Workshop Manual: (4HK1 Model)

2010-2012MY
2010-2012MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4HK1 model)

ENGINE
(4HK1 model)
No.LG4HK-WE-1001
55898_Maegaki 2008.5.15 10:41 AM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
55898_Maegaki 2008.5.15 10:41 AM ページ 2
LG4HK-WE-1001.book 1 ページ２０１３年１月１１日　金曜日　午後１２時５５分
Engine Mechanical (4HK1) 1B-1
ENGINE
Engine Mechanical
(4HK1)
TABLE OF CONTENTS
4HK1Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-59
Maintenance Precautions . . . . . . . . . . . . . . . . . 1B-3 Valve Stem Seal and Valve Spring . . . . . . . . . . . 1B-60
Service Technology Information . . . . . . . . . . . . 1B-3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-60
Reading the Model . . . . . . . . . . . . . . . . . . . . . . 1B-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-60
Description of Function and Operation . . . . . . . 1B-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-61
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1B-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-62
Failure Symptom List . . . . . . . . . . . . . . . . . . . 1B-12 Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . 1B-65
Symptom: Engine Does not Run. . . . . . . . . . . 1B-13 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-65
Symptom: Engine Cranks but Does not Start . 1B-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-65
Symptom: There is Much Black Exhaust Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-66
Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-66
Symptom: There is Much White Exhaust Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-68
Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-69
Phenomenon: Engine is Experiencing List of Tightening Torques . . . . . . . . . . . . . . . . 1B-71
Knocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Camshaft Position Sensor . . . . . . . . . . . . . . . . . 1B-72
Symptom: Engine Rotation Problem . . . . . . . . 1B-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-72
Symptom: Charging Failure . . . . . . . . . . . . . . 1B-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-72
Primary Specifications. . . . . . . . . . . . . . . . . . . 1B-19 Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 1B-73
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-21 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-73
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1B-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-74
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-74
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-31 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-31 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-78
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-32 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-79
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-32 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-79
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . 1B-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-79
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-33 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-33 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-34 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-91
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-98
Intake Throttle Valve. . . . . . . . . . . . . . . . . . . . . . 1B-36 List of Tightening Torques . . . . . . . . . . . . . . . 1B-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-36 Crankshaft Position Sensor . . . . . . . . . . . . . . . 1B-109
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
Inlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-38 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-110
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-38 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-110
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-41 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-113
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-113
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 List of Tightening Torques . . . . . . . . . . . . . . . 1B-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-118
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-43 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-118
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . 1B-45 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-120
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-45 List of Tightening Torques . . . . . . . . . . . . . . . 1B-121
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-45 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1B-122
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-48 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-122
1B-2 Engine Mechanical (4HK1)

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-123
List of Tightening Torques . . . . . . . . . . . . . . . 1B-128
Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 1B-129
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-129
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-129
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-130
Piston and Connecting Rod . . . . . . . . . . . . . . . 1B-134
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-134
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-135
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-136
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-141
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-143
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-146
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-146
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-146
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-147
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-147
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-148
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-152
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1B-156
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-156
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-156
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-157
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-158
4HK1Engine
Maintenance Precautions Precautions for work particular to this engine
To prevent damaging the engine and to ensure the Including the inside of the injector, the holes and gaps
reliability of engine performance, be careful of the that are the fuel paths for the fuel system have an
following points when performing engine maintenance. extremely precise finish. Therefore, because there is
Note that information relating to working safely can be the possibility of damage if foreign material becomes
found in the Overview. mixed in, cover the cap after removing parts, etc., to
• When lifting or supporting the engine, do not prevent the entry of foreign material.
directly attach the jack to the oil pan.
When lowering the engine to the ground, do not let Service Technology Information
the oil pan directly contact the ground. Use a
frame, etc. to support it with the engine foot or Using the Plastigauge
flywheel housing.
(There is only a small gap between the oil pan and
oil pump strainer, so be careful not to damage the Measurable Range
oil pan and oil pump strainer.) Type mm(in)
• When the air intake system, such as the air duct or 0.025 - 0.076
air cleaner, has been removed, cover the air intake PG-1 (Green)
(0.000984 - 0.002992)
to prevent foreign material from entering the
cylinder. 0.051 - 0.152
PR-1 (Red)
• To perform maintenance on the engine, always (0.002008 - 0.005984)
remove the battery ground terminals. If the battery 0.102 - 0.229
ground terminals are not removed while PB-1 (Blue)
(0.004016 - 0.009016)
performing work, there is the possibility of
damaging the wire harness or electrical
(Example) Measuring the Gap Between the Control
components. Take adequate precautions for
Rod Bearing and Crank Pin
safety, such as short circuits, when inspections
require an energized state. • Clean the connecting rod and bearing, and
assemble that to the connecting rod.
• To protect and lubricate the sliding surfaces when
running for the first time, apply an adequate • Cut the Plastigauge to the width of the crank pin
amount of engine oil to the sliding surfaces. and lay it parallel avoiding the crank pin oil hole.
• When the valve related parts, injector, pistons, • Align the markings on the connecting rod and on
piston rings, control rod, control rod bearing, the cap for assembly to the crank pin. Apply
crankshaft journal bearing, etc. have been molybdenum disulfide to the threaded portion of
removed, organize them in order for storage. the tightening bolts and seat surface. Alternately
tighten them so that the cap is at the specified
• When reinstalling them, use the same part and
torque.
install it in the same position as when it was
removed. NOTE:
• Whenever disassembling the gasket, oil seals and Absolutely never move the connecting rod when the
O-rings, replace them with new ones. Plastigauge is in use.
• Completely wipe off old liquid gasket from the
locations where it is used. After cleaning to
completely remove any oil, moisture and filth,
apply the specified liquid gasket for assembly.
• After applying the liquid gasket, install it within a
specified amount of time. If the specified amount of
time is exceeded, wipe away the liquid gasket and
reapply it.
• When assembling and installing, tighten at the
specified torque.

