a wire.
17. Generator disconnect
pump.
18. Engine removal
1) Install the wire to the engine hanger and hoist, and
hold the engine.
2) Remove the mounting bolts on the chassis frame
side of the engine mounting.
3) Slowly operate the hoist to raise the engine to the
top surface of the chassis frame.
5) Move from the chassis frame top surface, and
remove the engine.
6) Remove the wire from the engine hanger and hoist.
Caution：
・ Pay careful attention to the interference from
various parts when performing the procedure.
・ Never go under the engine while it is hoisted.
installation during assembly, temporarily tighten the bolts

1. Engine installation tighten from the engine side in turn.
1) Install the wire to the engine hanger and hoist. ・ Do not reuse the removed bolt and nut.
2) Operate the hoist to move the engine to the ・ Visually confirm that there is no foreign
installation position. material inside the exhaust pipe or silencer.
3) Rotate the engine by 90 degrees. 1) Install front exhaust pipe A to the exhaust pipe
adapter.
4) Slowly lower it to the engine installation position.
5) Connect the engine mounting aligned with the holes
on the engine mounting cross member. 2) Install the clamp to front exhaust pipe A.
6) Remove the wire from the engine hanger and hoist. 3) Install front exhaust pipe B and the exhaust brake
valve as a set to front exhaust pipe A.
2. Generator connect
1) Connect the connector to the generator.
4) Connect the vacuum hose to the exhaust brake
2) Connect the B-terminal cable to the generator. valve.
3) Connect the vacuum hose to the vacuum pump.
flywheel housing.

and mount bracket.
Front exhaust pipe B side
1. Flywheel housing section bolt 7) Remove the clamp from the tailpipe.
Caution：
・ Because vibrations and looseness of the cleaner.
mispositioning of exhaust system components Tightening torque： 6 N・m { 0.6 kgf・m / 53 lb・in }
1. Air duct 10. Engine control cable connect
6. Cooling fan installation 1) Connect the engine control cable to the engine
controllever.
2) Connect the engine stop cable to the injection

pump.
7. Radiator installation
11. Oil level gauge guide tube installation 1. Vacuum hose

1) Install the oil level gauge guide tube to the 13. Inlet pipe installation
Tightening torque： 50 N・m { 5.1 kgf・m / 37 lb・ft } turbocharger intake pipe and intake pipe.
Inlet pipe bolt

guide tube.
1. Inlet pipe bolt
14. Clutch installation

15. Cab installation
Refer to "9.Body, Cab, Accessories 9M.Cab Mounting
Cab installation".
1. Post procedures
1) Lower the cab.
2) Lower the vehicle.
terminal.
17. Coolant filling
1. Coolant refill
pipe.

2. MAX line
3. MIN line

8) Stop the engine.
1. Radiator cap 14) Increase the engine speed.
Note：
2) Replenish the radiator with coolant. ・ Increase the engine speed to around 2000 rpm
Caution： and run the engine for 5 minutes once the
・ Fill slowly to prevent air from entering the
gauge reaches the center.
system.
15) Touch the radiator upper hose, and confirm that the
coolant in the hose has become warm.
Caution：
ft }
・ If the radiator upper hose has not become
4) Press the radiator upper hose manually several warm, raise the engine speed to continue to
times to remove the air from the hose. warm it up.
Caution：・ Do not try determining it by using only an
・ Repeat the operation until the coolant level no engine coolant temperature gauge and the hot
longer lowers. air coming out of the heater.
5) Install the radiator cap to the radiator. 16) Idle the engine for 5 minutes.
6) Add coolant up to the MAX line of the radiator 17) Stop the engine.
reserve tank. 18) Remove the radiator cap from the radiator.
Warning：
cap when the coolant is hot, as doing so may
or hot water.
longer lowers.
Caution：
MAX line.
18. Fuel air bleed
1) Prepare the fuel pan.
2) Install the transparent hose to the air bleeding plug
on the fuel filter.
1. Priming pump
5) Tighten the air bleeding plug of the fuel filter.

Caution：
plug.
1. Cap 8) Depress the accelerator pedal all the way to rev the
2. Air bleeding plug engine to its maximum speed and then release the
3) Loosen the air bleeding plug of the fuel filter.
Caution：
4) Press the priming pump until air is no longer
discharged.
19. Engine vehicle inspection
1. Inspection before starting the engine
・ Coolant level
・ Items around the engine that may get caught
2. Inspection after starting the engine
・ Abnormal noise
・ Abnormal vibration
・ Fuel leakage
・ Oil leakage
・ Coolant leakage
・ Air leakage
・ Exhaust gas leakage
・ Exhaust gas color
3. Inspection after stopping the engine
・ Coolant level
Engine mounting
removal 1. Component views
Engine mounting
Part name Note：

1. Fan guide ・ Place it on the cooling fan.
2. Engine mounting 4. Engine mounting removal
Tightening torque 1) Install the wire to the engine hanger and the hoist,
and hold the engine.
1： 48 N・m { 4.9 kgf・m / 35 lb・ft }
2) Remove the nuts and bolts from the engine
2： 51 N・m { 5.2 kgf・m / 38 lb・ft }
mounting.
3： 106 N・m { 10.8 kgf・m / 78 lb・ft }
3) Slightly winch up the engine, and remove the
2. Preliminary and post procedures engine mounting from the engine and frame.
1. Preliminary procedures
1) Disconnect the battery cable from the battery
negative terminal.
3) Tilt the cab.
3. Fan guide removal
1) Remove the fan guide from the radiator.
installation 1. Component views
Engine mounting
Part name 1) Install the fan guide to the radiator.

1. Fan guide 4. Preliminary and post procedures
2. Engine mounting
1. Post procedures
Tightening torque 1) Lower the cab.
1： 48 N・m { 4.9 kgf・m / 35 lb・ft } 2) Lower the vehicle.
2： 51 N・m { 5.2 kgf・m / 38 lb・ft } 3) Connect the battery cable to the battery negative
3： 106 N・m { 10.8 kgf・m / 78 lb・ft } terminal.
2. Engine mounting installation

1) Install the engine mounting to the engine and frame.
2) Install the nuts and bolts to the engine mounting.
Tightening torque： 106 N・m { 10.8 kgf・m / 78 lb・
ft } Engine foot side nut
Engine foot side bolt
Chassis frame side nut
3) Remove the wire from the engine hanger and the
hoist.
3. Fan guide installation
Inlet cover
Inlet cover
Part name 1) Remove the inlet hose and inlet pipe as a set from
1. Inlet case
2. Gasket
3. Inlet cover
4. Intake pipe
5. Mounting rubber
Tightening torque
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2： 18 N・m { 1.8 kgf・m / 13 lb・ft }
3： 19 N・m { 1.9 kgf・m / 14 lb・ft }
negative terminal.
2) Tilt the cab.
1. Inlet pipe

chamber.
1. Fuel suction pipe

2. Fuel feed pipe
3. Fuel return pipe
1. Vacuum hose
4. Fuel pipe
7. Injection pipe removal
1) Loosen the injection pipe.
guide tube.
Caution：
crankcase and cylinder head. ・ Do not apply excessive force to the injection
pipe.
2) Remove the injection pipe clip from the injection
pipe.
3) Remove the injection pipe from the injection pump
and injection nozzle.
6. Fuel pipe removal

1) Remove the fuel return pipe from the injection
pump.
1. Injection pipe clip
2. Injection pipe
8. Inlet cover removal

1) Remove the intake pipe from the inlet cover.
2) Remove the inlet cover and gasket from the inlet
case.
1. Gasket
2. Intake pipe
3. Inlet cover
4. Mounting rubber
3) Remove the inlet case from the cylinder head.
1. Inlet case
Inlet cover
Part name 3) Install the inlet case to the cylinder head in the
order shown in the diagram.
1. Inlet case
2. Gasket Tightening torque： 19 N・m { 1.9 kgf・m / 14 lb・ft }
3. Inlet cover
4. Intake pipe
5. Mounting rubber
Tightening torque
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2： 18 N・m { 1.8 kgf・m / 13 lb・ft }
3： 19 N・m { 1.9 kgf・m / 14 lb・ft }
2. Inlet cover installation
1) Clean the cylinder head installation surface.
2) Align with the groove on the inlet case, and then
apply ThreeBond 1207C to the inlet case.
Caution：
・ Do not apply to the wide groove inside.
・ Install the inlet cover within 7 minutes of
applying liquid gasket. 1. Application area
Standard： 2.5 to 5.5 mm { 0.098 to 0.217 in } Bead 4) Install the inlet cover and gasket to the inlet case in
width the order shown in the diagram.
Caution： 1. 41 mm {1.61 in}
・ Do not drop the gasket. 2. 14 mm {0.55 in}
3. 13 mm {0.51 in}
3) Final tighten the injection pipe to the injection
pump and injection nozzle.
4. Fuel pipe installation
pump.
5) Install the intake pipe to the inlet cover.

3. Injection pipe installation
1) Temporarily tighten the injection pipe to the
injection pump and injection nozzle.
2) Referring to the diagram, install the injection pipe
clip to the injection pipe.
2. Fuel feed pipe
Caution： 3. Fuel return pipe
・ Make sure to confirm that the clips are 4. Fuel pipe
correctly positioned.
・ Injection pipe noise occurs when clips are
attached at inappropriate locations. 1) Install the oil level gauge guide tube to the
1. Oil level gauge guide tube 1. Inlet pipe bolt

guide tube. 8. Preliminary and post procedures
6. Vacuum hose connect 1. Post procedures
1) Connect the vacuum hose to the throttle chamber. 1) Lower the cab.
terminal.
1. Vacuum hose
7. Inlet pipe installation

turbocharger intake pipe and intake pipe.
Inlet pipe bolt
Cylinder head cover
Cylinder head cover
Part name 1. Preliminary procedures

1. Cylinder head cover 1) Disconnect the battery cable from the battery
2. Gasket negative terminal.
3. Mounting rubber
2) Tilt the cab.
4. Cylinder head
5. Cam end gasket 3. Inlet pipe removal
6. Mounting rubber
Tightening torque the turbocharger intake pipe and intake pipe.
1： 18 N・m { 1.8 kgf・m / 13 lb・ft }

2： 18 N・m { 1.8 kgf・m / 13 lb・ft }
1. Inlet pipe 1. Cylinder head cover

2. Gasket
4. Turbocharger intake pipe removal
3) Remove the cam end gasket from the cylinder head.
1) Remove the Turbocharger intake pipe from the
turbocharger. Caution：
・ Carefully remove the liquid gasket still on the
cylinder head.
1. Turbocharger intake pipe
5. Cylinder head cover removal

1) Remove the cylinder head cover from the cylinder
head.
2) Remove the gasket from the cylinder head cover.
Cylinder head cover
Part name Caution：

1. Cylinder head cover ・ Clean the application surface of the gasket
2. Gasket before applying the gasket.
3. Mounting rubber ・ Install the cylinder head cover within 7 minutes
4. Cylinder head of applying liquid gasket.
5. Cam end gasket
Standard： 3 to 4 mm { 0.12 to 0.16 in } Bead height
6. Mounting rubber
Standard： 3 to 4 mm { 0.12 to 0.16 in } Bead width
Tightening torque
1： 18 N・m { 1.8 kgf・m / 13 lb・ft }
2： 18 N・m { 1.8 kgf・m / 13 lb・ft }
2. Cylinder head cover installation
1) Referring to the diagram, apply ThreeBond 1207B
to the cam end gasket and cylinder head.
1. 10 mm {0.39 in} 1. Turbocharger intake pipe

2. 30 mm {1.18 in}
4. Inlet pipe installation
2) Install the gasket to the cylinder head cover.
3) Install the cylinder head cover to the cylinder head turbocharger intake pipe and intake pipe.
in the order shown in the diagram.
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } Inlet pipe bolt
3. Turbocharger intake pipe installation

1) Install the Turbocharger intake pipe to the
turbocharger. 1. Inlet pipe bolt
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } 2. Inlet pipe hanger bolt

1. Post procedures
1) Lower the cab.
terminal.
Rocker arm shaft
Rocker arm shaft
Part name 3. Rocker arm shaft removal

1. Camshaft bearing cap 1) Remove the rocker arm shaft from the cylinder head
2. Rocker arm as a set with the camshaft bearing cap.
3. Rocker arm shaft spring
Note：
4. Rocker arm bracket
5. Valve stem end cap ・ Do not remove the bolts in the diagram at this
6. Rocker arm shaft time since they are the bolts for securing the
rocker arm shaft.
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 27 N・m { 2.8 kgf・m / 20 lb・ft }
3： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4： 56 N・m { 5.7 kgf・m / 41 lb・ft }
5： 27 N・m { 2.8 kgf・m / 20 lb・ft }
6： 27 N・m { 2.8 kgf・m / 20 lb・ft }
7： 56 N・m { 5.7 kgf・m / 41 lb・ft }
Refer to "Cylinder head cover removal" in this section.
Caution：
・ Do not drop the bridge cap into the cylinder
head rear gear case section or the front oil
return hole.
disassembly 1. Component views
Rocker arm shaft
Part name ・ Spring

・ Rocker arm bracket
1. Camshaft bearing cap
2. Rocker arm
5. Valve stem end cap
6. Rocker arm shaft
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 27 N・m { 2.8 kgf・m / 20 lb・ft }
3： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4： 56 N・m { 5.7 kgf・m / 41 lb・ft }
5： 27 N・m { 2.8 kgf・m / 20 lb・ft }
6： 27 N・m { 2.8 kgf・m / 20 lb・ft }
7： 56 N・m { 5.7 kgf・m / 41 lb・ft }
2. Rocker arm shaft disassembly
1) Remove the following parts from the rocker arm
shaft.
・ Camshaft bracket
・ Rocker arm
inspection 1) Measure the outer diameter of the 8 rocker arm

sliding sections of the rocker arm shaft using a
1. Rocker arm shaft inspection micrometer.
1. Visual inspection Note：
1) Inspect the oil hole on the camshaft bracket rear ・ If the measured value exceeds the limit,
side for clogging. replace the rocker arm shaft.
Standard： 21.979 to 22.000 mm { 0.86531 to 0.86614
in }
Limit： 21.85 mm { 0.8602 in }
2. Rocker arm shaft runout measurement

1) Apply the dial gauge to the shaft center, and
measure the runout of the rocker arm shaft while
rotating the shaft. 2) Measure the bushing inner diameter of the rocker
Note： arm using a cylinder gauge.
・ If minor fluctuation is found upon Standard： 22.010 to 22.035 mm { 0.86653 to 0.86752
measurement, correct it using the press. in }
・ If the measured value exceeds the limit, Limit： 22.15 mm { 0.8720 in }
replace the rocker arm shaft.
Limit： 0.3 mm { 0.012 in }
3) Calculate the clearance between the rocker arm and

rocker arm shaft.
3. Oil clearance measurement
Note：
・ If the measured value exceeds the limit,
replace the rocker arm and rocker arm shaft.
Standard： 0.010 to 0.056 mm { 0.00039 to 0.00220 in }
Limit： 0.2 mm { 0.008 in }
4. Clearance measurement between roller pin and
roller
1) Referring to the diagram, pass a string, etc., through
the clearance between the rocker arm and the roller.
2) Strongly pull the string in the direction of the arrow
shown in the diagram to push out the roller from the
rocker arm.
3) Measure the step of the rocker arm and roller using
a vernier caliper, etc., and apply a mark to the
measured point.
4) Remove the string from the rocker arm shaft.
5) Referring to the diagram, measure the level
difference at the mark position with the roller
pressed in the rocker arm as far as possible using a
vernier caliper, etc.
1. With roller pushed out

2. With roller pushed in
6) Calculate the clearance between the roller and the

rocker arm from the difference between the step
dimension measured with the roller pushed out and
the dimension measured with the roller pushed in.
Note：
replace the rocker arm.
Limit： 0.5 mm { 0.020 in }
reassembly 1. Component views
Rocker arm shaft

1. Camshaft bearing cap ・ Final tighten the rocker arm shaft to the
2. Rocker arm cylinder head after it has been installed.
6. Rocker arm shaft
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 27 N・m { 2.8 kgf・m / 20 lb・ft }
3： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4： 56 N・m { 5.7 kgf・m / 41 lb・ft }
5： 27 N・m { 2.8 kgf・m / 20 lb・ft }
6： 27 N・m { 2.8 kgf・m / 20 lb・ft }
7： 56 N・m { 5.7 kgf・m / 41 lb・ft }
2. Rocker arm shaft reassembly
1) Temporarily tighten the camshaft bearing cap to the 2) Apply engine oil to the rocker arm inner diameter,
rocker arm shaft. roller and rocker arm pin.
3) Install the rocker arm to the rocker arm shaft. 6) Temporarily tighten the camshaft bearing cap to the
rocker arm shaft.
4) Install the spring to the rocker arm shaft.
Caution：
・ Final tighten the rocker arm shaft to the
cylinder head after it has been installed.
5) Install the rocker arm bracket to the rocker arm

shaft.
Caution：
・ Do not mistake the assembly position and
direction.
Rocker arm shaft
Part name Note：

1. Camshaft bearing cap ・ Workability will be improved if the bolts
2. Rocker arm indicated by arrows in the diagram are
3. Rocker arm shaft spring loosened.
6. Rocker arm shaft
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 27 N・m { 2.8 kgf・m / 20 lb・ft }
3： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4： 56 N・m { 5.7 kgf・m / 41 lb・ft }
5： 27 N・m { 2.8 kgf・m / 20 lb・ft }
6： 27 N・m { 2.8 kgf・m / 20 lb・ft }
7： 56 N・m { 5.7 kgf・m / 41 lb・ft }
2. Rocker arm shaft installation
1) Apply engine oil to the rocker arm roller section.
2) Install the rocker arm shaft to the cylinder head. 3) Install the bolt to the cylinder head.
Tightening torque： 56 N・m { 5.7 kgf・m / 41 lb・ft } Measurement point when the No.1 cylinder is at the
Bolt 1 (Engine oil application) compression top dead center
Bolt 2 (Engine oil application)
Bolt 3
Measurement point when the No.4 cylinder is at the

compression top dead center
1. Bolt 1
2. Bolt 2
3. Bolt 3
3. Rocker arm shaft adjustment

1. Valve clearance adjustment
Caution：
・ Be sure to work while the engine is cool.
・ Adjust so that the bridge is level.
Standard： 0.4 mm { 0.016 in } Inlet valve
Standard： 0.4 mm { 0.016 in } Exhaust valve
Measurable valve position
#1 #2 #3 #4 1) Rotate the crankshaft in the forward direction
Cylinder position E E E E (clockwise) to align the No. 1 cylinder piston to
IN IN IN IN compression top dead center.
X X X X
No. 1 cylinder Note：
compression top dead ○ ○ ○ ○ ・ Check the crankshaft pulley marking and front
center cover alignment mark.
No. 4 cylinder
compression top dead ○ ○ ○ ○
center
2) Tighten the adjust screw, and adjust the valve

clearance to the specified value.
Standard： 0.4 mm { 0.016 in }
1. Feeler gauge
3) Secure the adjust screw with the lock nut.

4) Rotate the crankshaft for 1 turn, and adjust any
remaining valve clearance.
Refer to "Cylinder head cover installation" in this
section.
Camshaft
Camshaft
Part name Note：

1. Camshaft bearing cap ・ Check with the crankshaft pulley marking and
2. Upper camshaft bearing front cover alignment mark.
3. Knock pin 2) Confirm that the I mark on the camshaft gear end
4. Camshaft gear face is aligned with the top surface of the cylinder
5. Lower camshaft bearing head.
6. Camshaft
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 142 N・m { 14.5 kgf・m / 105 lb・ft }
2. Rocker arm shaft removal
Refer to "Rocker arm shaft removal" in this section.
3. Camshaft removal
1) Rotate the crankshaft in the forward direction
(clockwise) to align the No. 1 cylinder piston to
compression top dead center.
3) Measure the end play of the camshaft gear and

camshaft bearing cap using a feeler gauge.
Limit： 0.25 mm { 0.0098 in }
4) Remove the camshaft from the cylinder head.

Note：
・ For removed caps and bearings, attach labels
etc. with marks so that they can be installed to
their original position.
Camshaft
Part name
2. Upper camshaft bearing
3. Knock pin
4. Camshaft gear
5. Lower camshaft bearing
6. Camshaft
SST: 5-8840-2027-0 - universal puller
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 142 N・m { 14.5 kgf・m / 105 lb・ft }
2. Camshaft disassembly
1) Remove the camshaft gear mounting bolt from the
camshaft gear.
2) Remove the camshaft gear from the camshaft using SST: 5-8840-0086-0 - timing pulley remover
the special tool.
Note：
・ Pinch the puller by a wooden block, and
remove the camshaft gear.
・ Use 5-8840-2027-0 or 5-8840-0086-0.
1. Wooden block
3) Remove the knock pin from the camshaft.

inspection
1. Camshaft inspection
1. Visual inspection
1) Inspect the camshaft journal and cam for the
following.
・ Damage
・ Wear
Note：
・ Replace the camshaft if a malfunction is found.
3. Camshaft journal measurement

1) Measure the diameter of the camshaft journal using
a micrometer.
Note：
replace the camshaft.
Standard： 39.950 to 39.975 mm { 1.57283 to 1.57382
in }
Limit： 39.850 mm { 1.56889 in }
Limit： 0.05 mm { 0.0020 in } Uneven wear
2. Cam lobe measurement
1) Measure the height of the cam lobe using a
micrometer.
Note：
Limit： 51.8 mm { 2.039 in }
4. Camshaft runout measurement

1) Measure the runout of the camshaft using a dial
gauge.
Note：
・ Slowly turn the camshaft to measure the
camshaft runout using a dial gauge.

Limit： 0.05 mm { 0.0020 in }
5. Oil clearance measurement

1) Measure the inner diameter of the camshaft bearing
using a cylinder gauge.
Standard： 40.000 to 40.037 mm { 1.57480 to 1.57626
in }
2) Read the difference of the inner diameter of the
camshaft bearing and diameter of the camshaft
journal and calculate the camshaft journal oil
clearance.
Note：
replace the camshaft bearing.
Limit： 0.15 mm { 0.0059 in }
Camshaft
Part name
3. Knock pin
4. Camshaft gear
6. Camshaft
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 142 N・m { 14.5 kgf・m / 105 lb・ft }
2. Camshaft reassembly
1) Install the dowel pin to the camshaft.
2) Face the projecting side of the camshaft gear center
boss section towards the camshaft side, align it with
the dowel pin, and install the camshaft gear to the
camshaft.
ft }
Caution：
・ Do not damage the cam or journal section.
Camshaft
Part name 4) Install the camshaft on the cylinder head so that the
top surface of the cylinder head is aligned with the I
mark on the camshaft gear end face.
3. Knock pin
4. Camshaft gear
6. Camshaft
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2： 142 N・m { 14.5 kgf・m / 105 lb・ft }
2. Camshaft installation
Note：
・ Check the crankshaft pulley marking and front
cover alignment mark.
2) Apply engine oil to the lower camshaft bearing. 5) Install the upper camshaft bearing to the camshaft
3) Install the lower camshaft bearing to the cylinder bearing cap.
head. 6) Apply engine oil to the upper camshaft bearing.
7) Orient the front mark of the bearing cap towards the
engine front, and temporarily install the camshaft
bearing cap to the cylinder head in the order of the
numbers.
8) Apply engine oil to the threaded portion and seat

surface of the bearing cap tightening nut.
9) Install the tightening nut to the bearing cap, and
final tighten the bearing cap.
Caution：
・ After tightening, make sure the I mark is
aligned.
3. Rocker arm shaft installation

Refer to "Rocker arm shaft installation" in this section.
Idle gear
Idle gear
Part name 13. Idle gear B

14. Idle gear A
1. Power steering oil pump idle gear
15. Power steering oil pump
2. Idle gear cover
3. Clutch pressure plate Tightening torque
4. Clutch disc
5. Flywheel 1： 48 N・m { 4.9 kgf・m / 35 lb・ft }
6. Crankshaft rear oil seal 2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
7. Flywheel housing
8. Engine speed sensor 3： 44 N・m { 4.5 kgf・m / 32 lb・ft }
9. Slinger 4： 25 N・m { 2.5 kgf・m / 18 lb・ft }
10. Oil pump
11. Oil pan 5： 96 N・m { 9.8 kgf・m / 71 lb・ft }
12. Idle gear B shaft 6： 96 N・m { 9.8 kgf・m / 71 lb・ft }
7： 96 N・m { 9.8 kgf・m / 71 lb・ft } Note：
8： 96 N・m { 9.8 kgf・m / 71 lb・ft } ・ If the measured value exceeds the limit,
replace the idle gear or thrust collar.
9： 134 N・m { 13.7 kgf・m / 99 lb・ft }
10： 19 N・m { 1.9 kgf・m / 14 lb・ft }
Limit： 0.200 mm { 0.00787 in }
11-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
Note：
11-2： 90 to 120 °
・ Measure idle gear play in the axis direction
12： 40 N・m { 4.1 kgf・m / 30 lb・ft } before removing idle gear B.
13： 8 N・m { 0.8 kgf・m / 71 lb・in }
14： 48 N・m { 4.9 kgf・m / 35 lb・ft }
15： 157 N・m { 16.0 kgf・m / 116 lb・ft }
16： 110 N・m { 11.2 kgf・m / 81 lb・ft }
17： 31 N・m { 3.2 kgf・m / 23 lb・ft }
2. Flywheel housing removal
Refer to "Flywheel housing removal" in this section.
3. Idle gear removal
1) Apply the dial gauge to the idle gear tooth to be
measured, and gently move the gear left and right to
measure the fluctuation of the dial gauge.
Note：
・ Measure idle gear backlash before removing
the idle gear A.
3) Remove idle gear A from the cylinder block.
replace the idle gear. 4) Remove idle gear B from the idle gear shaft.
Caution： 5) Remove the idle gear B shaft from the cylinder

block.
・ Always fasten the other gear.
Limit： 0.30 mm { 0.0118 in }
2) Measure the clearance between the idle gear and the

thrust collar using a feeler gauge.
inspection 3) Calculate the clearance between the idle gear and

idle gear shaft.
1. Idle gear inspection
Note：
1) Use a micrometer to measure the outer diameter of ・ If the measured value exceeds the limit,
the idle gear shaft. replace the idle gear or idle gear shaft.
Note： Standard： 0.020 to 0.062 mm { 0.00079 to 0.00244 in }
Limit： 0.200 mm { 0.00787 in }
replace the idle gear shaft.
Standard： 29.959 to 29.980 mm { 1.17949 to 1.18031
in }
Limit： 29.800 mm { 1.17323 in }
2) Use a dial gauge to measure the inner diameter of

the idle gear bushing.
Standard： 30.000 to 30.021 mm { 1.18110 to 1.18193
in }
Limit： 30.100 mm { 1.18504 in }
Idle gear
Part name
Tightening torque
1： 48 N・m { 4.9 kgf・m / 35 lb・ft }
2. Idle gear cover
3. Clutch pressure plate 2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
4. Clutch disc
3： 44 N・m { 4.5 kgf・m / 32 lb・ft }
5. Flywheel
6. Crankshaft rear oil seal 4： 25 N・m { 2.5 kgf・m / 18 lb・ft }
7. Flywheel housing 5： 96 N・m { 9.8 kgf・m / 71 lb・ft }
8. Engine speed sensor
10. Oil pump 7： 96 N・m { 9.8 kgf・m / 71 lb・ft }
11. Oil pan
12. Idle gear B shaft 8： 96 N・m { 9.8 kgf・m / 71 lb・ft }
13. Idle gear B 9： 134 N・m { 13.7 kgf・m / 99 lb・ft }
14. Idle gear A
15. Power steering oil pump 10： 19 N・m { 1.9 kgf・m / 14 lb・ft }
11-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
11-2： 90 to 120 °
12： 40 N・m { 4.1 kgf・m / 30 lb・ft }
13： 8 N・m { 0.8 kgf・m / 71 lb・in }
14： 48 N・m { 4.9 kgf・m / 35 lb・ft }
15： 157 N・m { 16.0 kgf・m / 116 lb・ft }
16： 110 N・m { 11.2 kgf・m / 81 lb・ft }
17： 31 N・m { 3.2 kgf・m / 23 lb・ft }
2. Idle gear installation
1) Install the idle gear B shaft to the cylinder block.
1. Idle gear B
2. Thrust collar
3. Bolt

Note：
2) Apply engine oil to the idle gear B shaft.

3) Referring to the diagram, install idle gear B to the
idle gear shaft.
ft }
5) Align the alignment markings for the crankshaft

gear and idle gear A.
6) Apply engine oil to the threaded portion and the
seating surface of the bolt.
7) Apply engine oil to both sides of washer.
8) Apply engine oil to the bearing surface of idle gear
A.
9) Install idle gear A to the cylinder block.
Caution： and both sides of the washer are completely
・ Before assembling, be sure to confirm that the covered in engine oil.
threaded portion and seat surface of the bolt
ft }
1. Idle gear C 6. Crankshaft gear

2. Camshaft gear 7. Oil pump drive gear
3. Idle gear B 8. Injection nozzle gear
4. Power steering oil pump gear 9. Idle gear A
3. Flywheel housing installation

Refer to "Flywheel housing installation" in this section.
Cylinder head
Cylinder head
Part name 4： 95 N・m { 9.7 kgf・m / 70 lb・ft }

1. Valve stem end cap 5： 48 N・m { 4.9 kgf・m / 35 lb・ft }
2. Split collar
6-1： 98 N・m { 10.0 kgf・m / 72 lb・ft }
3. Valve spring upper seat
4. Valve spring 6-2： 147 N・m { 15.0 kgf・m / 108 lb・ft }
5. Valve stem oil seal
6-3： 30 to 60 °
6. Valve spring lower seat
7. Valve guide 7： 48 N・m { 4.9 kgf・m / 35 lb・ft }
8. Idle gear C 2. Camshaft removal
9. Idle gear C cover
10. Rear engine hanger Refer to "Camshaft removal" in this section.
11. Intake and exhaust valve 3. Coolant drain
12. Cylinder head
13. Front engine hanger 1. Coolant discharge
14. Thermostat Warning：
15. Water outlet pipe
Tightening torque cap when coolant is hot, as doing so may
1： 24 N・m { 2.4 kgf・m / 18 lb・ft } or hot water.
2： 24 N・m { 2.4 kgf・m / 18 lb・ft } 1) Remove the radiator cap from the radiator.
3： 38 N・m { 3.9 kgf・m / 28 lb・ft }
Caution：
double action mechanism.
・ Do not damage the radiator cap or filler neck.
1. Drain plug

1. Radiator cap
Caution：
2) Loosen the radiator side drain plug, and drain the
・ Do not start the engine without coolant in the
coolant into a pan.
radiator.
chamber.
1. Drain plug

1. Vacuum hose

guide tube.

2. Fuel feed pipe
3. Fuel return pipe
4. Fuel pipe
1. Oil level gauge guide tube 8. Fuel filter removal

1) Remove the fuel filter from the bracket.
6. Water bypass hose disconnect
1) Disconnect the connector from the thermometer
unit. 1) Loosen the injection pipe.
2) Disconnect the water bypass hose from the cylinder Caution：
head. ・ Do not apply excessive force to the injection
pipe.
2) Remove the injection pipe clip from the injection
pipe.
1. Water bypass hose
7. Fuel pipe removal

1) Remove the fuel feed pipe from the injection pump
and fuel filter.
2) Remove the fuel suction pipe from the injection 1. Injection pipe clip
pump and fuel filter. 2. Injection pipe
2. Intake pipe
10. Injection nozzle removal
3. Inlet cover
1) Remove the nozzle leak off pipe from the injection 4. Mounting rubber
nozzle.
3) Remove the inlet case from the cylinder head.
2) Remove the injection nozzle from the cylinder
head.
Caution：
・ Store the removed injection nozzles with the
cylinder numbers attached.
1. Inlet case
12. Radiator upper hose removal

1) Remove the radiator upper hose from the water
outlet pipe and radiator.
1. Injection nozzle 2) Disconnect the coolant reserve tank hose from the
2. Nozzle holder radiator.
3. Gasket
11. Inlet cover removal
case.
valve.
adapter.
1. Gasket
14. Air duct removal 1. Feed oil pipe

2. Turbocharger
1) Remove the air duct from the turbocharger and air
3. Heat protector
cleaner.
4. Water return pipe
5. Water feed pipe
6. Oil drain pipe
16. Feed oil pipe removal

1) Remove the feed oil pipe from the turbocharger and
flywheel housing.
17. Oil drain pipe removal
1) Remove the oil drain pipe from the turbocharger
and cylinder block.
18. Turbocharger removal
1) Remove the heat protector from the exhaust pipe
adapter.
2) Remove the exhaust pipe adapter from the
turbocharger.
1. Air duct
15. Water feed pipe removal

1) Remove the water return pipe from the turbocharger
and the cylinder head.
2) Remove the water feed pipe from the turbocharger
and cylinder block.
1. Turbocharger 4) Remove the cylinder head gasket from the cylinder
2. Exhaust pipe adapter block.
3) Remove the turbocharger from the cylinder head. Caution：

・ Do not reuse the cylinder head gasket.
1. Cylinder head
2. Turbocharger
4) Remove the gasket from the cylinder head.

19. Cylinder head removal
1) Remove the dummy plug from the cylinder head.
2) Loosen the cylinder head bolts evenly in the order
shown in the diagram.
Caution：
・ Do not overlook bolt 1 and 2 in the diagram,
because they are tightened to the flywheel
housing.
3) Remove the cylinder head from the cylinder block.

Cylinder head
Part name 6-1： 98 N・m { 10.0 kgf・m / 72 lb・ft }

1. Valve stem end cap 6-2： 147 N・m { 15.0 kgf・m / 108 lb・ft }
2. Split collar
6-3： 30 to 60 °
4. Valve spring 7： 48 N・m { 4.9 kgf・m / 35 lb・ft }
2. Front engine hanger removal
7. Valve guide 1) Remove the front engine hanger from the cylinder
8. Idle gear C head.
10. Rear engine hanger
11. Intake and exhaust valve
12. Cylinder head
13. Front engine hanger
14. Thermostat
Tightening torque
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
3： 38 N・m { 3.9 kgf・m / 28 lb・ft }
4： 95 N・m { 9.7 kgf・m / 70 lb・ft }
5： 48 N・m { 4.9 kgf・m / 35 lb・ft }
3. Rear engine hanger removal 1. Thermostat

2. Cylinder head
1) Remove the rear engine hanger from the bracket.
2) Remove the bracket from the cylinder head. 3) Remove the thermostat housing gasket from the
thermostat.
5. Thermometer unit removal
1) Remove the thermometer unit from the cylinder
head.
1. Bracket
4. Thermostat removal
1) Remove the water outlet pipe from the cylinder
6. Idle gear C removal
head.
1) Remove the idle gear C cover from the cylinder
2) Remove the thermostat from the cylinder head.
head using a screwdriver.
Note：
・ Referring to the diagram, lightly bring the tip of
the screwdriver into contact with the sealing
cup outer circumference, lightly tap it, turn the
sealing cup in the reverse direction, and draw
it out with pliers or other tool.
2) Remove the idle gear C from the cylinder head. 2) Remove the upper spring seat from the valve spring.
3) Remove the valve spring from the cylinder head.
Note：
・ Organize the removed valve springs in the
order of the cylinder number.
8. Valve removal
1) Remove the inlet valve and the exhaust valve from
the cylinder head.
Note：
・ Organize removed valves by cylinder using
labels. etc.
1. Idle gear C
2. Idle gear shaft
3. Washer
4. Bolt
7. Valve spring removal

1) Remove the split collar from the bulb using special
tool.
9. Valve stem oil seal removal

1) Remove the valve stem oil seal from the cylinder
head using pliers.
SST: 5-8840-2228-0 - valve spring compressor
Caution：
・ Do not reuse the oil seal.
Note：
・ The valve seat insert becomes easier to
remove by contraction caused by cooling.
3) Remove the valve seat insert from the cylinder head
using a screwdriver.
Caution：
・ Do not damage the cylinder head.
2) Remove the lower spring seat from the cylinder

head.
10. Valve guide removal
1) Drive out the valve guide from the cylinder head
lower side using the special tool and remove it.
1. Arc welded section

2. Cylinder head
3. Valve seat insert
4. Screwdriver
SST: 5-8840-2227-0 - valve guide replacer
11. Valve seat insert removal

1) Arc weld the entire inner circumference of the valve
seat insert.
2) Cool the valve seat insert for about 3 minutes.
inspection
1. Valve guide inspection
1) Inspect the valve stem and valve guide inner
diameter section for the following.
・ Scratches
・ Abnormal wear
Note：
・ Replace the valve and valve guide as a set if a
malfunction is found.
2. Bridge cap inspection
1. Valve stem end cap measurement
1) Measure the contact surface with the valve stem end
cap rocker arm.
Limit： 0.1 mm { 0.004 in }
Caution：
・ Replace the valve and valve guide as a set.
2. Clearance measurement between valve guide and
valve stem
1) Measure the clearance between the valve guide and
the valve stem within the range of the measuring
points from the valve guide using a dial gauge.
Note：
replace the valve and valve guide as a set.
Measurem From the top
ent edge section of ： 10.0 mm { 0.394 in }
position the valve guide
： 0.038 to 0.071 mm
Specified value { 0.00150 to 0.00280
Inlet valve in }
Note：： 0.20 mm { 0.0079
Limit
・ Replace the valve stem end cap if wear in }
exceeds the limit or if there is abnormal wear. ： 0.064 to 0.096 mm
3. Valve inspection Specified value { 0.00252 to 0.00378
Exhaust
in }
1. Valve stem measurement valve
： 0.25 mm { 0.0098
Limit
1) Measure the diameter of the valve stem using a in }
micrometer.
Note：
Inlet valve
Limit： 8.88 mm { 0.3496 in } Inlet valve
Exhaust valve
Limit： 8.80 mm { 0.3465 in } Exhaust valve
2) Install the bulb to the cylinder head.
3) Using a depth gauge or a simple straight ruler,
measure the valve depth from the cylinder head
lower surface.
Note：
replace the valve and valve seat.
Limit： 2.5 mm { 0.098 in }
5. Valve contact surface measurement
1) Measure the contact surface of the valve seat.
Note：
・ If the reading exceeds the specified value,
repair or replace the valve, valve guide, and
1. Valve stem valve seat as a set.
2. Measurement point Standard： 45 °
3. Valve guide
6. Valve seat contact width measurement
3. Valve depth measurement
1) Measure the touching width of the valve seat.
1) Measure the thickness of the valve using a
Note：
micrometer.
・ Repair or replace the valve seat if the reading
Note： exceeds the limit.
1. Width of the contact length