• Gently remove the cap and connecting rod and NOTE:
use a scale printed on the packaging of the Absolutely never rotate the crankshaft when the
Plastigauge to measure the flattened Plastigauge Plastigauge is in use.
(gap).
• Gently remove the crankcase and use a scale
printed on the packaging of the Plastigauge to
measure the flattened Plastigauge (gap).
HCW30ASH002001
HCW30ASH002201
HCW30ASH002101
(Example) Measuring the Gap Between the Crank

HCW30ASH002301
Bearing and Crank Journal
• Clean the bearing and the bearing installation
surfaces of the cylinder block and crankcase, and
assemble them to the cylinder block and
crankcase.
• Gently place the crankshaft on the cylinder block,
and settle it by turning it approximately 30°.
• Cut the Plastigauge to the width of the crank
journal and lay it parallel avoiding the journal oil
hole.
• Gently place the crankcase on the cylinder block,
and apply molybdenum disulfide to the threaded
portion of the tightening bolts and seat surface.
Tighten in order, at the specified torques.

Reading the Model
1 2
LNW91BLF002301
Legend
1. Engine type casted (4HK1) 2. Engine number stamping (******)

Description of Function and Operation
External appearance of engine
2 3
4 5
LNW91BLF002401
Legend
1. Upper surface 4. Rear surface
2. Front surface 5. Right side
3. Left side
Description of Function and Operation Cylinder liner

Electronic Control Engine Control The cylinder liner is selected and assembled to match
This controls fuel injection amounts, injection timing, the inner diameter of the cylinder block bore and its
the using the engine control module (ECM). grade is marked on the left side surface of the cylinder.
Cylinder block Piston

The cylinder block is cast iron. The pitches between The pistons are autothermatic pistons cast with
bores are equal, and it is a highly rigid structure with aluminum alloy, and the combustion chamber is a
symmetry to the right and left centering on the crank spherical re-entrant system.
shaft. Tighten the bearing cap using the plastic region Cylinder head
rotational angle tightening method, with the ladder The cylinder head is cast iron. It has 4 valves per
frame structure. cylinder. Tighten the head bolts using the plastic region
rotational angle tightening method.

Crankshaft
Apply TUFFTRIDE treatment. Gradations of the journal
diameter are marked on the No.1 balance weight.
Connecting rod cap bolt
Tighten the mounting bolt of the connecting rod cap
using the plastic region rotational angle tightening
method.
Common rail type electronic control injection
system
The common rail type control injection system is
composed of a supply pump that sets and supplies the
target pressure of high-pressure fuel, a common rail
that measures that high-pressure fuel, and an injector
that injects the high-pressure fuel after it has been
micronized. Each control system regulates the injection
timing and amount based on various signals when the
ECM is in all traveling conditions.
Injector
The injector is a multi-hole nozzle, and adjusts the
injection timing and amount using the opening and
closing of a solenoid valve at the top of the injector.
Fuel filter with sedimenter
This is a fuel filter that has a sedimenter to remove
moisture content by using the difference of the relative
density of light diesel oil and water.
EGR device
The ECM applies controls based on information such
as water temperature, engine speed and engine load.
Also, some of the exhaust gas is re-circulated to be
cleaned.
The primary components are the EGR valve, EGR
cooler, exhaust brake valve and various sensors.
Lubricating system
This is a full-flow bypass unitized oil filter. Oil flows
through the oil cooler and around the sliding sections
from the oil gallery for lubrication.
Glow control system
The glow control system makes it easier to start the
engine in low temperatures, and reduces the amount of
white smoke and noise generated immediately after
starting the engine. When the ignition switch is turned
"ON", the ECM detects the temperature of the engine
coolant from a signal sent from the engine coolant
temperature (ECT) sensor. This can change the glow
time to always start the engine under optimum
conditions. Also, an after-glow function stabilizes the
idling immediately after starting the engine. ECM
determines the glow time according to the engine
coolant temperature, and starts the glow relay and glow
plug (preheat) indicator light.