2. Sinking amount
4. Valve depth measurement 3. Contact surface angle
1) Remove the carbon and water deposit on the bottom 4. Valve spring inspection
surface of the cylinder head.
1) Inspect the valve spring for the following.
・ Damage
・ Wear
Note：
・ Replace the valve spring if a malfunction is
found.
2. Valve spring free length measurement
1) Measure the free length of the valve spring using a
vernier caliper.
Note：
replace the valve spring.
4. Valve spring installation load measurement

Note：
1) Measure the load using load test equipment.
Installation
Load
length
： 414 to 477 N { 42.2
Specified
to 48.6 kg / 93 to 107
： 47 mm value
lb }
{ 1.85 in }
： 401 N { 40.9 kg / 90
Limit
lb }

Limit： 59.4 mm { 2.339 in }
3. Valve spring perpendicularity measurement
1) Measure the perpendicularity of the valve spring
using a right-angle gauge.
Note：
Limit： 1.0 mm { 0.039 in }
5. Valve seat insert inspection

1) Remove the carbon from the valve seat insert top
surface.
2) Adjust the valve seat to the specified value using a
seat cutter.
Note： 3) Inspect between the valve seat and the exhaust port
・ Minimize scratches and other uneven sections of the cylinder head for cracks.
to adjust the contact width to the specified Note：
value.
・ Perform a dye penetrant check as necessary.
Caution：
・ Get rid of only the scratches and uneven
portions, but be careful not to over-cut.
・ Use an adjustable valve cutter pilot.
・ The valve cutter pilot should not be allowed to
scrape inside the valve guide.
Standard： 30 ° Angle 1
2. Cylinder head deformation measurement

1) Measure the deformation of the cylinder block
installation surface using a simple straight ruler and
feeler gauge.
Note：
・ Refer to the diagram, and measure the 4 sides
and across opposite corners.
・ Replace the cylinder head if the measured
value exceeds the limit.
1. Angle 1 Standard： 0.05 mm or less { 0.0020 in or less }

2. Angle 2 Limit： 0.20 mm { 0.0079 in }
3. Angle 3
3) Attach compound to the valve seat, and rub together

by turning the valve and tapping.
Caution：
・ Confirm that it is touching evenly around the
entire circumference.
・ After fitting, remove all applied compound.
6. Cylinder head inspection
1) Inspect the cylinder head bolts for damage and
elongation.
Caution：
・ Replace dubious bolts.
2) Inspect the inside of the combustion chamber and
the glow plug hole.
2) Measure the deformation of the exhaust manifold
installation surface using a simple straight ruler and
feeler gauge.
Note：
・ Measure the 4 sides and across opposite
corners.
・ Replace the cylinder head if the measured
value exceeds the limit.
Standard： 0.05 mm or less { 0.0020 in or less }
Limit： 0.20 mm { 0.0079 in }
Cylinder head

2. Split collar
6-3： 30 to 60 °
2. Valve seat insert installation
7. Valve guide 1) Put the dolly block on the valve seat insert.
8. Idle gear C Note：
10. Rear engine hanger ・ Carefully place a dolly block having an outer
11. Intake and exhaust valve diameter smaller than the valve seat insert on
12. Cylinder head top of the valve seat insert.
13. Front engine hanger 2) Install the valve seat insert to the cylinder head
14. Thermostat using a press.
Note：
Tightening torque ・ Gradually apply pressure to the dolly block and
push in the valve seat insert.
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
Caution：
2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
・ Do not apply excessive pressure with the
3： 38 N・m { 3.9 kgf・m / 28 lb・ft } press.
4： 95 N・m { 9.7 kgf・m / 70 lb・ft }
5： 48 N・m { 4.9 kgf・m / 35 lb・ft }
1. Dolly block 2) Check the height of the valve guide.

2. Valve seat insert
3. Press
3) Attach compound to the valve seat, and rub together

by turning the valve and tapping.
Caution：
・ Confirm that it is touching evenly around the
entire circumference.
・ After fitting, remove all applied compound.
3. Valve guide installation
1) Tap in the valve guide from the top of the cylinder
head using the special tool.
1. Height from cylinder head top surface to the

valve guide end surface
SST: 5-8840-2227-0 - valve guide replacer
Caution： 4. Valve stem oil seal installation
・ When replacing the valve guide, replace with 1) Install a lower spring seat to the cylinder head.
the valve as a set. 2) Apply engine oil to the valve guide outer periphery
section.
3) Install the valve stem oil seal to the cylinder head
using the special tool.
Caution：
・ Check that the valve stem oil seal is securely
inserted after installing it.
・ Confirm that the valve stem oil seal is not
inclined.
・ Confirm that the garter spring is not off.
1) Install the valve spring to the cylinder head with the
paint mark or the spring pitch narrow end facing
down.
SST: 8-9439-6815-0 - valve stem seal installer
1. Narrow spring pitch

2. Paint mark
2) Install the spring upper seat to the valve spring.

3) Install the split collar to the valve using the special
5. Valve installation tool.
1) Apply engine oil to the stem section of the valve. Note：
2) Install the bulb to the cylinder head. ・ After installing the split collar, lightly tap the top
of the valve stem with a rubber hammer to
Caution： stabilize the split collar.
・ After assembling the valve, confirm it is not Caution：
improperly assembled.
・ Check that the split collar is securely in the
valve stem groove.
SST: 5-8840-2228-0 - valve spring compressor
6. Valve spring installation

4) Apply Loctite 262 to the outer circumference of the
idle gear C cover.
5) Tap the idle gear C cover into the cylinder head to
the specified value using the special tool.
SST: 5-8840-2222-0 - sealing cup installer
7. Idle gear C installation

1) Apply engine oil to the following parts.
・ Idle gear C inner circumference
・ Idle gear shaft
・ Both surfaces of the thrust collar
2) Apply molybdenum disulfide grease to the threaded
portions and seating surfaces of the bolts.
3) Install idle gear C to the cylinder head by facing the
machined side of the gear groove toward the rear of
the engine.
Caution：
・ Do not use an impact wrench.
1. Specified value
8. Thermometer unit installation

1) Apply Loctite 262 or 962 to the threaded portion of
the thermometer unit.
2) Install the thermometer unit to the cylinder head.
1. Idle gear C
2. Idle gear shaft
3. Thrust collar
4. Bolt
9. Thermostat installation 10. Rear engine hanger installation

1) Install the thermostat housing gasket to the 1) Install the bracket to the cylinder head.
thermostat.
2) Install the thermostat to the cylinder head. ft }
Caution： 2) Install the rear engine hanger to the bracket.
・ Securely insert so that the thermostat housing Tightening torque： 48 N・m { 4.9 kgf・m / 35 lb・ft }
gasket does not ride up outside the thermostat
housing.
・ Do not mistake the assembly position and
direction.
1. Bracket
11. Front engine hanger installation

1. Thermostat 1) Install the front engine hanger to the cylinder head.
2. Cylinder head
3) Install the water outlet pipe to the thermostat
housing.
Cylinder head

2. Split collar
6-3： 30 to 60 °
2. Cylinder head installation
7. Valve guide 1) Clean the piston head and cylinder block top
8. Idle gear C surface.
9. Idle gear C cover 2) Referring to the diagram, measure the protrusion
10. Rear engine hanger amount of the piston in each cylinder at 2 locations.
12. Cylinder head
13. Front engine hanger
14. Thermostat
Tightening torque
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
3： 38 N・m { 3.9 kgf・m / 28 lb・ft }
4： 95 N・m { 9.7 kgf・m / 70 lb・ft }
5： 48 N・m { 4.9 kgf・m / 35 lb・ft }
Head gasket selection
Gasket Identific Protrusion amount of the
grade ation piston, maximum value
： 0.579 to 0.659 mm
A No hole
{ 0.02280 to 0.02594 in }
： 0.659 to 0.739 mm
B 1 hole
{ 0.02594 to 0.02909 in }
： 0.739 to 0.819 mm
C 2 holes
{ 0.02909 to 0.03224 in }
1. Grade identification hole

to the cylinder block.
Standard： 3.0 mm { 0.118 in } Bead width
Caution：
・ After applying the liquid gasket, install the
1. Reference point of cylinder block top surface cylinder head within 5 minutes.
2. 50°
3. 20 °
4. Measurement point of piston head
5. 100 mm {3.94 in}
6. 70 mm {2.76 in}
3) Find the maximum of the average values of the

cylinders.
4) Refer to the table, and select a cylinder head gasket
of the appropriate grade according to the maximum
value.
Caution：
・ Select from the 3 types of head gaskets shown
in the table according to the protrusion amount
of the piston.
1. Liquid gasket application position

6) Install the cylinder head gasket to the cylinder block
with the side with the part number marking on the
cylinder head gasket facing up.
Caution：
・ Align the dowel with the cylinder head rear
gear case, and install.
SST: 5-8840-0266-0 - angle gauge

ft } 1st time (M14)
ft } 2nd time (M14)
Tightening Angle ： 30 to 60 ° 3rd time (M14)
7) Install the cylinder head to the cylinder block while

aligning the dowel of the cylinder block.
Caution：
・ When installing, do not damage the cylinder
head gasket.
10) Apply engine oil to the threaded portion and the

seating surface of the M10 head bolt.
11) Tighten the head bolt (M10) to the cylinder head in
the order shown in the diagram.
(M10)

portion and seating surface of the M14 head bolt.
9) Install the head bolt (M14) to the cylinder head in
the order shown in the diagram using the special
tool.
12) Install the dummy plug to the cylinder head. 1. Turbocharger

2. Exhaust pipe adapter
3. Turbocharger installation 4) Install the heat protector to the exhaust pipe adapter.
1) Install the gasket to the cylinder head. Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
2) Install the turbocharger to the cylinder head in the 4. Oil drain pipe installation
order shown in the diagram. 1) Install the oil drain pipe to the turbocharger and
Tightening torque： 34 N・m { 3.5 kgf・m / 25 lb・ft } cylinder block.
Turbocharger side
Cylinder block side
5. Feed oil pipe installation
1) Temporarily tighten the feed oil pipe to the
turbocharger and flywheel housing in the order
3) Install the exhaust pipe adapter to the turbocharger.

Nut
Bolt
2) Install the feed oil pipe to the turbocharger and
flywheel housing in the order shown in the diagram.
Flywheel housing side
Turbocharger side
Cylinder head side
1. Bolt 1
2. Nut
3. Bolt 2

cleaner.
6. Water feed pipe installation
1) Install the water feed pipe to the turbocharger and
cylinder block.
Eyebolt
Bracket bolt
2) Install the water return pipe to the turbocharger.
Turbocharger side eyebolt
Bolt 1 and nut
Bolt 2
1. Air duct

Caution：
during assembly, temporarily tighten the bolts
tighten from the engine side in turn.
・ Do not reuse the removed bolt and nut. 10. Inlet cover installation
・ Visually confirm that there is no foreign 1) Clean the cylinder head installation surface.
1) Install front exhaust pipe A to the exhaust pipe apply ThreeBond 1207C to the inlet case.
adapter.
Caution：
Tightening torque： 67 N・m { 6.8 kgf・m / 49 lb・ft } ・ Do not apply to the wide groove inside.
2) Install the clamp to front exhaust pipe A. ・ Install the inlet cover within 7 minutes of
applying liquid gasket.
Standard： 2.5 to 5.5 mm { 0.098 to 0.217 in } Bead
3) Install front exhaust pipe B and the exhaust brake
width
3) Install the inlet case to the cylinder head in the
valve.
1. Application area
and mount bracket. 4) Install the inlet cover and gasket to the inlet case in
Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft } the order shown in the diagram.
Mounting bracket side Caution：
Tightening torque： 50 N・m { 5.1 kgf・m / 37 lb・ft } ・ Do not drop the gasket.
9. Radiator upper hose installation
1) Install the radiator upper hose to the water outlet
pipe and radiator.
Tightening torque： 5.0 N・m { 0.51 kgf・m / 44.3 lb・
in }
2) Connect the coolant reserve tank hose to the
radiator.

Tightening torque： 24 N・m { 2.4 kgf・m / 18 lb・ft } 5) Install the nozzle leak off pipe to the injection
nozzle.
11. Injection nozzle installation
1) Install the gasket and O-ring to the injection nozzle.
in }
Caution：
・ Do not mistake the gasket direction.
Caution：
・ Make sure to confirm that the clips are
attached at inappropriate locations.
1. Gasket
2. O-ring
3. Injection nozzle
2) Install the holder to the injection nozzle.

3) Temporarily tighten the injection nozzle to the
cylinder head.
4) Install the injection nozzle to the cylinder head in
Caution：
・ Do not mistake the injection nozzle direction. 1. 41 mm {1.61 in}
2. 14 mm {0.55 in}
3. 13 mm {0.51 in}

13. Fuel filter installation
1) Install the fuel filter to the bracket.
1) Install the fuel suction pipe to the injection pump
and fuel filter.
2) Install the fuel feed pipe to the injection pump and
fuel filter.
2) Connect the connector to the thermometer unit.
1) Install the oil level gauge guide tube to the

2. Fuel feed pipe
3. Fuel return pipe
4. Fuel pipe
15. Water bypass hose connect

1) Connect the water bypass hose to the cylinder head. 1. Oil level gauge guide tube

guide tube.
ft }
Caution：
・ Repeat the operation until the coolant level no
longer lowers.
6) Add coolant up to the MAX line of the radiator
reserve tank.
1. Vacuum hose
18. Camshaft installation

Refer to "Camshaft installation" in this section.
19. Coolant filling
1. Coolant refill
pipe.

2. MAX line
3. MIN line

8) Stop the engine.
14) Increase the engine speed.
1. Radiator cap Note：
2. Air bleeding plug ・ Increase the engine speed to around 2000 rpm
and run the engine for 5 minutes once the
Caution： gauge reaches the center.
・ Fill slowly to prevent air from entering the 15) Touch the radiator upper hose, and confirm that the
system. coolant in the hose has become warm.
Caution： 4) Press the priming pump until air is no longer
・ If the radiator upper hose has not become discharged.
warm, raise the engine speed to continue to
warm it up.
・ Do not try determining it by using only an
engine coolant temperature gauge and the hot
air coming out of the heater.
16) Idle the engine for 5 minutes.
17) Stop the engine.
Warning：
cap when the coolant is hot, as doing so may
or hot water.
longer lowers.
Caution：
MAX line.
20. Fuel air bleed
1) Prepare the fuel pan. 1. Priming pump
2) Install the transparent hose to the air bleeding plug 5) Tighten the air bleeding plug of the fuel filter.
on the fuel filter.
Caution：
plug.
8) Depress the accelerator pedal all the way to rev the
engine to its maximum speed and then release the
Caution：
1. Cap
3) Loosen the air bleeding plug of the fuel filter.

Front cover
Front cover

1. Generator 6： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2. Adjust plate
7： 11 N・m { 1.1 kgf・m / 97 lb・in }
3. Front cover
4. Oil pan gasket 8： 11 N・m { 1.1 kgf・m / 97 lb・in }
5. Oil pan
9： 200 N・m { 20.4 kgf・m / 148 lb・ft }
6. Rubber seal
7. Slinger 2. Engine oil drain
8. Crankshaft front oil seal 1) Remove the drain plug from the oil pan, and drain
9. Crankshaft pulley the engine oil to a pan.
10. Water pump
11. Cooling fan belt 2) Install the drain plug to the oil pan.
12. Fan pulley Caution：
13. Cooling fan
・ Do not forget to tighten the drain plug.
Tightening torque Tightening torque： 83 N・m { 8.5 kgf・m / 61 lb・ft }
1： 24 N・m { 2.4 kgf・m / 18 lb・ft } 3. Crankshaft front oil seal removal
2： 24 N・m { 2.4 kgf・m / 18 lb・ft } Refer to "Crankshaft front oil seal removal" in this
3： 39 N・m { 4.0 kgf・m / 29 lb・ft } section.
4： 24 N・m { 2.4 kgf・m / 18 lb・ft } 4. Generator disconnect

pump.
5. Generator removal
1) Remove the vacuum pump oil feed hose from the
vacuum pump and cylinder block.
2) Remove the vacuum pump oil return hose from the
1. Water pump
2. Fan pulley
3. Set plate
8. Front cover removal

1) Remove the adjust plate from the front cover.
1. Vacuum pump oil return hose

2. Vacuum pump oil feed hose
3) Remove the generator from the generator bracket

and adjust plate.
6. Oil pan removal
1) Remove the oil pan from the cylinder block.
7. Water pump removal
1) Remove the set plate from the water pump pulley.
2) Remove the fan pulley from the water pump.
3) Remove the water pump from the front cover. 1. Adjust plate
Note：
2) Remove the oil relief valve from the front cover.
・ Referring to the diagram, insert the
screwdriver and remove while prying with the
screwdriver.
3) Remove the oil cooler bypass valve from the

cylinder block.
4) Remove the front cover from the cylinder block and

crankcase.
Front cover
Part name 7： 11 N・m { 1.1 kgf・m / 97 lb・in }

1. Generator 8： 11 N・m { 1.1 kgf・m / 97 lb・in }
2. Adjust plate
9： 200 N・m { 20.4 kgf・m / 148 lb・ft }
3. Front cover
4. Oil pan gasket 2. Front cover installation
5. Oil pan
1) Install the oil cooler bypass valve to the cylinder
6. Rubber seal
block.
7. Slinger
8. Crankshaft front oil seal Caution：
9. Crankshaft pulley ・ Do not mistake the insertion direction of the oil
10. Water pump cooler bypass valve.
11. Cooling fan belt ・ Do not remove the rubber cap.
12. Fan pulley
13. Cooling fan
Tightening torque
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
3： 39 N・m { 4.0 kgf・m / 29 lb・ft }
4： 24 N・m { 2.4 kgf・m / 18 lb・ft }
5： 24 N・m { 2.4 kgf・m / 18 lb・ft }
6： 24 N・m { 2.4 kgf・m / 18 lb・ft }
5) Install the front cover to the cylinder block and

crankcase in alignment with the cylinder block
dowel pins.
6) Install the oil relief valve to the front cover.
2) Clean the cylinder block front side.