Functional Inspection:
Inspecting and Adjusting Valve Clearance Position to inspect when the 4th cylinder is
1. Inspecting Valve Clearance at the compression top dead center
NOTE:
Work while the engine is cooling.
Valve clearance mm(in)

Inlet valve 0.4(0.016)
Exhaust valve 0.4(0.016)
• When the 1st cylinder is at the compression top

dead center, a circle is marked in the table;
when the 4th cylinder is at the compression top
dead center, an X is marked in the table for
inspection of valve clearance.
LNW21BSH030001
Cylinder No. 1 2 3 4
Valve
IN EX IN EX IN EX IN EX a. Put the engine 1st cylinder at the compression
arrangement
top dead center.
1st cylinder • Rotate the crankshaft in the forward
at direction. Align the crank pulley alignment
compression { { { { mark and the front cover BTDC 0° mark.
top dead
center
4th cylinder
at
compression X X X X
top dead
center
Parts to inspect when the 1st cylinder is at

the compression top dead center
LNW71BSH002801
b. Insert the thickness gauge between the rocker

arm and bridge cap, and measure the
clearance.
c. Put the engine 4th cylinder at the compression
top dead center.
• Rotate the crankshaft in the forward
direction 360°. Align the crank pulley
LNW21BSH029901
alignment mark and the front cover BTDC 0°
mark.

d. Insert the thickness gauge between the rocker
arm and bridge cap, and measure the b. Insert a 0.4 mm (0.016 in) thickness gauge
clearance. between the rocker arm end (valve side) and
e. When the measured value is not standard, cap (assembly on bridge top), and tighten the
adjust the valve clearance. rocker arm adjust screw. When the movement
2. Adjusting Valve Clearance of the thickness gauge becomes stiff, fasten the
adjust screw nut of the rocker arm.
Valve clearance mm(in) Tightening torque: 22 N⋅m(2.2 kg⋅m/16 lb⋅ft)

Inlet valve 0.4(0.016)
Exhaust valve 0.4(0.016)
• When the 1st cylinder is at the compression top

dead center, a circle is marked in the table;
when the 4th cylinder is at the compression top
dead center, an X is marked in the table for
adjustment of valve clearance.
Cylinder No. 1 2 3 4
Valve IN EX IN EX IN EX IN EX
arrangement
1st cylinder
at
compression { { { {
top dead BLW51BSH005601
center
4th cylinder
at c. When lightly tightening the bridge adjust screw
compression X X X X while the thickness gauge is inserted, check
top dead that the leading end of the adjust screw and the
center valve shaft touch and that the movement of the
thickness gauge is stiff.
NOTE:
Adjust so that the bridge is level. (It should touch the 2
valve shaft ends.)
a. Completely loosen each adjust screw of the

bridge and the rocker arm.
LNW21BSH029801
BLW51BSH005501

d. Next, check whether the valve shaft end on the
opposite side is floating, or touching at an
angle. If it is floating or touching at an angle,
slightly loosen the bridge adjust screw and
adjust the valve shaft ends on both sides to
touch properly.
Valve bridge gap: 0.1 mm(0.004 in) or less
e. When both sides of the valve shaft have been
adjusted to touch properly, use a flat-blade
screwdriver to tighten the bridge adjust screw
nut so that it does not rotate.
Tightening torque: 22 N⋅m(2.2 kg⋅m/16 lb⋅ft)
1
LNW21BSH057101
Legend
1. Harness connector
4. Install the battery negative terminal.

5. Engage the starter to discharge foreign material
from inside the cylinders.
6. Install the compression gauge adaptor and the
gauge (special tools).
Special Tool
Compression gauge adaptor:
5-8840-2815-0
BLW51BSH005701
Compression gauge: 5-8840-2675-0
NOTE:
If the bridge adjust screw adjustment is poor, the bridge
will be pushed downward at an angle causing problems
of seizure or breakage of the bridge guide. Perform
accurate adjustment.
Compression pressure inspection

1. Warm-up the engine.
2. Remove the battery negative terminal and remove
all glow plugs.
3. Remove the injector harness connector installed to
the lower head cover. (This will prevent fuel
injection.)
NOTE:
When the harness connector is removed, the ECM
determines a malfunction and records the DTC. Delete LNW71BSH003501
the DTC after completing the measurements.
For details on how to delete the DTC, refer to the
"Engine Control System" in Section 1A, Engine Control 7. Engage the starter to inspect the compression
System (4HK1). pressure.
Compression
pressure MPa (kg⋅cm2/psi) / r/min
2.60 - 2.90
/ 220
(26.5 - 29.5 / 377 - 419)
2.50 - 2.80
Standard values / 185
(25.5 - 28.5 / 363 - 405)
2.40 - 2.70
/ 150
(24.5 - 27.5 / 349 - 391)
Limit 2.16 (22 / 313)
Cylinder
294 kPa (3.0 / 43)
differences
• Sequentially measure each cylinder.
NOTE:
To ensure the engine speed of more than 200 r/min,
use a completely charged battery.
8. Remove the compression gauge.

9. Disconnect the battery negative terminal.
10. Install the injector harness connector installed to
the lower head cover.
11. Install all of the glow plugs.
12. Install the battery negative terminal.
Determining the overhaul period

Increasing engine oil consumption amounts
If the consumption rate (the traveling distance on
consumption of 1 L(0.22 Imp⋅gal) of oil) of a new
vehicle is set as 100%, an overhaul is required when
that rate falls below 50%.
Increasing the fuel consumption rate

The fuel consumption rate (km/L) of a new vehicle is
set as 100%. An overhaul is required when that rate
falls below 60%.
Abnormal noises in engine

If the cause of the abnormal noise is inside the engine,
overhaul the engine immediately for repair.
* A variety of causes of abnormal noises are
conceivable. However, there are many cases of the
parts of the engine being worn, or foreign material
causing chewing of the engine.

Failure Symptom List
• Engine Does not Run
• Engine Cranks but Does not Start.
• There is Much Black Exhaust Smoke.
• There is Much White Exhaust Smoke.
• The Engine is Experiencing Knocking.
• Engine Rotation Problem
• Charging Problem

Symptom: Engine Does not Run
Condition Possible Cause Correction

Starter does not run The anti-theft system is activated Check the key
For details on the immobilizer, refer to
"Immobilizer Control System" in Section
9I, Security and Lock.
Insufficient battery charge Recharge or replace the battery
Defective battery relay Replace
Defective wiring Connect or repair
Defective starter unit Inspect the starter. If defective, replace
it
The starter works, but it does not rotate Wear of the ring gear Repair or replace
the flywheel Improper adjustment of the starter Adjust or repair
magnetic switch
The starter pinion meshes with the ring Insufficient battery charge Recharge or replace the battery
gear, but the engine does not run Insufficient tightening of the wiring Perform a repair
circuit terminal
Defective starter unit Inspect the starter. If defective, replace
it
Seizure inside the engine Disassemble and repair

Symptom: Engine Cranks but Does not Start

No fuel in supply pump Air entering into the fuel system Remove air
Air taken-in from the fuel pipe Remove the air or replace
Fuel out Refill
Clogging of the strainer in the fuel Clean or replace
suction unit
Clogging of the fuel pipe Clean or replace
Malfunction of the supply pump Replace
Extremely cold periods (fuel is not for Replace it with the proper fuel
use in cold climates)
Clogging of the fuel filter Replace
Engine control system problem Diagnose engine control system
For details, refer to "Diagnostic
Information and Procedures" in Section
1A, Engine Control System (4HK1)
Fuel has made it to the supply pump Looseness of the injection pipe Further tightening of each part
connection
Poor air-tightness of the over-flow valve Replace
Malfunction inside the supply pump Replace
Improper wiring connection or open Repair or replace
circuit
Fuel injection amount is insufficient or Air entering into the fuel system Remove air
unstable Clogging of the fuel pipe Clean or replace
Malfunction of the supply pump Replace
Locking of the injector nozzle Replace
Improper wiring connection or open Repair or replace
circuit
Clogging of the fuel filter Replace
Engine control system problem Diagnose engine control system.

Symptom: There is Much Black Exhaust Smoke

Improper fuel injection timing Engine control system problem Diagnose engine control system
Improper fuel injection condition of the Locked nozzle Replace
injector Engine control system problem Diagnose engine control system.
Improper compression pressure Excessive valve clearance Adjust
Sticking of valve stem (valve open Disassemble and repair
condition)
Defective valve spring Replace
Valve seat wear Disassemble and repair
Compression leak caused by defective Disassemble and repair
piston ring, etc.
Defective gasket Disassemble and repair
Piston seizure Disassemble and repair
Improper fuel Fuel contains moisture Replace
Bad quality fuel used Replace
Air intake problem Clogging of the air intake pipe Repair or replace
Clogging of the air cleaner element Clean or replace
Locking of the throttle valve Disassemble and repair
Clean or replace
Error detected by engine control system Abnormalities in each sensor, etc Repair or replace
EGR or intake throttle valve malfunction Locking of the intake throttle valve Repair or replace
Locking of the EGR valve Repair or replace
Locking of the exhaust brake valve Repair or replace

Symptom: There is Much White Exhaust Smoke

Error detected by engine control system Abnormalities in each sensor, etc Replace
ECM error Replace
Improper compression pressure Excessive or insufficient valve Adjust
clearance
Sticking of valve stem (valve open Disassemble and repair
condition)
Defective valve spring Replace
Valve seat wear Disassemble and repair
Compression leak caused by defective Disassemble and repair
piston ring
Defective gasket Disassemble and repair
Piston seizure Disassemble and repair
Improper fuel Moisture in fuel Replace
Large oil consumption amount Piston ring wear or breakage Disassemble and repair
Defective valve stem oil seal Disassemble and repair

Phenomenon: Engine is Experiencing Knocking

Error detected by engine control system Abnormalities in each sensor, etc Replace
ECM error Replace
Fuel Bad quality fuel used Replace
Air intake problem Clogging of the air intake pipe Repair or replace
Engine malfunction Foreign material in cylinders Repair or replace
Seizure of the piston or bearing Repair or replace

Symptom: Engine Rotation Problem

Rotation does not increase. ECM error Replace
Unstable rotation ECM error. Replace
Clogging of the fuel filter element Replace the element
Injector failure Replace
Fuel contains moisture Replace
Air entering into the fuel system Remove air
Locking of the exhaust brake valve Repair or replace
Locking of the intake throttle valve Repair or replace