Caution：
・ Completely remove any excess liquid gasket
when installing the crankcase.
3) Install 2 O-rings to the front cover.
4) Apply ThreeBond 1207B to the front cover in
alignment with the grooves on the front cover
mounting surface. 7) Install the adjust plate to the front cover.
Standard： 2.5 to 3.5 mm { 0.098 to 0.138 in } Bead Note：

width ・ Tighten the bolts indicated by the arrows
together with the generator adjust plate.
height
Caution：
・ Do not allow liquid gasket to get on the O-ring.
・ Install the front cover within 5 minutes of
applying the liquid gasket.
1. 35 mm {1.38 in}
2. 25 mm {0.98 in}
3. 65 mm {2.56 in}
4. 30 mm {1.18 in}
5. Oil relief valve
3. Water pump installation

1. O-ring
1) Apply ThreeBond 1207B to the groove of the water
pump mounting surface.
Caution：
・ Install the water pump within 5 minutes of
1. Fan pulley
2. Set plate
4. Oil pan installation

to the seams between the crankcase and both the
1. 1.0 to 1.5 mm {0.039 to 0.059 in} front cover and the flywheel housing.
2. 3.0 to 4.0 mm {0.118 to 0.157 in}
Standard： 3 mm { 0.12 in } Bead width
3. 1.0 mm {0.039 in} or more
Caution：
2) Install the water pump to the front cover aligned
・ After applying the liquid gasket, install the oil
with the stud on the front cover.
pan within 5 minutes.
3) Install the fan pulley to the water pump.
4) Install the set plate to the water pump.
Note：
・ After adjusting the drive belt, tighten the fan
pulley and set plate to the specified torque.
2) Install the oil pan gasket to the crankcase using the

stud as a guide.
3) Install the oil pan and oil pan rubber to the
crankcase.
2. Tightening positions
4) Check the tightening of the oil pan drain plug.

5. Generator installation
1) Temporarily tighten the generator to the generator
bracket and adjust plate.
Note：
・ Tighten the generator after adjusting the
cooling fan belt.
2) Install the vacuum pump oil return hose to the
3) Install the vacuum pump oil feed hose to the
Cylinder block side
Vacuum pump side
1. Oil pan rubber

2. Oil pan
3. Oil pan gasket
Note：
・ After tightening the 1, 2, 3, and 4 locations in
the diagram, tighten the others.
・ No particular order is required.

6. Generator connect
1) Connect the connector to the generator.
2) Connect the B-terminal cable to the generator.
3) Connect the vacuum hose to the vacuum pump.
7. Crankshaft front oil seal installation
Refer to "Crankshaft front oil seal installation" in this
section.
8. Engine oil filling
1) Replenish the engine with the engine oil.
Caution：
Crankshaft pulley
Crankshaft pulley
Part name
1. Crankshaft pulley
2. Crankshaft front oil seal
3. Crankshaft front slinger
Tightening torque
1： 200 N・m { 20.4 kgf・m / 148 lb・ft }
2. Radiator removal
Radiator removal".
Note：
pulley and the set plate. 4. Cooling fan belt removal
1) Loosen the adjust plate lock nut.
2) Loosen the generator fixing nut.
3) Loosen the adjust bolts, and remove the cooling fan
belt from the following parts.
・ Generator
・ Fan pulley
・ Crankshaft pulley
1. Adjust bolt 1. B-terminal

2. Lock nut 2. S-terminal
3. Generator fixing nut
4) Remove the starter motor from the clutch housing.
5. Starter motor removal
6. Crankshaft pulley removal
1) Remove the ground cable from the starter motor.
1) Install the special tool to the starter installation
Note： section of the flywheel housing.
・ Disconnect the front frame harness connector Caution：
near the control box of the transmission, and
・ Make sure the stopper is properly engaged
remove each of the clips fastening the
with the ring gear and installed.
harness.
SST: 5-8840-2230-0 - crankshaft stopper
2) Disconnect the harness from the S-terminal.

3) Disconnect the harness from the B-terminal.
2) Remove the crankshaft pulley from the crankshaft.
Crankshaft pulley
Part name
Tightening torque
1： 200 N・m { 20.4 kgf・m / 148 lb・ft }
2. Crankshaft pulley installation
1) Apply engine oil to the threaded portion of the
bolts.
2) Install the crankshaft pulley to the crankshaft in the
Note：
・ Install the crankshaft pulley aligned with the
knock pin of the crankshaft.
Tightening torque： 200 N・m { 20.4 kgf・m / 148 lb・ 3. Starter motor installation
ft } 1) Install the starter motor to the clutch housing.
2) Connect the harness to the B-terminal. 4. Cooling fan belt installation

Tightening torque： 7.5 to 10.0 N・m { 0.76 to 1.02 1) Install the cooling fan belt to the following parts.
kgf・m / 66 to 89 lb・in }
・ Fan pulley
3) Connect the harness to the S-terminal. ・ Crankshaft pulley
・ Generator
Tightening torque： 1.0 to 1.5 N・m { 0.10 to 0.15 kgf・
m / 8.9 to 13.3 lb・in } 5. Cooling fan installation
1. B-terminal
2. S-terminal
4) Connect the ground cable to the starter motor. 6. Radiator installation

7. Cooling fan belt adjustment
When installing a new belt, initial stretching of the belt
occurs.
In addition, when reusing the belt, the belt needs to adapt
to the pulley groove.
1) Loosen the adjust plate lock nut and generator 2. Adjust plate lock nut
fixing nut. 3. Generator fixing nut
2) Turn the adjust bolt to adjust the cooling fan belt.
Caution：
・ Accurately adjust the tension because if the
tension is not within the appropriate range,
there is a possibility the service life will be
shortened, or belt squeal may be generated.
・ Use a sonic tension meter to verify accurate
tension adjustment.
Adjustmen
t Deflection Vibration frequency
conditions
： 8 to 12 mm
When new ： 140 to 170 Hz
{ 0.31 to 0.47 in }
When ： 10 to 14 mm
： 121 to 139 Hz
reused { 0.39 to 0.55 in }
Note：
・ The specified vibration frequency is a value for
when adjustment is performed using a sonic
tension meter.
・ The specified deflections shown are the values
obtained when the specified pressure is
applied to the midpoint between the fan pulley
and generator.
Standard： 98 N { 10.0 kg / 22 lb }
3) After adjusting, tighten the adjust plate lock nut and
generator fixing nut to the specified torque.
Adjust plate lock nut
Generator fixing nut
1. Adjust bolt
Flywheel
Flywheel
Part name 2) Remove the tailpipe from the exhaust silencer.

1. Engine speed sensor 3) Remove the exhaust silencer from front exhaust
2. Flywheel housing pipe B and the mount bracket.
3. Flywheel
4. Washer
valve.
5. Clutch disc
6. Pressure plate 5) Remove front exhaust pipe B and the exhaust brake
7. Pilot bearing valve as a set from front exhaust pipe A.
Tightening torque 6) Remove the clamp from front exhaust pipe A.
1-1： 78 N・m { 8.0 kgf・m / 58 lb・ft } 7) Remove front exhaust pipe A from the exhaust pipe
adapter.
1-2： 90 to 120 °
2： 40 N・m { 4.1 kgf・m / 30 lb・ft }
3： 8.0 N・m { 0.8 kgf・m / 71 lb・in }
2. Clutch removal
4. Engine speed sensor removal

1) Disconnect the connector from the engine speed
sensor.
2) Remove the engine speed sensor from the flywheel
housing.
2) Gradually loosen the flywheel mounting bolts in the

order shown in the figure, and remove the washer
and flywheel from the crankshaft.
Note：
・ After loosening all of the bolts, remove the
special tool and then remove the flywheel.
5. Flywheel removal
1) Install special tool to the flywheel housing.
Note：
・ Install the special tool to the starter installation
section of the flywheel housing, and prevent
the crankshaft from turning.
Caution：
・ Check that the stopper is properly engaged
disassembly
1. Flywheel disassembly
1) Remove the pilot bearing from the flywheel.
1. Washer
2. Pilot bearing
3. Flywheel
2) Place a rod on the ring gear, and remove the ring

gear from the flywheel while tapping with a
hammer.
inspection
1. Flywheel inspection
1) Inspect the flywheel for the following.
・ Wear
・ Damage
・ Cracking
Note：
・ Repair or replace the flywheel if a malfunction
is found.
2) Inspect the ring gear tooth surface for the following.
・ Wear
・ Damage
Note：
・ Replace the ring gear if a malfunction is found. 1. Depth from the installation surface of the pressure
plate to the friction surface of the flywheel
2. Flywheel measurement
1) Measure the flywheel friction surface using a
vernier caliper.
Note：
・ Measure the depth from pressure plate
installation surface to friction surface.
・ Repair it if the measured value is within the
specified value and limit value and if it can be
repaired by polishing or sanding.
Standard： 19 mm { 0.75 in }
reassembly
1. Flywheel reassembly
1) Uniformly heat up the ring gear with a gas burner.
Caution：
・ Perform this with the heating temperature at
less than the specified value.
Standard： less than 200 ℃ { less than 392 °F }
1. Washer
2. Pilot bearing
3. Flywheel
2) Install the ring gear to the flywheel with the

chamfered side of the ring gear facing toward the
front.
Caution：
・ When shrink-fitting and cooling the ring gear,
apply a load of the specified value to maintain
flatness.
Standard： 68,600 N { 6,995 kg / 15,422 lb }
Caution：
・ After shrink-fitting, check that the ring gear is
securely attached to the flywheel.
3) Install the pilot bearing to the flywheel.
Flywheel
Part name Note：

1. Engine speed sensor ・ Install the special tool to the starter installation
2. Flywheel housing section of the flywheel housing, and prevent
3. Flywheel the crankshaft from turning.
4. Washer Caution：
5. Clutch disc
6. Pressure plate
7. Pilot bearing
Tightening torque
1-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
1-2： 90 to 120 °
2： 40 N・m { 4.1 kgf・m / 30 lb・ft }
3： 8.0 N・m { 0.8 kgf・m / 71 lb・in }
2. Flywheel installation
portion of the bolt and bearing surface.
2) Temporarily tighten the washer and the flywheel to
the crankshaft.
4) Final tighten the flywheel to the crankshaft using a

torque wrench and the special tool in the order
2) Connect the engine speed sensor to the CKP sensor.
4. Clutch installation
Caution：
SST: 5-8840-0266-0 - angle gauge exhaust system can be caused by
Tightening torque： 78 N・m { 8.0 kgf・m / 58 lb・ft } during assembly, temporarily tighten the bolts
1st time until all components are in position, and final
Tightening Angle ： 90 to 120 ° 2nd time tighten from the engine side in turn.
・ Do not reuse the removed bolt and nut.
・ Visually confirm that there is no foreign
1) Install front exhaust pipe A to the exhaust pipe
adapter.
2) Install the clamp to front exhaust pipe A.
3) Install front exhaust pipe B and the exhaust brake
valve.
3. Engine speed sensor installation

1) Install the engine speed sensor to the flywheel
housing.

and mount bracket.
Flywheel housing
removal
Refer to "Cylinder head removal" in this section.
2. Crankshaft rear oil seal removal
Refer to "Crankshaft rear oil seal removal" in this
section.
3. Engine oil drain
1) Remove the drain plug from the oil pan, and drain
the engine oil to a pan.
2) Install the drain plug to the oil pan.
Caution：
5. Engine controllever removal
pump.
2) Disconnect the engine control cable from the engine

controllever.
6. Oil pipe removal
1) Remove the oil pipe from the following parts.
・ Injection pump
・ Oil filter
・ Flywheel housing
7. Fuel hose disconnect
1) Disconnect the fuel return hose from the fuel return
pipe.
pipe.
Note： 1) Disconnect the connector from the engine speed
・ Plug to prevent fuel from coming out, and tie sensor.
upward. 2) Remove the engine speed sensor from the flywheel
8. Fuel pipe removal housing.

pump.
2) Remove the fuel pipe from the injection pump.
11. Injection pump removal

1) Remove the injection pump and bracket from the
cylinder block.
2. Fuel feed pipe
3. Fuel return pipe
4. Fuel pipe
9. Blow-by hose removal

1) Remove the blow-by hose from the flywheel
housing.
1. Nut
2. Injection pump
3. Bolt (M12)
4. Bolt (M10)
5. Bracket
12. Oil pan removal

10. Engine speed sensor removal 13. Power steering oil pump disconnect
1) Disconnect the power steering oil pump from the
flywheel housing.
Note：
with a wire.
14. Power steering oil pump idle gear removal
1) Remove the idle gear cover from the flywheel
housing.
2) Remove the power steering oil pump idle gear and
idle gear shaft as a set from the flywheel housing.
3) Remove the idle gear shaft from the power steering

oil pump idle gear.
15. Flywheel housing removal
1) Remove the flywheel housing from the cylinder
block.
Caution：
・ Do not forget to remove the bolts shown in the
diagram.
installation
1. Flywheel housing installation
1) Clean the cylinder block using a scraper.
Caution：
2) Apply ThreeBond 1207B to the cylinder block.
height
Note：
・ Apply liquid gasket evenly to the inside of the
bolt holes, except for the bolt hole indicated by
the arrow.
1. Bolt
2. Bolt
3. Bolt
4. Bolt
2. Power steering oil pump idle gear installation

1) Apply engine oil to the gear assembly sections of
the idle gear shaft.
2) Install the idle gear shaft to the power steering oil
pump idle gear.
3) Position the cylinder block knock pin, and install

the flywheel housing to the cylinder block.
Bolt 1
Bolt 2
Bolt 3
3) Install the power steering oil pump idle gear and
Bolt 4
idle gear shaft as a set to the flywheel housing.
Note：
・ The number behind the tightening torque ft }
indicates the diagram number.
4) Install the idle gear cover to the flywheel housing. 1. Flywheel housing section bolt
front cover and the flywheel housing.
Caution：

flywheel housing.

stud as a guide.
crankcase.

5. Injection pump installation
(clockwise) to align the crank damper pulley timing
mark with BTDC 13°.
Note：
・ Check the No. 1 cylinder inlet locker arm and
exhaust locker arm, and if the No. 1 cylinder
inlet locker arm and exhaust locker arm are
pushed down, piston No. 4 is at the top of the
compression stroke.
・ Rotate the crankshaft 1 rotation (360°) to
adjust the crank damper pulley timing mark to
BTDC 13° again.
・ Adjustment to BTDC 13° is for the angle set by
the injector pump, and is in no way related to
the injection timing.
1. Oil pan rubber

2. Oil pan
3. Oil pan gasket
Note：
1. TDC
2. BTDC 5°
3. BTDC 7°
4. BTDC 9°
5. BTDC 11°
6. BTDC 13°
2) Align the flange section groove with the groove on

the timer outer circumference using a flathead
screwdriver.
mark with BTDC 7°.
3) Install the injection pump and bracket to the

cylinder block.
M10 bolt 1. TDC
2. BTDC 5°
3. BTDC 7°
M12 bolt
4. BTDC 9°
Tightening torque： 50 N・m { 5.1 kgf・m / 37 lb・ft } 5. BTDC 11°
Nut 6. BTDC 13°
Tightening torque： 48 N・m { 4.9 kgf・m / 35 lb・ft } 6) Referring to the diagram, check the injection
Bracket timing.
1. Nut 1. Pointer
2. Injection pump 2. Timer outside mark
3. Bolt (M12) 3. Timing check hole
4. Bolt (M10)
5. Bracket 7) Install the check hole plug to the injection pump.
4) Remove the check hole plug from the injection 6. Engine speed sensor installation
pump.
housing.

2. Fuel feed pipe
3. Fuel return pipe
4. Fuel pipe
7. Blow-by hose installation
1) Install the blow-by hose to the Flywheel housing.
10. Oil pipe installation
1) Install the oil pipe to the following parts.
・ Injection pump
・ Oil filter
Injection pump and oil filter side
1) Install the fuel pipe to the injection pump.
pump.
12. Engine control cable connect 13. Crankshaft rear oil seal installation
1) Connect the engine control cable to the engine Refer to "Crankshaft rear oil seal installation" in this
controllever. section.
Caution：
Refer to "Cylinder head installation" in this section.
2) Connect the engine stop cable to the injection

pump.
Crankshaft front oil seal
Part name
Tightening torque
1： 200 N・m { 20.4 kgf・m / 148 lb・ft }
Refer to "Crankshaft pulley removal" in this section.
3. Crankshaft front oil seal removal
1) Remove the crankshaft front oil seal from the front
cover using a screwdriver.
Caution：
・ Do not damage the oil seal mounting surface
of the front cover or shaft.
1. Felt
2. Slinger
3. Oil seal
2) Remove the slinger from the crankshaft using the

special tool.
Note：
・ It is easier to pull out by fastening the outer
circumference of the puller with a clip band.
SST: 5-8840-2360-0 - rear oil seal remover

Part name 5-8840-2709-0 Adapter ○ ○

1. Crankshaft pulley 5-8840-2710-0 Collar ○ ○
2. Crankshaft front oil seal 5-8840-2945-0 Adapter ring ○
3. Crankshaft front slinger 5-8840-2713-0 Center bolt ○ ○
5-8840-2714-0 Fixing bolt ○ ○
Tightening torque
Fixing bolt
1： 200 N・m { 20.4 kgf・m / 148 lb・ft } 8-9439-3010-0 (For flywheel ○ ○
2. Crankshaft front oil seal installation PTO)
Caution：
・ Replace the slinger and oil seal as a set.
1) Prepare special tool.
SST: 5-8840-2940-0 - oil seal installer

Front use
Part number Part name Slinger Oil seal
5-8840-2941-0 Sleeve ○ ○
5-8840-2705-0 Adapter ○ ○
5-8840-2942-0 Adapter ring ○ 1. Front slinger
5-8840-2943-0 Washer ○ ○ 2. 5-8840-2705-0
5-8840-2713-0 Center bolt ○ ○ 3. 5-8840-2714-0
4. 5-8840-2941-0
5-8840-2714-0 Fixing bolt ○ ○
5. 5-8840-2943-0
Rear use 6. 5-8840-2713-0
5-8840-2944-0 Sleeve ○ ○
2) Insert the slinger into the tip of the adapter.
3) Install the adapter to the crankshaft. 1. 5-8840-2705-0
2. 5-8840-2941-0
4) Install the sleeve to the adapter.
3. Slinger
5) Install the washer to the center bolt. 4. 40.2 to 40.8 mm {1.583 to 1.606 in}
5. 33.9 to 34.1 mm {1.335 to 1.343 in}
6) Install the center bolt to the sleeve, tighten the
sleeve until full contact is made with the adapter, 8) Install the adapter to the crankshaft by the fixing
and then press-fit the slinger. bolt.
7) Measure the dimension from the crankshaft end 1. 5-8840-2705-0

face to the oil seal lip section contact surface after
pressing in the slinger. 9) Thinly apply engine oil to the lip section of the
Caution： crankshaft front oil seal.
・ Check the fluctuation in the 4 directions of the Caution：
slinger. ・ Make sure to apply oil to the lip section of the
・ Do not mistake the installation direction and crankshaft front oil seal.
front and rear of the slinger. 10) Install the crankshaft front oil seal to the adapter.
・ Check whether the 4-thread screw (left) is cut.