Symptom: Charging Failure

Will not charge. Open circuit or short circuit, or improper Repair or replace
connection of wiring
Malfunction inside the generator Disassemble and repair
Insufficient charge Wire short circuit, improper connection Connect or repair
Loosening of the generator drive belt Replace
Defective battery Replace
Overcharge Wire short circuit Connect or repair
Primary Specifications
Item Engine model 4HK1-TC

Type Diesel, 4-cycle, water-cooled inline OHC
Combustion chamber model Direct injection
Cylinder liner model Dry type
Number of cylinders - inner diameter mm(in) 4-115(4.53)x125(4.92)
stroke
Total piston displacement L(cu⋅in) 5.193(316.88)
Compression ratio 17.5
2
Compression pressure MPa(kg/cm /psi) / r/min 2.75 (28/398) / 220
Idling speed r/min 575
Valve clearance Intake 0.4(0.0157)(while cool)
mm(in) Exhaust 0.4(0.0157)(while cool)
Ignition method Compression ignition
Injection order 1-3-4-2
Injection period (top dead center) 0°
Lubrication device
Lubricating method Force feed method
Oil pump type Gear type
Lubricant capacity 2WD model; 11.0(2.42),
L(lmp⋅gal)
[reference values] 4WD model; 12.5(2.75)
Oil filter type Full-flow filter (cartridge type)
Oil cooler type Built-in type, water cooled
Item Engine model 4HK1-TC

Cooling device
Cooling method Water cooled
Radiator type Corrugated type (force feed type)
Water pump type Centrifugal type, belt type
Thermostat type Wax type (2 pcs.)
Thermostat open valve temperature °C(°F) 82(180), 85(185)
Coolant capacity [reference values] L(lmp⋅gal) 18.0(3.96) (Including radiator)
Fuel device
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Injection nozzle type Multi-hole nozzle
Charging device
Generator type Alternating current type
Output V-A 24 - 50, 24 - 80
Regulator type IC
Starter device
Starter type Reduction type
Output V-kW 24 - 4.0, 24 - 4.5
Preheat device model Glow plugs
Glow plug rated voltage and current V-A 23 - 3.5

Special Tool
Illustration Tool Number/ Description Illustration Tool Number/ Description
5-8840-2815-0
5-8840-0019-0
Compression gauge
Sliding hammer
adaptor
5884028150
5-8840-2675-0 5-8840-2628-0
Compression gauge Valve guide replacer
5884026750
5-8840-2230-0 5-8840-2930-0
Crankshaft stopper Valve guide installer
5884022300 5884029300
5-8840-2621-0 5-8840-2222-0
Valve spring replacer Sealing cup installer
5884026210 5884022220
5-8840-2808-0 5-8840-0266-0
Pivot Angle gauge
5884028080
5-8840-2625-0 5-8840-2826-0
Valve stem seal installer Injector remover
5884028260
Illustration Tool Number/ Description Illustration Tool Number/ Description
5-8840-2623-0 5-8840-2360-0
Nozzle sleeve remover Slinger puller
5-8840-2627-0 5-8840-2703-0
Oil seal installer Oil seal installer kit
5884026270 5884027030
5-8840-2626-0 8-9439-6818-0
Bridge guide setting tool Crankshaft gear puller
5884026260 8943968180
5-8840-2624-0 8-9439-6819-0
Nozzle sleeve setting tool Crankshaft gear installer
5884026240
5-8840-2340-0 5-8840-2844-0
Connecting rod bushing Fuel Pressure / Vacuum
replacer Gauge Set
5884023400 5884028440
5-8840-9018-0 5-8840-0279-0
Piston setting tool Vacuum Pump
5884090180
Illustration Tool Number/ Description
1-8522-1097-0
Oil filter wrench
1852210970
5-8840-2845-0
Fuel test adaptor set
5884028450
Engine Assembly
Removal
CAUTION:
• Always apply chock blocks to the vehicle wheels.
• Select an engine hoist that is able to withstand the
weight of the engine.
• Never get under the engine while it is hoisted.
• Never put your hands where they can get easily
caught.
1. Disconnect the battery cable negative terminal (1).
LNWA1GSH000101
6. Remove the transmission.

Refer to "Smoother Transmission Assembly" in
Section 5B, Automatic Transmission for details on
the Smoother vehicle.
Refer to "Transmission Assembly" in Section 5C,
Manual Transmission for details on M/T vehicles.
LNW71BSH008101
2. Drain the engine coolant.

3. Disconnect the starter ground cable.
• Disconnect the front frame harness connector
near the transmission control box and remove
each of the clips fastening the harness.
• Remove the 2 bolts (upper and lower) installing
the starter, and remove the starter from the
clutch housing.
• Fasten with a wire, etc. to a position where it
will not interfere with the removal of the
transmission.
4. Remove the starter motor. HCW31BSH055801
5. Remove the front exhaust pipe A and exhaust

brake assembly.
• Remove the front exhaust pipe A and 7. Remove the air duct from the turbocharger.
turbocharger installation nut. • Remove the PCV hose (2) from the air duct.
• Remove the front exhaust pipe A and exhaust • Loosen the air duct tightening clamp (5) at the
brake assembly installation nut. turbocharger inlet.
At this time, the exhaust brake assembly is 8. Remove the air intake hose(4).
removed together.
• Loosen the air intake hose tightening hose
• Remove the transmission right side exhaust clamp(3).
pipe bracket mounting bolts.

9. Remove the connector (6) from the turbocharger • Remove the 2 main harness connectors from
actuator. the ECM.
• Remove the engine ground cable.
12. Remove the radiator upper hose.
• Remove the upper hose at the engine side.
4
3
13. Remove the coolant reserve tank hose.
• Remove the coolant reserve tank hose at the
2 radiator side.
5
6
LNW81JSH000801
Legend
1. Bolt
2. PCV hose
3. Clamp
4. Air intake hose
5. Clamp
LNW21BSH027601
6. Connector
10. Remove the air intake hose. 14. Remove the heater hose.
• Loose the air intake hose tightening clamp. • Remove the 2 heater hoses at the engine side.
• Remove the boost sensor connector.
LNW21BSH027501
LNW81BSH002901
Legend 15. Remove the fuel return hose.

1. Air intake hose 16. Remove the fuel feed hose.
2. Boost sensor
• Remove from the supply pump side and put a
plug so that fuel is not spilled, and tie closed
11. Remove the engine harness. pointing upward.
• Remove the ECM.

17. Remove the radiator lower hose (1) at the engine • Remove the compressor from the A/C
side. compressor bracket. Fasten to a suitable
position with wire along with the hoses.
22. Vacuum hose
• Remove the hose at the vacuum pump side.
23. AC generator harness
• Remove the B terminal cable and harness
connector from the generator.
24. Engine mount
• Before removing the engine mount, use the
hoist to suspend the engine.
• Remove the mounting bolts on the chassis
frame side of the engine mount.
25. Dismount the engine assembly.
1 • Slowly operate the hoist to raise the engine to
the top surface of the chassis frame.
LNW91BSH006801
18. Remove the fan guide and place it on the fan

assembly.
19. Remove the radiator.
• Remove the mounting nuts on the left and right
sides of the radiator to remove the radiator.
• Remove the fan guide placed on the fan
assembly.
LNW71BSH005501
• Turn the engine 90° and move it from the

chassis frame top surface to remove the engine
assembly.
LNWA1BSH000301
20. Remove the power steering pump.

• Remove the power steering pump from the
engine side together with the bracket. Fasten to
a suitable position with wire along with the
hoses.
21. A/C compressor
• Remove the A/C compressor drive belt.
LNW71BSH005601

Installation • Install the harness connector (1 pole) and B
terminal cable to the generator.
1. Install the engine assembly.
4. Install the vacuum hose.
• Install the hoist wire to the engine hanger and
hoist to lift the engine. • Install to the vacuum pump side of the vacuum
hose.
• Operate the hoist to move the engine to the
installation position. 5. Install the A/C compressor.
• Install the A/C compressor as shown in the
diagram, and tighten at the specified torque.
Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
LNW71BSH005601
• Turn the engine over 90° and slowly lower the

engine to the installation position. LNW71ESH001501
• At this time, operate the hoist so that the

transmission side is low, while pulling to the • Install the drive belt and adjust its tension using
rear of the engine. the adjustment bolt of the tension pulley.
• For details on adjusting belt tension, refer to
"Drive Belt" in Section 1C, Engine Cooling
(4HK1).
6. Install the power steering pump

• Install the power steering pump and tighten it at
its specified torque.
Tightening torque
Flywheel mounting
43 N⋅m(4.4 kg⋅m/32 lb⋅ft)
bolt (1)
Cylinder block
44 N⋅m(4.5 kg⋅m/33 lb⋅ft)
installation bolt (2)
LNW71BSH005501
2. Install the engine mount.

• Align the engine mount to the hole in the engine
mounting cross member, and tighten at the
specified torque.
3. Install the AC generator harness.

Without HBB • When removing the frame side bracket, tighten
at the specified torque.
Frame from frame side bracket

Tightening torque 22.8 N⋅m (2.3 kg⋅m/17 lb⋅ft)
LNW41BSH001501
Legend
1. Flywheel housing section bolt
2. Cylinder block section bolt
With HBB LNWA1BSH000301
8. Install the fan guide.