2. 5-8840-2705-0
3. 5-8840-2943-0
4. 5-8840-2714-0 Caution：
5. 5-8840-2941-0 ・ Check that there is no runout in the 4
6. 5-8840-2943-0 directions of the crankshaft front oil seal.
7. 5-8840-2713-0
11) Install the adapter ring to the sleeve.
12) Install the washer to the center bolt.
13) Install the center bolt to the sleeve, and tighten until
the sleeve contacts the adapter to press-fit the
crankshaft front oil seal.
1. 5-8840-2942-0
2. 5-8840-2941-0
3. 5-8840-2705-0
5. 30.7 to 31.3 mm {1.209 to 1.232 in}
1. Crankshaft front oil seal 3. Crankshaft pulley installation

2. 5-8840-2942-0 Refer to "Crankshaft pulley installation" in this section.
3. 5-8840-2941-0
4. 5-8840-2713-0
14) Measure the dimension from the crankshaft end

face to the oil seal surface after pressing in the
Crankshaft rear oil seal
Part name 2. Flywheel removal

1. Starter motor Refer to "Flywheel removal" in this section.
2. Transmission
3. Clutch pressure plate
4. Clutch disc 1) Remove the crankshaft rear oil seal from the
5. Flywheel flywheel housing using a screwdriver.
6. Crankshaft rear oil seal
Caution：
7. Crankshaft rear slinger
・ Do not damage the oil seal installation section
Tightening torque of the flywheel housing or shaft.
1-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
1-2： 90 to 120 °
1. Felt
2. Slinger
3. Oil seal
2) Remove the crankshaft rear slinger from the

crankshaft using the special tool.
Note：


1. Starter motor ・ Replace the slinger and oil seal as a set.
2. Transmission 1) Prepare special tool.
4. Clutch disc
5. Flywheel
7. Crankshaft rear slinger
Tightening torque
1-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
1-2： 90 to 120 °
Front use
2. Crankshaft rear oil seal installation
5-8840-2941-0 Sleeve ○ ○
5-8840-2705-0 Adapter ○ ○
5-8840-2942-0 Collar ○ ○
5-8840-2943-0 Adapter ring ○
5-8840-2713-0 Center bolt ○ ○
5-8840-2714-0 Fixing bolt ○ ○
Rear use
5-8840-2944-0 Sleeve ○ ○
5-8840-2709-0 Adapter ○ ○
5-8840-2710-0 Collar ○ ○
5-8840-2945-0 Adapter ring ○
5-8840-2713-0 Center bolt ○ ○
5-8840-2714-0 Fixing bolt ○ ○
Fixing bolt
8-9439-3010-0 (For flywheel ○ ○
PTO)
Note： 1. 5-8840-2710-0
・ 5-8840-2940-0 includes an engine sleeve 2. 5-8840-2714-0
(5-8840-2948-0) for use with engines from 3. 5-8840-2709-0
before May 1993. Do not use this sleeve
(5-8840-2948-0) for this engine. 5) Install the sleeve to the adapter.
2) Install the slinger to the tip of the adapter. 6) Install the center bolt to the sleeve, tighten the
sleeve until full contact is made with the adapter,
and then press-fit the slinger.
1. Slinger
2. 5-8840-2714-0
3. 5-8840-2713-0 7) Measure the dimension from the crankshaft end
4. 5-8840-2944-0 face to the oil seal lip section contact surface after
5. 5-8840-2710-0 press-fitting the slinger.
6. 5-8840-2709-0 Caution：
3) Install the collar to the fixing bolt. ・ Check the fluctuation in the 4 directions of the
slinger.
4) Install the adapter to the crankshaft.
・ Do not mistake the installation direction and
front and rear of the slinger.
・ Check whether the 4-thread screw (right) is
cut.
1. 5-8840-2710-0
2. 5-8840-2714-0
1. Crankshaft
3. 5-8840-2709-0
2. 5-8840-2709-0
3. 17.0 to 17.6 mm {0.669 to 0.693 in} 10) Thinly apply engine oil to the lip section of the
4. 10.7 to 10.9 mm {0.421 to 0.429 in} crankshaft rear oil seal.
5. Slinger
6. 5-8840-2944-0 11) Install the crankshaft rear oil seal to the adapter.
7. 5-8840-2710-0 12) Install the adapter ring to the sleeve.
8) Install the collar to the fixing bolt.
1. 5-8840-2944-0
2. 5-8840-2945-0
1. 5-8840-2709-0
2. 5-8840-2714-0 13) Install the center bolt to the sleeve, and tighten until
3. 5-8840-2713-0 the sleeve contacts the adapter to press-fit the
4. 5-8840-2944-0 crankshaft rear oil seal.
5. 5-8840-2710-0
6. 5-8840-2945-0


face to the crankshaft rear oil seal surface after
pressing in the crankshaft rear oil seal.
Caution：
・ Check that there is no runout in the 4
directions of the crankshaft rear oil seal.
1. Crankshaft
3. 7.5 to 8.1 mm {0.295 to 0.319 in}
4. 5-8840-2710-0
5. 5-8840-2945-0
6. 5-8840-2944-0
7. 5-8840-2709-0
Refer to "Flywheel installation" in this section.
Piston
Piston
Part name 5. Oil strainer removal

1. Piston ring 1) Remove the oil strainer from the cylinder block.
2. Snap ring
2) Remove the O-ring from the oil strainer.
3. Piston
4. Connecting rod 6. Piston removal
5. Connecting rod bearing
1) Clean the top of the cylinder liner using a scraper.
6. Piston pin
2. Engine oil drain

Caution：
Refer to "Cylinder head removal" in this section.
4. Oil pan removal
6) Remove the connecting rod bearing from the
connecting rod.
Note：
・ When reusing the bearing, organize them
according to the order of the cylinders so that
other cylinder bearings do not get mistaken.
2) Rotate the crankshaft in the forward direction so

that the piston of the cylinder to be removed is at
bottom dead center.
3) Remove the connecting rod bearing cap from the
connecting rod.
connecting rod bearing cap.
Note：
・ Organize the removed bearings according to
the cylinders using tags, etc.

that the piston to be removed is at top dead center.
Caution：
・ Push out from the lower end of the connecting
rod by using the handle of a hammer, etc., so
as not to damage the bearing.
・ When pushing out the connecting rod, do not
damage the oil jet and the cylinder liner.
Piston
Part name
1. Piston ring
2. Snap ring
3. Piston
4. Connecting rod
6. Piston pin
2. Piston disassembly
1) Remove the piston rings from the pistons using ring
pliers.
Note：
・ When reusing the piston rings, organize them
other cylinder pistons and piston rings do not
get mistaken.
2) Remove the snap ring from the piston.
3) Remove the piston pin from the piston.
Note：
・ Organize the disassembled piston pins,
pistons and connecting rods as sets according
to cylinder number.
1. Snap ring
4) Remove the piston from the connecting rod.

5) Clean off any carbon adhered to the piston heads
and piston ring grooves.
Caution：
・ Do not use a wire brush to clean the pistons.
inspection 4) Measure the piston pin hole inner diameter of the

piston using a cylinder gauge.
1. Piston inspection
5) Measure the outer diameter of the piston pin using a
1. Clean micrometer at the 6 measurement positions shown
1) Remove any carbon from the following parts. in the diagram.
・ Piston head Note：

・ Piston ring groove ・ If the measured value exceeds the limit,
・ Piston ring end gap replace the piston or piston pin.
2. Visual inspection Standard： 35.995 to 36.000 mm { 1.41712 to 1.41732
1) Inspect the piston pin for the following. in }
・ Cracking Limit： 35.970 mm { 1.41614 in }

・ Damage
2) Inspect the connecting rod bearing for the
following.
・ Wear
・ Damage
3. Piston pin oil clearance measurement
1) Apply the engine oil to the piston pin.
2) Install the piston pin to the piston. You should feel a
slight resistance when inserting the piston pin into
the piston hole.
Note：
・ Perform work with the piston at room
temperature.
6) Calculate the oil clearance of the piston pin section

of the piston from the difference between the inner
diameter of the piston pin hole and the outer
diameter of the piston pin.
Note：
replace the piston and piston pin.
Limit： 0.04 mm { 0.0016 in }
7) Measure the connecting rod small end inner
diameter using a dial gauge.
8) Calculate the oil clearance of the connecting rod
small end from the difference between the inner
diameter of the connecting rod small end and the
3) Inspect the piston pin for smooth rotation without
outer diameter of the piston pin.
looseness by rotating it by hand.
Note：
Note：
・ When the piston pin rotates smoothly without
replace the connecting rod or piston pin.
looseness, the clearance between the piston
and piston pin is normal. Standard： 0.012 to 0.027 mm { 0.00047 to 0.00106 in }
・ If there is looseness, measure the oil Limit： 0.05 mm { 0.0020 in }
clearance of the piston and piston pin.
Standard：115.031 to 115.050 mm { 4.52877 to 4.52952
in } For repair use
3) Measure the outer diameter of the piston from the
measurement position shown in the diagram that is
at a right angle from the piston pin.
： 85 mm { 3.35 in } Measurement position
Standard：114.940 to 114.959 mm { 4.52519 to 4.52594
in } Grade A
Limit： 114.950 to 114.969 mm { 4.52558 to 4.52633
in } Grade B
Limit： 114.960 to 114.979 mm { 4.52598 to 4.52672
in } Grade C
Standard：114.944 to 114.969 mm { 4.52535 to 4.52633
in } For repair use
4. Clearance measurement between cylinder liner and

piston
1) Measure the inner diameter of the cylinder liner in
the thrust direction and radial direction using a
cylinder gauge at the 3 measurement positions
4) Calculate the clearance between the cylinder liner

and the piston from the difference between the inner
diameter of the cylinder liner and the outer diameter
of the piston.
Note：
・ If the measured value exceeds the specified
value, replace the piston or the cylinder liner.
1. 20 mm {0.79 in}
2. 90 mm {3.54 in}
STD
3. 160 mm {6.30 in}
2) Calculate the cylinder liner inner diameter based on For repair use
the average of the measured values at 6 locations.
Note：
Standard：115.031 to 115.040 mm { 4.52877 to 4.52912
・ There is only one type of grade of the piston
in } Grade A
and the inner diameter of the cylinder liner.
Standard：115.041 to 115.050 mm { 4.52916 to 4.52952 There is no need to select the grade.
in } Grade B ・ When replacing the cylinder liner, there are
Standard：115.051 to 115.060 mm { 4.52956 to 4.52991 two types of liner outer diameters, so it is
in } Grade C necessary to select for the cylinder blocks.
・ Grades A, B, and C are marked on the top of ： 0.31 to 0.55

No. 1 compression ： 1.50 mm
the piston when shipped from the factory. mm { 0.0122 to
ring { 0.0591 in }
0.0217 in }
： 0.42 to 0.66
mm { 0.0165 to
ring { 0.0591 in }
0.0260 in }
： 0.22 to 0.51
： 1.50 mm
Oil ring mm { 0.0087 to
{ 0.0591 in }
0.0201 in }
1. Front mark
5. Measurement of piston ring end gap

1) Install the piston ring to the cylinder liner.
2) Using the piston, press in the piston ring to the
specified value of the cylinder liner.
Standard： about 150 mm { about 5.91 in } 6. Clearance measurement between piston ring and
piston ring groove
1) Install the piston ring to the piston.
2) Measure the clearance between the piston ring and
piston ring groove using a feeler gauge.
Note：
・ The No.1 compression ring cannot be
measured because of the half keystone ring.
replace the piston or piston ring.
Piston ring Specified value Limit
： 0.04 to 0.08
mm { 0.0016 to
ring { 0.0059 in }
0.0031 in }
： 0.02 to 0.06
： 0.15 mm
Oil ring mm { 0.0008 to
{ 0.0059 in }
0.0024 in }
3) Measure the piston ring end gap using a feeler
gauge.
Note：
・ If the measured value exceeds the limit value,
replace the piston ring.
Piston ring Specified value Limit
3) Inspect the connecting rod bearing for damage and
wear.
4) Place PLASTIGAUGE on the crank pin.
7. Connecting rod measurement

1) Measure the twisting and degree of parallelization
of the connecting rod using a connecting rod
aligner.
Note： portions and seating surfaces of the tightening bolts.
・ If the measured value exceeds the limit, 6) Install the connecting rod bearing caps and
replace the connecting rod. connecting rods to the crankshaft using the special
Standard： 0.05 mm { 0.0020 in } tool.
Limit： 0.20 mm { 0.0079 in } Caution：

・ Do not rotate the crankshaft.

1st time
Tightening Angle ： 60 ° 2nd time
Tightening Angle ： 30 ° 3rd time
connecting rod.
8. Connecting rod oil clearance measurement 8) Measure the widest point of the flattened
PLASTIGAUGE, and inspect the oil clearance of
1) Remove the connecting rod bearing cap from the the crank pin section.
connecting rod.
Note：
Note：
・ Set the removed caps in the order of the replace the bearings as a set.
cylinder number.
2) Clean the bearing and crankshaft pin.
Limit： 0.10 mm { 0.0039 in }
9) Remove any PLASTIGAUGE adhering to the

following parts.
・ Connecting rod bearing
・ Crank pin
Piston
Part name ： 0.037 to

1. Piston ring 0.076 mm
B Yellow
2. Snap ring { 0.00146 to
3. Piston 0.00299 in }
4. Connecting rod
6. Piston pin
2. Piston reassembly
1) Perform the bearing selection when installing a new
connecting rod or replacing a bearing in use.
Note：
・ Select the bearing by carefully considering the
grade of the large end diameter of the
connecting rod for installation.
Bearing selection table
Grade of the Bearing
large end hole identification Oil clearance
diameter color
： 0.037 to
0.076 mm 1. Front/rear identification boss
A Green
{ 0.00146 to 2. Big end bore diameter grade marking
0.00299 in } 3. Cylinder number
1. Grade identification color 1. Front mark

2. Convex mark
2) Install the snap ring for one side to the piston using
pliers. 6) Install the piston ring to the piston using ring pliers.
3) Apply the engine oil to the piston pin. Caution：
4) Install the piston pin the piston and small end of the ・ Install the oil ring so that the coil expander end
connecting rod so that the front mark on the piston gap is 180°in the opposite direction.
head and the protruding mark on the connecting rod ・ Install the No. 2 and No. 1 compression rings
face in the same direction. in that order with the markings facing upwards.
・ Confirm that there is no gap at the location of
the arrow in the diagram when the oil ring coil
expander is installed.
1. Front mark
2. Convex mark
5) Install the snap ring to the piston using pliers.

1. No. 1 compression ring
Caution： 2. No. 2 compression ring
・ Check that the snap ring is securely installed 3. Oil ring
in the ring groove.
・ Confirm that the connecting rod slides
smoothly.
Piston
Part name ・ If the crank pin is at bottom dead center when

1. Piston ring installing the piston and connecting rod, the
2. Snap ring connecting rod may hit and damage the oil jet.
3. Piston 6) Face the front mark of the piston forward and install
4. Connecting rod the piston to the cylinder liner using the special
5. Connecting rod bearing tool.
6. Piston pin
Note：
2. Piston installation ・ Referring to the diagram, adjust the position of
1) Install the connecting rod bearing to the connecting the piston ring end gaps so that the No. 1 ring,
rod. No. 2 ring, and oil ring are each separated by
120°.
2) Apply the engine oil to the connecting rod bearing.
Caution：
3) Apply the engine oil to the piston ring.
・ When pushing in the piston, fit the piston ring
Caution： compressor firmly to the cylinder liner.
・ Sufficiently apply to the piston ring and ring ・ If the adherence is inadequate, the ring can be
groove. damaged when pushed.
4) Apply engine oil to the piston side surface. ・ When pushing the piston, the connecting rod
should not make contact with the oil jet.
5) Turn the crankshaft.
・ Do not damage the inner surface of the
Caution： cylinder liner when inserting the piston.
・ Place the crank pin of the cylinder to which the
piston and connecting rod are to be installed at
top dead center.
1. Front/rear identification boss
2. Big end bore diameter grade marking
3. Cylinder number

portion and seating surface of the tightening bolts.
11) Install the connecting rod bearing caps and
SST: 5-8840-9018-0 - piston setting tool connecting rods to the crankshaft using the special
tool.
Caution：
・ Check that the crankshaft turns smoothly.

1st time
Tightening Angle ： 60 ° 2nd step
Tightening Angle ： 30 ° 3rd step
1. No. 1 compression ring end gap

3. Oil ring end gap
4. Front mark
7) Install the connecting rod bearing to the connecting

rod bearing cap.
9) Install the connecting rod bearing caps to the
connecting rods after matching their cylinder
numbers.
3. Oil strainer installation

1) Install the O-ring to the oil strainer.
2) Install the oil strainer to the cylinder block.
front cover and the flywheel housing.
Caution：
Note：

stud as a guide.
crankcase. 1. Tightening positions

Caution：
Refer to "Cylinder head installation" in this section.
1. Oil pan rubber

2. Oil pan
3. Oil pan gasket
Crankshaft
Crankshaft
Part name 1-3： 30 to 60 ° M14

1. Crankshaft upper bearing 2： 37 N・m { 3.8 kgf・m / 27 lb・ft } M10
2. Upper thrust bearing
2. Engine removal
3. Crank gear
4. Crankshaft Refer to "Engine (tilt cab model) removal" in this
5. Crankshaft lower bearing section.
6. Lower thrust bearing
Refer to "Engine (non tilt cab model) removal" in this
7. Crankcase
section.
Tightening torque 3. Engine oil drain
1-1： 98 N・m { 10.0 kgf・m / 72 lb・ft } M14 1. Engine oil draining
1-2： 132 N・m { 13.5 kgf・m / 97 lb・ft } M14
3) Remove the cam end gasket from the cylinder head.
Caution：
・ Carefully remove the liquid gasket still on the
Caution： cylinder head.
6. Rocker arm shaft removal
1) Remove the rocker arm shaft from the cylinder head
4. Turbocharger intake pipe removal as a set with the camshaft bearing cap.
1) Remove the Turbocharger intake pipe from the Note：
turbocharger. ・ Do not remove the bolts in the diagram at this
time since they are the bolts for securing the
rocker arm shaft.

Caution：
1) Remove the cylinder head cover from the cylinder ・ Do not drop the bridge cap into the cylinder
head. head rear gear case section or the front oil
2) Remove the gasket from the cylinder head cover. return hole.
7. Camshaft removal
Note：
・ Check with the crankshaft pulley marking and
front cover alignment mark.
2) Confirm that the I mark on the camshaft gear end
face is aligned with the top surface of the cylinder
head.
1. Cylinder head cover

2. Gasket
3) Measure the end play of the camshaft gear and 8. Water bypass hose disconnect
camshaft bearing cap using a feeler gauge.
1) Disconnect the connector from the thermometer
Standard： 0.085 to 0.205 mm { 0.00335 to 0.00807 in } unit.
Limit： 0.25 mm { 0.0098 in } 2) Disconnect the water bypass hose from the cylinder
head.
4) Remove the camshaft from the cylinder head.

Note：
・ For removed caps and bearings, attach labels 9. Fuel pipe removal
etc. with marks so that they can be installed to
their original position.
pump.
2) Remove the fuel pipe from the injection pump.
3) Remove the fuel feed pipe from the injection pump
and fuel filter.
4) Remove the fuel suction pipe from the injection
pump and fuel filter.
12. Injection nozzle removal

1) Remove the nozzle leak off pipe from the injection
nozzle.
2) Remove the injection nozzle from the cylinder
head.
Caution：
・ Store the removed injection nozzles with the
cylinder numbers attached.

2. Fuel feed pipe
3. Fuel return pipe
4. Fuel pipe
10. Fuel filter removal

1) Remove the fuel filter from the bracket.
1) Loosen the injection pipe.
Caution： 1. Injection nozzle
・ Do not apply excessive force to the injection 2. Nozzle holder
pipe. 3. Gasket
2) Remove the injection pipe clip from the injection 13. Inlet cover removal
pipe.
case.
1. Injection pipe clip

1. Gasket
2. Injection pipe
2. Intake pipe 1) Remove the feed oil pipe from the turbocharger and
3. Inlet cover flywheel housing.
4. Mounting rubber
16. Oil drain pipe removal
3) Remove the inlet case from the cylinder head. 1) Remove the oil drain pipe from the turbocharger
and cylinder block.
17. Turbocharger removal
1) Remove the heat protector from the exhaust pipe
adapter.
2) Remove the exhaust pipe adapter from the
turbocharger.
1. Inlet case
14. Water feed pipe removal

1) Remove the water return pipe from the turbocharger
and the cylinder head.
2) Remove the water feed pipe from the turbocharger
and cylinder block.
1. Turbocharger
3) Remove the turbocharger from the cylinder head.
1. Feed oil pipe

2. Turbocharger
3. Heat protector
5. Water feed pipe 1. Cylinder head
6. Oil drain pipe 2. Turbocharger
15. Feed oil pipe removal 4) Remove the gasket from the cylinder head.
1) Remove the dummy plug from the cylinder head.
2) Loosen the cylinder head bolts evenly in the order
Caution：
・ Do not overlook bolt 1 and 2 in the diagram,
because they are tightened to the flywheel
housing.
20. Flywheel removal

Note：
Caution：
3) Remove the cylinder head from the cylinder block. with the ring gear and installed.
4) Remove the cylinder head gasket from the cylinder
block.
Caution：
・ Do not reuse the cylinder head gasket.
sensor.
housing.
2) Gradually loosen the flywheel mounting bolts in the Note：
order shown in the figure, and remove the washer ・ It is easier to pull out by fastening the outer
and flywheel from the crankshaft. circumference of the puller with a clip band.
Note：
・ After loosening all of the bolts, remove the
special tool and then remove the flywheel.

1) Remove the crankshaft rear oil seal from the
flywheel housing using a screwdriver.
Caution：
・ Do not damage the oil seal installation section 22. Oil pipe removal
of the flywheel housing or shaft.
1) Remove the oil pipe from the following parts.
・ Injection pump
・ Oil filter
23. Blow-by hose removal
1) Remove the blow-by hose from the flywheel
housing.
1. Felt
2. Slinger
3. Oil seal
2) Remove the crankshaft rear slinger from the

crankshaft using the special tool.
24. Injection pump removal 3) Remove the idle gear shaft from the power steering
oil pump idle gear.
1) Remove the injection pump and bracket from the
cylinder block. 27. Flywheel housing removal
1) Remove the flywheel housing from the cylinder
block.
Caution：
・ Do not forget to remove the bolts shown in the
diagram.
1. Nut
2. Injection pump
3. Bolt (M12)
4. Bolt (M10)
5. Bracket
25. Oil filter removal

28. Idle gear removal
1) Remove the oil filter from the cylinder block.
1) Apply the dial gauge to the idle gear tooth to be
2) Remove the O-ring from the oil filter. measured, and gently move the gear left and right to
26. Power steering oil pump idle gear removal measure the fluctuation of the dial gauge.
1) Remove the idle gear cover from the flywheel Note：

housing. ・ Measure idle gear backlash before removing
the idle gear A.
2) Remove the power steering oil pump idle gear and
idle gear shaft as a set from the flywheel housing. ・ If the measured value exceeds the limit,
replace the idle gear.
Caution： 5) Remove the idle gear B shaft from the cylinder
・ Always fasten the other gear. block.

Limit： 0.30 mm { 0.0118 in }
29. Oil pump removal

1) Remove the oil pump from the cylinder block.
2) Measure the clearance between the idle gear and the

thrust collar using a feeler gauge.
Note：
replace the idle gear or thrust collar.
Limit： 0.200 mm { 0.00787 in }
Note：
・ Measure idle gear play in the axis direction
before removing idle gear B.
30. Cooling fan belt removal

1) Loosen the adjust plate lock nut.
2) Loosen the generator fixing nut.
3) Loosen the adjust bolts, and remove the cooling fan
belt from the following parts.
・ Generator
・ Fan pulley
3) Remove idle gear A from the cylinder block.

4) Remove idle gear B from the idle gear shaft.
2) Remove the crankshaft pulley from the crankshaft.
32. Crankshaft front oil seal removal
1) Remove the crankshaft front oil seal from the front
cover using a screwdriver.
Caution：
・ Do not damage the oil seal mounting surface
of the front cover or shaft.
1. Adjust bolt
2. Lock nut

1) Install the special tool to the starter installation
section of the flywheel housing.
Caution：
・ Make sure the stopper is properly engaged 1. Felt
with the ring gear and installed. 2. Slinger
3. Oil seal
2) Remove the slinger from the crankshaft using the

special tool.
Note：

Note：
・ Referring to the diagram, insert the
screwdriver and remove while prying with the
screwdriver.
33. Generator removal

1) Remove the vacuum pump oil feed hose from the
2) Remove the vacuum pump oil return hose from the
vacuum pump and cylinder block. 1. Water pump
2. Fan pulley
3. Set plate
35. Oil pan removal

36. Front cover removal
1) Remove the adjust plate from the front cover.

3) Remove the generator from the generator bracket

and adjust plate.
34. Water pump removal
1) Remove the set plate from the water pump pulley.
2) Remove the fan pulley from the water pump. 1. Adjust plate
3) Remove the water pump from the front cover. 2) Remove the oil relief valve from the front cover.
3) Remove the oil cooler bypass valve from the 2) Rotate the crankshaft in the forward direction so
cylinder block. that the piston of the cylinder to be removed is at
bottom dead center.
connecting rod.
connecting rod bearing cap.
Note：
・ Organize the removed bearings according to
the cylinders using tags, etc.
4) Remove the front cover from the cylinder block and

crankcase.
37. Oil strainer removal
1) Remove the oil strainer from the cylinder block.
2) Remove the O-ring from the oil strainer.
38. Piston removal
1) Clean the top of the cylinder liner using a scraper.
that the piston to be removed is at top dead center.
Caution：
・ Push out from the lower end of the connecting
rod by using the handle of a hammer, etc., so
as not to damage the bearing.
・ When pushing out the connecting rod, do not
damage the oil jet and the cylinder liner.
connecting rod.
Note：
・ When reusing the bearing, organize them
other cylinder bearings do not get mistaken.
39. Crankshaft removal
1) Remove the engine foot from the cylinder block.
2) Measure the crankshaft thrust clearance using a dial
gauge.
Caution：
・ Measure the thrust clearance prior to
disassembly.
4) Remove the lower thrust bearing from the

crankcase.
5) Remove the crankshaft lower bearing from the
crankcase.
3) Gradually loosen the crankcase mounting bolts in

the order shown in the diagram, and remove the
crankcase from the cylinder block using the 3
replacer holes indicated with the arrows.
6) Remove the crankshaft from the cylinder block.

7) Remove the upper thrust bearing from the cylinder
block.
8) Remove the crankshaft upper bearings from the
cylinder block.
disassembly
1. Crankshaft disassembly
1) Remove the crank gear from the crankshaft using
the special tool.
SST: 8-9439-6818-0 - crankshaft gear puller

inspection
1. Crankshaft inspection
1. Clean
1) Clean the following parts.
・ Crankshaft journal
・ Crankshaft lower bearing
・ Crankshaft upper bearing
・ Crank pin
1) Inspect the crankshaft journal and crank pin for the
following.
・ Wear
・ Damage
2) Inspect the crankshaft lower bearing for the
following. 4. Crankshaft journal and crank pin measurement
・ Wear 1) Referring to the diagram, measure the 4 crankshaft
・ Damage journal locations using a micrometer.
Note：
Standard： 81.905 to 81.925 mm { 3.22460 to 3.22539
・ Replace the bearings as a set if a malfunction in } No.1,2,4,5 journal
is found.
Standard： 81.891 to 81.911 mm { 3.22405 to 3.22484
3) Inspect the crankshaft upper bearing for the in } No.3 journal
following.
Limit： 81.85 mm { 3.2224 in } No.1,2,4,5 journal
・ Wear
・ Damage Limit： 81.85 mm { 3.2224 in } No.3 journal
Note： 2) Referring to the diagram, measure the 4 crankshaft
・ Replace the bearings as a set if a malfunction crank pin locations using a micrometer.
is found. Standard： 65.902 to 65.922 mm { 2.59456 to 2.59535
3. Crankshaft runout measurement in } Pin section
1) While slowly turning the crankshaft, measure the Limit： 65.85 mm { 2.5925 in } Pin section
runout at the crankshaft center using a dial gauge.
Note：
・ If the measured value exceeds the specified
value, replace the crankshaft.
Limit： 0.30 mm { 0.0118 in }
5. Crankshaft regrinding precaution

Caution：
・ Regrind the journal and pin fillet section R so
that they are within the specified range.
5) Install the lower crankshaft bearing to the

crankcase.
portion and seating surface of the M14 bolt.
Caution： Note：
・ The journal and pin surface roughness should ・ Do not apply engine oil to the M10 bolt.
be 0.4 μm or less. 7) Install the crankcase to the cylinder block in the
6. Oil clearance measurement order shown in the diagram using the special tool.
1) Install the crankshaft upper bearing to the cylinder Caution：

block. ・ Gently place the crankcase on the cylinder
block.
2) Install the crankshaft to the cylinder block.
・ After tightening the crankcase, do not turn the
Caution： crankshaft.
・ Level the crankshaft to install.
3) Turn the crankshaft approximately 30° to stabilize
the crankshaft upper bearing.

ft } 1st time (M14)
ft } 2nd time (M14)
(M10)
ft } For checking (M14)
4) Place PLASTIGAUGE on the crankshaft journal.

11) Remove any PLASTIGAUGE adhering to the
following parts.
・ Crankshaft lower bearing
・ Crank pin
8) Remove the crankcase from the cylinder block.

Caution：
・ Remove carefully.
9) Measure the widest point of the flattened
PLASTIGAUGE, and inspect the oil clearance of
the crankshaft journal section.
10) Measure the maximum width portion of the
plastigage crushed by tightening the crankcase.
Note：
replace all the crankshaft bearings or the
crankshaft.
No. 1, 2, 4, and 5
No. 3
reassembly
1. Crankshaft reassembly
1. When heating the crank gear
1) Heat the crank gear with the specified value.
Standard： 170 to 250 ℃ { 338 to 482 °F }
2) Install the crank gear to the crankshaft. SST: 8-9439-6819-0 - crankshaft gear installer
Note：
・ Align the pin position at the rear of the
crankshaft with the groove position on the gear
side to install.
Caution：
・ When installing, quickly insert into place
without stopping, until it is seated to the flange,
with the "S" alignment mark on the gear end
surface facing outward.
1. Alignment mark S
1. Alignment mark S
2. If installing when cooled

1) Install the crank gear to the crankshaft using special
tool.
Note：
・ Align the pin position at the rear of the
crankshaft with the groove position on the gear
side to install.
Caution：
・ When installing, tap in until it makes full
contact, with the "S" alignment mark on the
gear end surface facing outward.
Crankshaft
Part name 2. Crankshaft installation

1. Crankshaft upper bearing 1) Install the crankshaft upper bearing to the cylinder
2. Upper thrust bearing block.
3. Crank gear
2) Apply engine oil to the crankshaft upper bearing.
4. Crankshaft
5. Crankshaft lower bearing Caution：
6. Lower thrust bearing ・ Do not apply oil to the cylinder block bearing
7. Crankcase installation surface or the outer circumference
of the bearing.
Tightening torque
1-1： 98 N・m { 10.0 kgf・m / 72 lb・ft } M14
1-2： 132 N・m { 13.5 kgf・m / 97 lb・ft } M14
1-3： 30 to 60 ° M14
2： 37 N・m { 3.8 kgf・m / 27 lb・ft } M10
3) If replacing the crankshaft bearing, select the
crankshaft bearing.
Note：
・ Be careful of the journal hole inner diameter
grade of the cylinder block and the crankshaft
journal diameter grade in selecting a new
bearing.
・ The journal numbers are #1 to #5 from the left
in the direction that the characters are read.
Caution：
・ When installing, pay attention to the
differences in bearing shape.
Bearing selection table

Grade combination Oil clearance
Cylinder Crank Bearing
block journal identificati #1, 2, 4, 5 #3
grade grade on color
： 0.041 to 0.068 mm { 0.00161 to ： 0.055 to 0.082 mm { 0.00217 to
1 1 Black
0.00268 in } 0.00323 in }
： 0.039 to 0.066 mm { 0.00154 to ： 0.053 to 0.080 mm { 0.00209 to
1 2 Brown
0.00260 in } 0.00315 in }
： 0.043 to 0.070 mm { 0.00169 to ： 0.057 to 0.084 mm { 0.00224 to
2 1 Blue
0.00276 in } 0.00331 in }
： 0.041 to 0.067 mm { 0.00161 to ： 0.055 to 0.081 mm { 0.00217 to
2 2 Black
0.00264 in } 0.00319 in }
Caution：
・ Gently place it on the cylinder block.
7) Install the upper thrust bearing on the rear side of
the cylinder block No. 5 journal.
Caution：
・ Install so that the oil groove of the thrust
bearing touches the crankshaft.
1. Upper bearing
2. Oil hole
3. Grade identification color
4. Oil groove
5. Lower bearing
6. Grade identification color
4) Install the thrust bearing upper to the cylinder block

No.5 journal section front side.
Note： 8) Install the crankshaft lower bearing to the
crankcase.
・ It is acceptable to use grease to attach the
upper bearing to the cylinder block. 9) Install the lower thrust bearing on the rear side of
the crankcase No. 5 journal.
Caution：
・ Wipe away any excess grease. Caution：
・ Install so that the oil groove of the thrust ・ Install so that the oil groove of the thrust
bearing touches the crankshaft. bearing touches the crankshaft.
5) Apply engine oil to the crankshaft journal section. 10) Referring to the diagram, apply ThreeBond 1207B
to the crankcase.
6) Install the crankshaft to the cylinder block.
Caution： Tightening torque： 37 N・m { 3.8 kgf・m / 27 lb・ft }
・ Install the crankcase within 5 minutes of (M10)
applying the liquid gasket. 13) Check the tightening torque of the M14 bolts.
Standard： 2 to 3 mm { 0.08 to 0.12 in } Bead height Tightening torque： 142 N・m { 14.5 kgf・m / 105 lb・
Standard： 3 to 4 mm { 0.12 to 0.16 in } Bead width ft } Added in the tightening direction
1. Bead height 14) Install the engine foot to the cylinder block.
2. Bead width Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft }
11) Apply molybdenum disulfide grease to the threaded 3. Piston installation
portions and seating surfaces of the M14 bolts.
Note： rod.
・ Do not apply engine oil to the M10 bolt. 2) Apply the engine oil to the connecting rod bearing.
12) Install the crankcase to the cylinder block in the 3) Apply the engine oil to the piston ring.
order shown in the diagram using the special tool.
Caution：
Caution：
・ Sufficiently apply to the piston ring and ring
・ Gently place the crankcase on the cylinder groove.
block.
4) Apply engine oil to the piston side surface.
5) Turn the crankshaft.
Caution：
・ Place the crank pin of the cylinder to which the
piston and connecting rod are to be installed at
top dead center.
・ If the crank pin is at bottom dead center when
installing the piston and connecting rod, the
SST: 5-8840-0266-0 - angle gauge connecting rod may hit and damage the oil jet.
Tightening torque： 98 N・m { 10.0 kgf・m / 72 lb・ 6) Face the front mark of the piston forward and install
ft } 1st step (M14) the piston to the cylinder liner using the special
tool.
ft } 2nd step (M14) Note：
Tightening Angle ： 30 to 60 ° 3rd step (M14) ・ Referring to the diagram, adjust the position of
the piston ring end gaps so that the No. 1 ring,
No. 2 ring, and oil ring are each separated by

120°.
Caution：
・ When pushing in the piston, fit the piston ring
compressor firmly to the cylinder liner.
・ If the adherence is inadequate, the ring can be
damaged when pushed.
・ When pushing the piston, the connecting rod
should not make contact with the oil jet.
・ Do not damage the inner surface of the
cylinder liner when inserting the piston.
1. Front/rear identification boss

2. Big end bore diameter grade marking
3. Cylinder number
SST: 5-8840-9018-0 - piston setting tool
portion and seating surface of the tightening bolts.
11) Install the connecting rod bearing caps and
connecting rods to the crankshaft using the special
tool.
Caution：

1. No. 1 compression ring end gap 1st time
3. Oil ring end gap Tightening Angle ： 60 ° 2nd step
4. Front mark Tightening Angle ： 30 ° 3rd step
rod bearing cap.
9) Install the connecting rod bearing caps to the
connecting rods after matching their cylinder
numbers.
4) Apply ThreeBond 1207B to the front cover in
alignment with the grooves on the front cover
mounting surface.
width
height
Caution：
・ Install the front cover within 5 minutes of
4. Oil strainer installation

1) Install the O-ring to the oil strainer.
2) Install the oil strainer to the cylinder block.
5. Front cover installation
1) Install the oil cooler bypass valve to the cylinder
block.
Caution：
・ Do not mistake the insertion direction of the oil
cooler bypass valve.
・ Do not remove the rubber cap. 1. O-ring
5) Install the front cover to the cylinder block and

crankcase in alignment with the cylinder block
dowel pins.
6) Install the oil relief valve to the front cover.
2) Clean the cylinder block front side.