9. Install the radiator lower hose (1).
Radiator hose clip

Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
2
LNW46ASH000801
Legend
2. Cylinder block section bolt
7. Install the radiator. 1

• Be careful not to scratch the radiator fins
withthe fan blades.
• Install the radiator bracket to the frame side LNW91BSH006801
bracket and tighten at the specified torque.
Frame side bracket from radiator bracket 10. Install the coolant reserve tank hose.
Tightening torque 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)


11. Install the radiator upper hose. • Use a new clamp.
Clamp (2)
Radiator hose clip Tightening torque: 8.4 N⋅m (0.86 kg⋅m/74 lb⋅in)
Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in) Clamp (5)
Tightening torque: 6.4 N⋅m (0.65 kg⋅m/57 lb⋅in) ABA
Stainless clamp
Tightening torque: 8.0 N⋅m (0.8 kg⋅m/71 lb⋅in)
NORMA W1 Steel clamp
LNW21BSH027601 3
5 4
12. Install the fuel feed hose. LNWB1BSH014801
13. Install the fuel return hose. Legend

14. Install the heater hose. 1. Air intake hose
2. Clamp
• Install the hose so that the mark is facing
3. Boost sensor
upward.
4. Air intake duct
5. Clamp
• Install the connector of the boost sensor.
16. Install the intake hose (4) to the turbocharger, and

tighten the hose clamp (3) at the specified torque.
NOTE:
• Firmly insert the hose without any twisting or
misalignment, and tighten the clamp to the specified
torque.
• Use a new clamp.
17. Install the air duct to the turbocharger.
LNW21BSH027501
NOTE:
15. Install the air intake hose. torque.
NOTE:
• Firmly insert the hose without any twisting or • Tighten the turbocharge inlet air duct tightening
misalignment, and tighten the clamp to the specified clamp (5) at its specified torque.
torque.
Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)

• Install the PCV hose (2) to the air duct.
18. Install the connector (6) to the turbocharger
actuator.
4
3
LNW21BSH011601
5
6
22. Install the front exhaust pipe A and exhaust brake

assembly, and tighten at the specified torque.
LNW81JSH000801
Legend
Tightening torque
1. Bolt
2. PCV hose Turbocharger side nut 67 N⋅m(6.8 kg⋅m/49 lb⋅ft )
3. Clamp Exhaust pipe bracket
4. Air intake hose 41 N⋅m(4.1 kg⋅m/30 lb⋅ft)
bolt
5. Clamp
Exhaust brake side nut 27 N⋅m(2.8 kg⋅m/ 21 lb⋅ft)
6. Connector
19. Install the engine harness.

• Install the engine ground cable.
• Install the 2 main harness connectors to the
ECM.
• Install the ECM.
20. Install the transmission assembly.
21. Install the starter motor.
• Install the starter to the clutch housing with a
bolt, and tighten at the specified torque. LNWA1GSH000101
23. Connect the front frame harness connector.

24. Refill the engine coolant.
25. Connect the battery cable negative terminal.
Engine Mount
Components
LNW71BMF004601
Legend
1. Engine mount 2. Heat protector
Removal • Slightly raise the engine assembly to remove

the engine mount.
1. Remove the fan guide from the radiator and place
it on the fan side.
2. Remove the engine mount.
• Before removing the engine mount, use the
hoist to suspend the engine.
• Remove the nuts mounting the engine foot and
engine mount.
• Remove the mounting bolts on the chassis
frame side of the engine mount.
LNW71BSH005501

Installation 2. Install the fan guide.
1. Install engine mount, and tighten at the specified • Start the engine to verify whether there are no
torque. abnormalities in the engine mount.
Tightening torque
Engine foot side bolt 106 N⋅m(10.8kg⋅m/78 lb⋅ft)
Engine foot side bolt 51 N⋅m(5.2 kg⋅m/38 lb⋅ft)
Chassis frame side nut 48 N⋅m(4.9 kg⋅m/35 lb⋅ft)
List of Tightening Torques
c
b
LNW71BMF004701
(a) 106 N⋅m (10.8 kg⋅m / 78 lb⋅ft)

(b) 51 N⋅m (5.2 kg⋅m / 38 lb⋅ft)
(c) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
Cylinder Head Cover

Components
2 3
LNW81BMF001601
Legend
1. Cylinder head cover 4. Lower cover
2. Gasket 5. Gasket
3. Noise cover (with noise cover type) 6. Camshaft end gasket
Removal 3. Remove the cylinder head cover (2) and gasket.

1. Remove the EGR cooler.
Refer to "EGR valve and EGR Cooler" in Section
1F, Emission Control (4HK1). 1
2. Remove the noise cover (1).
LNW41BSH001001

4. Disconnect the injector harness connector (2). 4. Connect the injector harness connector (2).
5. Remove the lower cover (1) and gasket.
NOTE:
Push in until the locking claw is completely raised.
1
LNW21BSH057001
2
LNW21BSH057001
6. Remove the camshaft end gasket.
• Clean the liquid gasket remaining on the
5. Install the gasket to the cylinder head cover.
cylinder head.
6. Install the cylinder head cover, and tighten in the
order shown in the diagram.
Installation
1. Install the camshaft end gasket (1).
• Apply liquid gasket (TB1207B) to the area
indicated in the diagram (2) with a width of 3 to
4 mm (0.118 to 0.157 in), and install it to the
cylinder head.
5 1 3 7
9
1
2 1
6 2 4 8
2
2
2
LNW21BSH030101
7. Install the noise cover (1).
LNW81BSH005101 Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
2. Install the gasket to the lower cover (1).