Caution：
3) Install 2 O-rings to the front cover.
7) Install the adjust plate to the front cover. 2) Install the oil pan gasket to the crankcase using the
stud as a guide.
Note：
・ Tighten the bolts indicated by the arrows 3) Install the oil pan and oil pan rubber to the
together with the generator adjust plate. crankcase.
1. 35 mm {1.38 in}
2. 25 mm {0.98 in}
3. 65 mm {2.56 in}
4. 30 mm {1.18 in}
5. Oil relief valve

front cover and the flywheel housing. 1. Oil pan rubber
2. Oil pan
Standard： 3 mm { 0.12 in } Bead width 3. Oil pan gasket
Caution：
Note：
pan within 5 minutes. ・ After tightening the 1, 2, 3, and 4 locations in
・ No particular order is required. 3. 1.0 mm {0.039 in} or more
Tightening torque： 11 N・m { 1.1 kgf・m / 97 lb・in } 2) Install the water pump to the front cover aligned
with the stud on the front cover.
3) Install the fan pulley to the water pump.
4) Install the set plate to the water pump.
Note：
・ After adjusting the drive belt, tighten the fan
pulley and set plate to the specified torque.

7. Water pump installation
1) Apply ThreeBond 1207B to the groove of the water
pump mounting surface.
1. Fan pulley
Caution： 2. Set plate
・ Install the water pump within 5 minutes of
applying the liquid gasket. 8. Generator installation
1) Temporarily tighten the generator to the generator
bracket and adjust plate.
Note：
・ Tighten the generator after adjusting the
cooling fan belt.
2) Install the vacuum pump oil return hose to the
3) Install the vacuum pump oil feed hose to the
Cylinder block side
Vacuum pump side
1. 1.0 to 1.5 mm {0.039 to 0.059 in}

2. 3.0 to 4.0 mm {0.118 to 0.157 in}
1. Vacuum pump oil return hose 1. Front slinger

2. Vacuum pump oil feed hose 2. 5-8840-2705-0
3. 5-8840-2714-0
9. Crankshaft front oil seal installation 4. 5-8840-2941-0
Caution： 5. 5-8840-2943-0
6. 5-8840-2713-0
1) Prepare special tool. 2) Insert the slinger into the tip of the adapter.
5) Install the washer to the center bolt.
Front use
5-8840-2941-0 Sleeve ○ ○
5-8840-2705-0 Adapter ○ ○
5-8840-2942-0 Adapter ring ○
5-8840-2943-0 Washer ○ ○
5-8840-2713-0 Center bolt ○ ○
5-8840-2714-0 Fixing bolt ○ ○
Rear use
5-8840-2944-0 Sleeve ○ ○
5-8840-2709-0 Adapter ○ ○
5-8840-2710-0 Collar ○ ○
5-8840-2945-0 Adapter ring ○
5-8840-2713-0 Center bolt ○ ○
5-8840-2714-0 Fixing bolt ○ ○ 7) Measure the dimension from the crankshaft end
Fixing bolt face to the oil seal lip section contact surface after
8-9439-3010-0 (For flywheel ○ ○ pressing in the slinger.
PTO)
Caution： 9) Thinly apply engine oil to the lip section of the
・ Check the fluctuation in the 4 directions of the crankshaft front oil seal.
slinger. Caution：
・ Do not mistake the installation direction and ・ Make sure to apply oil to the lip section of the
front and rear of the slinger. crankshaft front oil seal.
・ Check whether the 4-thread screw (left) is cut.
10) Install the crankshaft front oil seal to the adapter.

2. 5-8840-2705-0
1. 5-8840-2705-0 3. 5-8840-2943-0
2. 5-8840-2941-0 4. 5-8840-2714-0
3. Slinger 5. 5-8840-2941-0
4. 40.2 to 40.8 mm {1.583 to 1.606 in} 6. 5-8840-2943-0
5. 33.9 to 34.1 mm {1.335 to 1.343 in} 7. 5-8840-2713-0
8) Install the adapter to the crankshaft by the fixing 11) Install the adapter ring to the sleeve.
bolt. 12) Install the washer to the center bolt.
13) Install the center bolt to the sleeve, and tighten until
the sleeve contacts the adapter to press-fit the
1. 5-8840-2705-0
1. Crankshaft front oil seal 1. 5-8840-2942-0

2. 5-8840-2942-0 2. 5-8840-2941-0
3. 5-8840-2941-0 3. 5-8840-2705-0
4. 5-8840-2713-0 4. Crankshaft front oil seal
5. 30.7 to 31.3 mm {1.209 to 1.232 in}
10. Crankshaft pulley installation

1) Apply engine oil to the threaded portion of the
bolts.
2) Install the crankshaft pulley to the crankshaft in the
Note：
・ Install the crankshaft pulley aligned with the
knock pin of the crankshaft.
ft }

face to the oil seal surface after pressing in the
Caution：
・ Check that there is no runout in the 4
directions of the crankshaft front oil seal.
11. Cooling fan belt installation

1) Install the cooling fan belt to the following parts.
・ Fan pulley 2) Apply engine oil to the idle gear B shaft.
3) Referring to the diagram, install idle gear B to the
・ Generator
idle gear shaft.
12. Oil pump installation
1) Referring to the diagram, apply ThreeBond 1207B ft }
to the oil pump.
Caution：
・ Install the oil pump within 1 minute of applying
liquid gasket.
・ Apply liquid gasket so that it does not get in
the holes indicated by the arrows in the
diagram, nor inside the gear or oil pump body.
1. Idle gear B
2. Thrust collar
3. Bolt

Note：
2) Install the oil pump to the cylinder block.
Tightening torque： 24 N・m { 2.4 kgf・m / 18 lb・ft } cover alignment mark.
13. Idle gear installation
1) Install the idle gear B shaft to the cylinder block.
5) Align the alignment markings for the crankshaft

gear and idle gear A.
6) Apply engine oil to the threaded portion and the and both sides of the washer are completely
seating surface of the bolt. covered in engine oil.
7) Apply engine oil to both sides of washer. Tightening torque： 157 N・m { 16.0 kgf・m / 116 lb・
8) Apply engine oil to the bearing surface of idle gear ft }
A.
9) Install idle gear A to the cylinder block.
Caution：
・ Before assembling, be sure to confirm that the
threaded portion and seat surface of the bolt
1. Idle gear C 6. Crankshaft gear

2. Camshaft gear 7. Oil pump drive gear
3. Idle gear B 8. Injection nozzle gear
4. Power steering oil pump gear 9. Idle gear A
14. Flywheel housing installation Standard： 2.0 to 4.0 mm { 0.079 to 0.157 in } Bead
height
1) Clean the cylinder block using a scraper.
Note：
Caution：
・ Apply liquid gasket evenly to the inside of the
bolt holes, except for the bolt hole indicated by
the arrow.
2) Apply ThreeBond 1207B to the cylinder block.
15. Power steering oil pump idle gear installation
1) Apply engine oil to the gear assembly sections of
the idle gear shaft.
2) Install the idle gear shaft to the power steering oil
pump idle gear.
3) Position the cylinder block knock pin, and install

the flywheel housing to the cylinder block.
Bolt 1
Bolt 2
3) Install the power steering oil pump idle gear and
Tightening torque： 38 N・m { 3.9 kgf・m / 28 lb・ft } idle gear shaft as a set to the flywheel housing.
Bolt 3
Tightening torque： 48 N・m { 4.9 kgf・m / 35 lb・ft } ft }
Bolt 4
Note：
・ The number behind the tightening torque
indicates the diagram number.
4) Install the idle gear cover to the flywheel housing.

1. Bolt
2. Bolt
3. Bolt
4. Bolt
16. Oil filter installation 3) Install the oil pipe to the cylinder block and oil
filter.
1) Install the O-ring to the oil filter.
17. Injection pump installation
mark with BTDC 13°.
Note：
・ Check the No. 1 cylinder inlet locker arm and
exhaust locker arm, and if the No. 1 cylinder
inlet locker arm and exhaust locker arm are
pushed down, piston No. 4 is at the top of the
compression stroke.
・ Rotate the crankshaft 1 rotation (360°) to
adjust the crank damper pulley timing mark to
BTDC 13° again.
・ Adjustment to BTDC 13° is for the angle set by
the injector pump, and is in no way related to
1. O-ring the injection timing.
2. O-ring
2) Install the oil filter to the cylinder block.

Bracket
1. TDC
2. BTDC 5°
3. BTDC 7°
1. Nut
4. BTDC 9°
2. Injection pump
5. BTDC 11°
3. Bolt (M12)
6. BTDC 13°
4. Bolt (M10)
2) Align the flange section groove with the groove on 5. Bracket
the timer outer circumference using a flathead
4) Remove the check hole plug from the injection
screwdriver.
pump.
mark with BTDC 7°.
3) Install the injection pump and bracket to the

cylinder block.
M10 bolt
1. TDC
Tightening torque： 76 N・m { 7.7 kgf・m / 56 lb・ft } 2. BTDC 5°
M12 bolt 3. BTDC 7°
4. BTDC 9°
5. BTDC 11°
Nut
6. BTDC 13°
6) Referring to the diagram, check the injection Tightening torque： 23 N・m { 2.3 kgf・m / 17 lb・ft }
timing. Flywheel housing side
20. Crankshaft rear oil seal installation
Caution：
1) Prepare special tool.

Front use
5-8840-2941-0 Sleeve ○ ○
1. Pointer 5-8840-2705-0 Adapter ○ ○
2. Timer outside mark 5-8840-2942-0 Collar ○ ○
3. Timing check hole
5-8840-2943-0 Adapter ring ○
7) Install the check hole plug to the injection pump. 5-8840-2713-0 Center bolt ○ ○
18. Blow-by hose installation 5-8840-2714-0 Fixing bolt ○ ○
Rear use
1) Install the blow-by hose to the Flywheel housing.
5-8840-2944-0 Sleeve ○ ○
5-8840-2709-0 Adapter ○ ○
5-8840-2710-0 Collar ○ ○
5-8840-2945-0 Adapter ring ○
5-8840-2713-0 Center bolt ○ ○
5-8840-2714-0 Fixing bolt ○ ○
Fixing bolt
8-9439-3010-0 (For flywheel ○ ○
PTO)
Note：
・ 5-8840-2940-0 includes an engine sleeve
(5-8840-2948-0) for use with engines from
before May 1993. Do not use this sleeve
(5-8840-2948-0) for this engine.
2) Install the slinger to the tip of the adapter.
19. Oil pipe installation

1) Install the oil pipe to the following parts.
・ Injection pump
・ Oil filter
Injection pump and oil filter side
1. Slinger 7) Measure the dimension from the crankshaft end

2. 5-8840-2714-0 face to the oil seal lip section contact surface after
3. 5-8840-2713-0 press-fitting the slinger.
4. 5-8840-2944-0
Caution：
5. 5-8840-2710-0
6. 5-8840-2709-0 ・ Check the fluctuation in the 4 directions of the
slinger.
3) Install the collar to the fixing bolt. ・ Do not mistake the installation direction and
4) Install the adapter to the crankshaft. front and rear of the slinger.
・ Check whether the 4-thread screw (right) is
cut.
1. 5-8840-2710-0
2. 5-8840-2714-0
3. 5-8840-2709-0

1. Crankshaft
2. 5-8840-2709-0
3. 17.0 to 17.6 mm {0.669 to 0.693 in}
4. 10.7 to 10.9 mm {0.421 to 0.429 in}
5. Slinger
6. 5-8840-2944-0
7. 5-8840-2710-0
8) Install the collar to the fixing bolt.
1. 5-8840-2944-0
2. 5-8840-2945-0
1. 5-8840-2709-0
2. 5-8840-2714-0 13) Install the center bolt to the sleeve, and tighten until
3. 5-8840-2713-0 the sleeve contacts the adapter to press-fit the
4. 5-8840-2944-0 crankshaft rear oil seal.
5. 5-8840-2710-0
6. 5-8840-2945-0

face to the crankshaft rear oil seal surface after
pressing in the crankshaft rear oil seal.
Caution：
1. 5-8840-2710-0 ・ Check that there is no runout in the 4
2. 5-8840-2714-0 directions of the crankshaft rear oil seal.
3. 5-8840-2709-0 Standard： 7.5 to 8.1 mm { 0.295 to 0.319 in }
10) Thinly apply engine oil to the lip section of the
crankshaft rear oil seal.
11) Install the crankshaft rear oil seal to the adapter.
12) Install the adapter ring to the sleeve.
1. Crankshaft 4) Final tighten the flywheel to the crankshaft using a

2. Crankshaft rear oil seal torque wrench and the special tool in the order
3. 7.5 to 8.1 mm {0.295 to 0.319 in} shown in the diagram.
4. 5-8840-2710-0
5. 5-8840-2945-0
6. 5-8840-2944-0
7. 5-8840-2709-0

portion of the bolt and bearing surface.
2) Temporarily tighten the washer and the flywheel to
the crankshaft. Tightening torque： 78 N・m { 8.0 kgf・m / 58 lb・ft }
1st time
Tightening Angle ： 90 to 120 ° 2nd time
Note：
Caution：

housing.
1. Reference point of cylinder block top surface

2. 50°
3. 20 °
23. Cylinder head installation 4. Measurement point of piston head
5. 100 mm {3.94 in}
1) Clean the piston head and cylinder block top
6. 70 mm {2.76 in}
surface.
2) Referring to the diagram, measure the protrusion
amount of the piston in each cylinder at 2 locations. 3) Find the maximum of the average values of the
cylinders.
4) Refer to the table, and select a cylinder head gasket
of the appropriate grade according to the maximum
value.
Caution：
・ Select from the 3 types of head gaskets shown
in the table according to the protrusion amount
of the piston.
Head gasket selection
Gasket Identific Protrusion amount of the
grade ation piston, maximum value
： 0.579 to 0.659 mm
A No hole
{ 0.02280 to 0.02594 in }
： 0.659 to 0.739 mm
B 1 hole
{ 0.02594 to 0.02909 in }
： 0.739 to 0.819 mm
C 2 holes
{ 0.02909 to 0.03224 in }
1. Grade identification hole 7) Install the cylinder head to the cylinder block while
aligning the dowel of the cylinder block.
to the cylinder block. Caution：
・ When installing, do not damage the cylinder
head gasket.
Caution：
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.

portion and seating surface of the M14 head bolt.
9) Install the head bolt (M14) to the cylinder head in
1. Liquid gasket application position the order shown in the diagram using the special
tool.
6) Install the cylinder head gasket to the cylinder block
with the side with the part number marking on the
cylinder head gasket facing up.
Caution：
・ Align the dowel with the cylinder head rear
gear case, and install.

Tightening torque： 98 N・m { 10.0 kgf・m / 72 lb・ 2) Install the turbocharger to the cylinder head in the
ft } 1st time (M14) order shown in the diagram.
Tightening torque： 147 N・m { 15.0 kgf・m / 108 lb・ Tightening torque： 34 N・m { 3.5 kgf・m / 25 lb・ft }
ft } 2nd time (M14)
3) Install the exhaust pipe adapter to the turbocharger.

10) Apply engine oil to the threaded portion and the Nut
seating surface of the M10 head bolt.
11) Tighten the head bolt (M10) to the cylinder head in Bolt
(M10)
1. Turbocharger
4) Install the heat protector to the exhaust pipe adapter.

12) Install the dummy plug to the cylinder head.
25. Oil drain pipe installation
24. Turbocharger installation
1) Install the oil drain pipe to the turbocharger and
1) Install the gasket to the cylinder head. cylinder block.
Tightening torque： 9 N・m { 0.9 kgf・m / 80 lb・in } 1) Install the water feed pipe to the turbocharger and
Turbocharger side cylinder block.
Cylinder block side Eyebolt
26. Feed oil pipe installation Tightening torque： 24 N・m { 2.4 kgf・m / 18 lb・ft }
Bracket bolt
1) Temporarily tighten the feed oil pipe to the
turbocharger and flywheel housing in the order 2) Install the water return pipe to the turbocharger.
Turbocharger side eyebolt
Bolt 1 and nut
Bolt 2
2) Install the feed oil pipe to the turbocharger and

flywheel housing in the order shown in the diagram.
Turbocharger side
1. Bolt 1
Tightening torque： 24 N・m { 2.4 kgf・m / 18 lb・ft } 2. Nut
Cylinder head side 3. Bolt 2
28. Inlet cover installation

1) Clean the cylinder head installation surface.
apply ThreeBond 1207C to the inlet case.
Caution：
・ Do not apply to the wide groove inside.
・ Install the inlet cover within 7 minutes of
width
3) Install the inlet case to the cylinder head in the
27. Water feed pipe installation
1. Application area 1. Gasket

2. O-ring
4) Install the inlet cover and gasket to the inlet case in 3. Injection nozzle
2) Install the holder to the injection nozzle.
Caution：
・ Do not drop the gasket. 3) Temporarily tighten the injection nozzle to the
cylinder head.
4) Install the injection nozzle to the cylinder head in
Caution：
・ Do not mistake the injection nozzle direction.

29. Injection nozzle installation
1) Install the gasket and O-ring to the injection nozzle.
Caution： 5) Install the nozzle leak off pipe to the injection
・ Do not mistake the gasket direction. nozzle.
in }
Caution：
・ Make sure to confirm that the clips are
attached at inappropriate locations.
1. Fuel pipe

1) Install the fuel suction pipe to the injection pump
and fuel filter.
2) Install the fuel feed pipe to the injection pump and
fuel filter.
3) Install the fuel pipe to the injection pump.
1. 41 mm {1.61 in} Tightening torque： 23 N・m { 2.3 kgf・m / 17 lb・ft }
2. 14 mm {0.55 in}
3. 13 mm {0.51 in} 4) Remove the fuel return pipe from the injection
pump.
31. Fuel filter installation
1) Install the fuel filter to the bracket.
2) Connect the 2 fuel pipes to the fuel filter.

2. Fuel feed pipe
3. Fuel return pipe
4. Fuel pipe
33. Water bypass hose connect
1) Connect the water bypass hose to the cylinder head.
5) Install the upper camshaft bearing to the camshaft

bearing cap.
6) Apply engine oil to the upper camshaft bearing.
7) Orient the front mark of the bearing cap towards the
2) Connect the connector to the thermometer unit. engine front, and temporarily install the camshaft
34. Camshaft installation bearing cap to the cylinder head in the order of the
numbers.
Note：
2) Apply engine oil to the lower camshaft bearing.
3) Install the lower camshaft bearing to the cylinder
head.
4) Install the camshaft on the cylinder head so that the
top surface of the cylinder head is aligned with the I
mark on the camshaft gear end face.
8) Apply engine oil to the threaded portion and seat

surface of the bearing cap tightening nut.
9) Install the tightening nut to the bearing cap, and
final tighten the bearing cap.
Caution：
・ After tightening, make sure the I mark is
aligned.
35. Rocker arm shaft installation 1. Bolt 1

2. Bolt 2
1) Apply engine oil to the rocker arm roller section.
3. Bolt 3
2) Install the rocker arm shaft to the cylinder head.
Note：
・ Workability will be improved if the bolts
to the cam end gasket and cylinder head.
indicated by arrows in the diagram are
loosened. Caution：
・ Clean the application surface of the gasket
before applying the gasket.
・ Install the cylinder head cover within 7 minutes
of applying liquid gasket.
Standard： 3 to 4 mm { 0.12 to 0.16 in } Bead height
Standard： 3 to 4 mm { 0.12 to 0.16 in } Bead width
3) Install the bolt to the cylinder head.

Bolt 3 1. 10 mm {0.39 in}
2. 30 mm {1.18 in}
2) Install the gasket to the cylinder head cover.

3) Install the cylinder head cover to the cylinder head Refer to "Engine (tilt cab model) installation" in this
in the order shown in the diagram. section.
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } Refer to "Engine (non tilt cab model) installation" in
this section.
40. Cooling fan belt adjustment
When installing a new belt, initial stretching of the belt
occurs.
In addition, when reusing the belt, the belt needs to adapt
to the pulley groove.
1) Loosen the adjust plate lock nut and generator
fixing nut.
2) Turn the adjust bolt to adjust the cooling fan belt.
Caution：
・ Accurately adjust the tension because if the
tension is not within the appropriate range,
there is a possibility the service life will be
shortened, or belt squeal may be generated.
・ Use a sonic tension meter to verify accurate
tension adjustment.
37. Turbocharger intake pipe installation
Adjustmen
1) Install the Turbocharger intake pipe to the
t Deflection Vibration frequency
turbocharger.
conditions
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } ： 8 to 12 mm
When new ： 140 to 170 Hz
{ 0.31 to 0.47 in }
When ： 10 to 14 mm
： 121 to 139 Hz
reused { 0.39 to 0.55 in }
Note：
・ The specified vibration frequency is a value for
when adjustment is performed using a sonic
tension meter.
・ The specified deflections shown are the values
obtained when the specified pressure is
applied to the midpoint between the fan pulley
and generator.
Standard： 98 N { 10.0 kg / 22 lb }
3) After adjusting, tighten the adjust plate lock nut and
generator fixing nut to the specified torque.
Adjust plate lock nut
38. Engine oil filling Generator fixing nut
Caution：
39. Engine installation
1. Adjust bolt
2. Adjust plate lock nut
Cylinder block
Cylinder block
Part name 1) Disconnect the water bypass hose from the oil
cooler.
1. Cylinder liner
2. Cylinder block 2) Remove the heater cover and gasket from the oil
3. Piston oil jet cooler.
Tightening torque 3) Remove the water inlet pipe from the oil cooler.
1： 21 N・m { 2.1 kgf・m / 15 lb・ft }

2. Crankshaft removal
Refer to "Crankshaft removal" in this section.
3. Oil cooler removal
4) Remove the oil cooler from the cylinder block.

5) Remove the O-ring from the oil cooler.
4. Piston oil jet removal
1) Remove the piston oil jet from the cylinder block.
Cylinder block
Part name Standard： 0.09 to 0.14 mm { 0.0035 to 0.0055 in }

1. Cylinder liner Limit： 0.03 mm { 0.0012 in } Difference in protrusion
2. Cylinder block amount with the adjacent cylinder liner
3. Piston oil jet
Tightening torque
1： 21 N・m { 2.1 kgf・m / 15 lb・ft }
2. Cylinder liner removal
1) Measure the cylinder liner protrusion amount of the
cylinder block top surface using a dial gauge.
Caution：
・ The difference in protrusion amount with the
adjacent cylinder liner should not exceed the
limit.
2) Check the cylinder liner grade. 1. Measurement position: 20 mm {0.79 in}

2. Measurement position: 90 mm {3.54 in}
3. Measurement position: 160 mm {6.30 in}
4. Thrust direction
5. Radial direction
4) Calculate the average measured value excluding the

maximum and minimum values.
Caution：
・ If the average value exceeds the limit, replace
the cylinder liner.
Cylinder liner bore
Standard parts
Grade Specified value Limit
： 115.031 to
115.040 mm
A
{ 4.52877 to 4.52912
in }
1. Cylinder liner grade mark ： 115.041 to
115.050 mm ： 115.20 mm
3) Measure the 6 measurement positions for the B
{ 4.52916 to 4.52952 { 4.5354 in }
cylinder bore inner diameter in the radial direction in }
and thrust direction using a dial gauge.
： 115.051 to
115.060 mm
C
{ 4.52956 to 4.52991
in }
Service parts
Specified value Limit
： 115.041 to 115.060 mm ： 115.20 mm
{ 4.52916 to 4.52991 in } { 4.5354 in }
5) Remove the cylinder liner from the cylinder block
using the special tool.
Caution：
・ Because the cylinder bore will be damaged if
the cylinder liner remover ankle comes in
contact with the cylinder block, carefully pull

out the liner while checking.
・ Do not damage the cylinder block.
SST: 9-8523-1169-0 - cylinder liner remover
SST: 5-8840-2397-0 - cylinder liner remover ankle
1. 9-8523-1169-0
2. 5-8840-2397-0
3. Cylinder liner
inspection
1. Cylinder block inspection
1. Clean
1) Clean any foreign materials on the top of the
cylinder block surface such as liquid gasket or
water deposits.
Caution：
・ Do not damage the cylinder block.
1) Inspect the cylinder block for the following.
・ Cracking
・ Damage
Note：
・ Inspect by means of the dye penetrant check,
2. Cylinder liner inspection
water pressure, or air pressure test as
necessary. 1) Inspect the liner inner surface for damage.
・ Replace the cylinder block if a malfunction is
found.
3. Cylinder block measurement

1) Measure the 4 sides and 2 locations in a diagonal
line of the cylinder block top surface using a simple
straight ruler and feeler gauge.
Note：
replace the cylinder block.
Limit： 0.10 mm { 0.0039 in }
Cylinder block
Part name the liner with piston grade that matches the
1. Cylinder liner inner diameter of the liner, per cylinder, if the
2. Cylinder block liner outer diameter grade is specified.
3. Piston oil jet Cylinder block marking 1 2, 3
Tightening torque Liner outer diameter 1X 3X
1： 21 N・m { 2.1 kgf・m / 15 lb・ft } Cylinder block inner diameter and liner grade
(Reference)
2. Cylinder liner installation
Grade 1-1X 2-1X 3-3X
1) Referring to diagram, check that the cylinder block ： 118.001 ： 118.011 ： 118.021
inner diameter grade is marked in the location of the Cylinder to 118.010 to 118.020 to 118.030
arrows. block inner mm mm mm
Note： diameter { 4.64570 to { 4.64609 to { 4.64649 to
4.64605 in } 4.64645 in } 4.64684 in }
・ When replacing the liner, replenishment with
the liner set can be performed by replenishing
： 117.991 Caution：
Cylinder to 118.000 ・ Be sure to measure the protrusion amount of
：118.001 to 118.010 mm
liner outer mm the cylinder liner after replacing the cylinder
{ 4.64570 to 4.64605 in }
diameter { 4.64531 to liner.
4.64566 in }
Limit： 0.03 mm { 0.0012 in } Difference in protrusion
amount with the adjacent cylinder liner
2) Install the cylinder liner to the cylinder block.

Caution：
・ Install straight into the cylinder block.
・ When inserting the liner, do not hit it nor apply
excessive force.
・ Thoroughly wash the cylinder block and
cylinder liner, and install them after air-
blowing.
3) Measure the protrusion amount of each cylinder

liner using a dial gauge.
Cylinder block
Part name Tightening torque： 21 N・m { 2.1 kgf・m / 15 lb・ft }

1. Cylinder liner
2. Cylinder block
3. Piston oil jet
Tightening torque
1： 21 N・m { 2.1 kgf・m / 15 lb・ft }
2. Piston oil jet installation
1) Align the knock pin of the oil jet with the pin hole
of the cylinder block, and install the piston oil jet to
the cylinder block using the check valve.
Caution：
・ Do not damage or deform the oil jet nozzle.
3. Oil cooler installation

1) Install the O-rings to the inlet and outlet of the oil 4) Referring to the diagram, apply ThreeBond 1207B
cooler oil passage. to the groove of the water inlet pipe flange surface.
to the groove on the flange surface of the oil cooler.
Caution：
・ Install the oil cooler within 5 minutes of
1. Liquid gasket
2. 0.3 to 1.0 mm {0.012 to 0.039 in}
3. 2 to 3 mm {0.08 to 0.12 in}
4. 1 mm {0.04 in}
5) Install the water inlet pipe to the oil cooler.

Caution：
1. O-ring ・ Installation of the water inlet pipe should be
2. Liquid gasket performed immediately after the oil cooler is
3. O-ring installed, because the liquid gasket is being
4. 0.3 to 1.0 mm {0.012 to 0.039 in} used for collective tightening.
5. 2 to 3 mm {0.08 to 0.12 in}
6. 1 mm {0.04 in}
3) Install the oil cooler to the cylinder block in the

order shown in the figure.
6) Install the heater cover and gasket to the oil cooler.

4. Crankshaft installation
Refer to "Crankshaft installation" in this section.
Intake throttle control solenoid valve
removal
negative terminal.
2) Tilt the cab.
2. Intake throttle control solenoid valve removal
1) Disconnect the connector from the intake throttle
control solenoid valve.
2) Disconnect the vacuum hose from the intake throttle
3) Remove the intake throttle control solenoid valve
from the side cover.
inspection
1. Intake throttle control solenoid valve inspection
1) Measure the resistance between terminals 1 and 2 of
the intake throttle control solenoid valve using a
DMM.
Standard： 114 to 214 Ω 20°C {68°F}
installation
1. Intake throttle control solenoid valve installation
1) Install the intake throttle control solenoid valve to
the side cover.
2) Connect the vacuum hose to the intake throttle
3) Connect the connector to the intake throttle control
solenoid valve.
1. Post procedures
1) Lower the cab.
terminal.
Engine speed sensor
removal
negative terminal.
2) Tilt the cab.
sensor.
housing.
inspection
1. Engine speed sensor inspection
1) Inspect the engine speed sensor for the following.
・ Damaged sensor section
・ Dirty sensor section
・ Broken terminal
・ Bent terminal
2. Resistance measurement
1) Measure the engine speed sensor resistance using a
DMM.
Standard： 840 Ω
installation
housing.

1. Post procedures
1) Lower the cab.
terminal.
Supplementary Information
1. Component views
Engine mounting

1. Fan guide 2： 51 N・m { 5.2 kgf・m / 38 lb・ft }
2. Engine mounting
3： 106 N・m { 10.8 kgf・m / 78 lb・ft }
Tightening torque
Cylinder head cover
Part name 6. Mounting rubber

1. Cylinder head cover Tightening torque
2. Gasket
3. Mounting rubber 1： 18 N・m { 1.8 kgf・m / 13 lb・ft }
4. Cylinder head 2： 18 N・m { 1.8 kgf・m / 13 lb・ft }
5. Cam end gasket
Inlet cover
Part name
Tightening torque
1. Inlet case
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2. Gasket
3. Inlet cover 2： 18 N・m { 1.8 kgf・m / 13 lb・ft }
4. Intake pipe
3： 19 N・m { 1.9 kgf・m / 14 lb・ft }
5. Mounting rubber
Idle gear

1. Power steering oil pump idle gear 2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2. Idle gear cover
3： 44 N・m { 4.5 kgf・m / 32 lb・ft }
4. Clutch disc 4： 25 N・m { 2.5 kgf・m / 18 lb・ft }
5. Flywheel
5： 96 N・m { 9.8 kgf・m / 71 lb・ft }
7. Flywheel housing 6： 96 N・m { 9.8 kgf・m / 71 lb・ft }
8. Engine speed sensor 7： 96 N・m { 9.8 kgf・m / 71 lb・ft }
9. Slinger
10. Oil pump 8： 96 N・m { 9.8 kgf・m / 71 lb・ft }
11. Oil pan 9： 134 N・m { 13.7 kgf・m / 99 lb・ft }
12. Idle gear B shaft
13. Idle gear B 10： 19 N・m { 1.9 kgf・m / 14 lb・ft }
14. Idle gear A 11-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
15. Power steering oil pump
11-2： 90 to 120 °
Tightening torque
12： 40 N・m { 4.1 kgf・m / 30 lb・ft } 15： 157 N・m { 16.0 kgf・m / 116 lb・ft }
13： 8 N・m { 0.8 kgf・m / 71 lb・in } 16： 110 N・m { 11.2 kgf・m / 81 lb・ft }
14： 48 N・m { 4.9 kgf・m / 35 lb・ft } 17： 31 N・m { 3.2 kgf・m / 23 lb・ft }
Rocker arm shaft

1. Camshaft bearing cap 3： 27 N・m { 2.8 kgf・m / 20 lb・ft }
2. Rocker arm
4： 56 N・m { 5.7 kgf・m / 41 lb・ft }
4. Rocker arm bracket 5： 27 N・m { 2.8 kgf・m / 20 lb・ft }
6： 27 N・m { 2.8 kgf・m / 20 lb・ft }
6. Rocker arm shaft
7： 56 N・m { 5.7 kgf・m / 41 lb・ft }
Tightening torque
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
Camshaft
Part name 6. Camshaft

1. Camshaft bearing cap Tightening torque
3. Knock pin 1： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4. Camshaft gear 2： 142 N・m { 14.5 kgf・m / 105 lb・ft }
Cylinder head
Part name
Tightening torque
1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2. Split collar
3. Valve spring upper seat 2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
4. Valve spring
3： 38 N・m { 3.9 kgf・m / 28 lb・ft }
6. Valve spring lower seat 4： 95 N・m { 9.7 kgf・m / 70 lb・ft }
7. Valve guide 5： 48 N・m { 4.9 kgf・m / 35 lb・ft }
8. Idle gear C
9. Idle gear C cover 6-1： 98 N・m { 10.0 kgf・m / 72 lb・ft }
10. Rear engine hanger 6-2： 147 N・m { 15.0 kgf・m / 108 lb・ft }
12. Cylinder head 6-3： 30 to 60 °
13. Front engine hanger 7： 48 N・m { 4.9 kgf・m / 35 lb・ft }
14. Thermostat
Flywheel
Part name
Tightening torque
1. Engine speed sensor
1-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
2. Flywheel housing
3. Flywheel 1-2： 90 to 120 °
4. Washer
2： 40 N・m { 4.1 kgf・m / 30 lb・ft }
5. Clutch disc
6. Pressure plate 3： 8.0 N・m { 0.8 kgf・m / 71 lb・in }
7. Pilot bearing
Front cover
Part name Tightening torque

1. Generator 1： 24 N・m { 2.4 kgf・m / 18 lb・ft }
2. Adjust plate
2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
3. Front cover
4. Oil pan gasket 3： 39 N・m { 4.0 kgf・m / 29 lb・ft }
5. Oil pan
4： 24 N・m { 2.4 kgf・m / 18 lb・ft }
6. Rubber seal
8. Crankshaft front oil seal 6： 24 N・m { 2.4 kgf・m / 18 lb・ft }
10. Water pump 7： 11 N・m { 1.1 kgf・m / 97 lb・in }
11. Cooling fan belt 8： 11 N・m { 1.1 kgf・m / 97 lb・in }
12. Fan pulley
13. Cooling fan 9： 200 N・m { 20.4 kgf・m / 148 lb・ft }
Part name
Tightening torque
1： 200 N・m { 20.4 kgf・m / 148 lb・ft }
Part name 7. Crankshaft rear slinger

1. Starter motor Tightening torque
2. Transmission
3. Clutch pressure plate 1-1： 78 N・m { 8.0 kgf・m / 58 lb・ft }
4. Clutch disc 1-2： 90 to 120 °
5. Flywheel
Crankshaft pulley
Part name
Tightening torque
1： 200 N・m { 20.4 kgf・m / 148 lb・ft }
Piston
Part name 3. Piston

4. Connecting rod
1. Piston ring
2. Snap ring
6. Piston pin
Crankshaft
Part name
Tightening torque
1. Crankshaft upper bearing
1-1： 98 N・m { 10.0 kgf・m / 72 lb・ft } M14
2. Upper thrust bearing
3. Crank gear 1-2： 132 N・m { 13.5 kgf・m / 97 lb・ft } M14
4. Crankshaft
1-3： 30 to 60 ° M14
5. Crankshaft lower bearing
6. Lower thrust bearing 2： 37 N・m { 3.8 kgf・m / 27 lb・ft } M10
7. Crankcase
Cylinder block
Part name
1. Cylinder liner
2. Cylinder block
3. Piston oil jet
Tightening torque
1： 21 N・m { 2.1 kgf・m / 15 lb・ft }
Published: Apr., 2016
1st Edition All rights reserved.
'16
WORKSHOP MANUAL
Mechanical
(4HG1)
Issued by ISUZU MOTORS LIMITED
Service Technical & Training Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan

1B (4HG1)

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Engine = '16 Model 4HG1

Engine (tilt cab model)

3) Loosen the drain plug on the cylinder block side,

6. Vacuum hose disconnect

4) Drain coolant from the radiator reserve tank.

Caution： 7. Oil level gauge guide tube removal

1. Oil level gauge guide tube

8. Engine control cable disconnect

4) Rotate the engine by 90 degrees.

5) Move from the chassis frame top surface, and

installation 3) Connect the vacuum hose to the vacuum pump.

3) Rotate the engine by 90 degrees.

4. Exhaust brake valve installation

5) Install the exhaust silencer to front exhaust pipe B

1. Oil level gauge guide tube

2) Install the oil level gauge to the oil level gauge

11. Oil level gauge guide tube installation

2) Replenish the radiator with coolant.

Refer to "5.Transmission, Transaxle 5E.Clutch

1. Radiator reserve tank

7) Start and idle the engine for 5 minutes or more.

5) Tighten the air bleeding plug of the fuel filter.

Engine (non tilt cab model)

4) Drain coolant from the radiator reserve tank.

7) Start and idle the engine for 20 minutes.

2) Replenish the radiator with tap water.

1. Radiator cap 1. Drain plug

11) Loosen the drain plug on the cylinder block side,

7. Vacuum hose disconnect

2) Disconnect the engine control cable from the engine

8. Oil level gauge guide tube removal

10. Engine controllever removal

1. Oil level gauge guide tube

9. Engine control cable disconnect

11. Fuel hose disconnect 14. Air duct removal

15. Exhaust brake valve removal

16. Power steering oil pump disconnect

installation during assembly, temporarily tighten the bolts

5) Install the exhaust silencer to front exhaust pipe B

1. Air duct 10. Engine control cable connect

2) Connect the engine stop cable to the injection

11. Oil level gauge guide tube installation 1. Vacuum hose

1. Oil level gauge guide tube

2) Install the oil level gauge to the oil level gauge

14. Clutch installation

1. Radiator reserve tank

7) Start and idle the engine for 5 minutes or more.

5) Tighten the air bleeding plug of the fuel filter.

removal 1. Component views

Part name Note：

installation 1. Component views

Part name 1) Install the fan guide to the radiator.

2. Engine mounting installation

removal 1. Component views

4. Vacuum hose disconnect

1. Fuel suction pipe

1. Oil level gauge guide tube

6. Fuel pipe removal