3. Install the lower cover (1).

8. Install the EGR cooler.
Refer to "EGR valve and EGR Cooler" in Section
1 1F, Emission Control (4HK1).
LNW41BSH001001
a c
LNW81BMF001701
(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
Intake Throttle Valve

Removal NOTE:
The installation rubber comes off easily, so be careful
1. Remove the air duct hose.
not to lose it.
2. Disconnect the injection pipe clip.
3. Disconnect the intake throttle valve harness
connector.
4. Remove the fuel filter assembly.
• Remove the nut(1)
4
LNW91BSH008601
• Move the fuel filter assembly a little. 3

2
1
5. Remove the fuel pipe bracket.
LNW91BMH000301
Legend
1. Installation rubber
2. Intake throttle valve
3. Gasket
4. Inlet cover outer
Installation
1. Install the intake throttle valve.
• Securely install the installation rubber.
• Install the gasket and intake throttle valve , and
tighten at the specified torque.
Tightening torque: 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
1 2
LNW91BSH008701 2. Connect the intake throttle valve harness
connector.
Legend
1. Clip 3. Install the fuel pipe bracket.
2. Fuel pipe bracket Tightening torque: 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
4. Install the fuel filter assembly.
• Install the nut.
6. Remove the intake throttle valve.

5. Connect the injection pipe clip.
6. Install the air duct hose.
• Install the clip band, and tighten at the specified
torque. Use a new clip.
Clip
Inlet Cover
Components
2
3
4
5
6
LNW91BLF002801
Legend
1. Inlet cover 4. Throttle gasket
2. Inlet gasket 5. Throttle valve Assembly
3. Inlet cover outer 6. Installation rubber
Removal
1. Remove the common rail.
Refer to "Common Rail" in Section 1D, Engine
Fuel (4HK1).
2. Disconnect the harness connector.
3. Remove the throttle valve Assembly.
NOTE:
The installation rubber comes off easily, so be careful
not to lose it.

4. Remove the inlet cover outer. NOTE:
• Be careful not to forget tightening the bolt indicated
by the arrow.
• Tighten the stud along with the common rail.
1
3
2
1
LNW91BSH007801
Legend
2. Gasket
3. Inlet cover LNW91BSH008001
Legend
5. Remove the inlet cover. 1. Liquid gasket
• There is 1 bolt on the throttle valve Assembly
installation section (arrow) in the inlet cover. Be
careful not to forget to remove it.
• Carefully remove the fluid gasket. • Tighten in the order of the numbers in the
diagram.
6
2 1 7
3 5 4
LNW91BSH007901
Installation LNW91BSH008201
1. Install the inlet cover.

• Align to the inlet cover groove, and apply liquid
2. Install the inlet cover outer.
gasket (TB-1207C) to 2.5 - 5.5 mm(0.098 -
0.217 in) width.
• After applying the liquid gasket, install it within 5
minutes.

• Install the gasket and inlet cover outer, and 5. Install the common rail.
tighten at the specified torque. Refer to "Common Rail" in Section 1D, Engine
Fuel (4HK1).
3
2
1
LNW91BSH007801
Legend
2. Gasket
3. Inlet cover
• Tighten in the order of the numbers in the

diagram.
3 7 1
2
5 4 6
LNW91BSH008301
3. Install the throttle valve Assembly.

• Securely install the installation rubber.
• Install the gasket and throttle valve Assembly,
and tighten at the specified torque.
4. Connect the harness connector.

b
g
e b
a
d
LNW91BLF002901
(a) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(e) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(f) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Exhaust Manifold
Components
1
2
3
4
5
LNW91BMF002401
Legend
1. Turbocharger Assembly 4. A/C compressor
2. EGR cooler duct 5. Gasket
3. EGR cooler duct heat protector 6. Exhaust manifold
Removal
1. Remove the turbocharger assembly.
Refer to "Turbocharger Assembly" in Section 1J,
Induction (4HK1).
2. Remove the A/C compressor harness connector.
3. Remove the A/C compressor.

• Remove the compressor from the bracket • Inspect the flatness of the installation surface of
without disconnecting the A/C compressor the manifold and cylinder head.
hose.
mm
Flatness of the manifold installation
(in)
Standard values 0.3 (0.012) or less
Repair limit 0.5 (0.020)
NOTE:
Replace if the flatness is beyond the repair limit.
LNW71ESH001501
4. Remove the A/C compressor bracket.

Refer to "EGR valve and EGR cooler" in Section
1F, Emission Control (4HK1).
6. Remove the exhaust manifold.
• Remove 2 nuts and 6 bolts to remove the
exhaust manifold. LNW71BSH009001
• Visually check the exhaust manifold for cracks.

2. For turbocharger assembly inspection, refer to
1
"Turbocharger Assembly" in Section 1J, Induction
2
(4HK1).
Installation
3 1. Sandwich the gasket and install the exhaust
manifold.
• Install the 2 nuts and 6 bolts, and tighten in the
4 order shown in the diagram.
NOTE:
Since it will expand or contract due to the heat of the
LNW91BSH008501
manifold, do not over-tighten.
Legend
1. Cylinder head Tightening torque N⋅m(kg⋅m/lb⋅ft)
2. Gasket
Bolts (1), (2), (3), (4), (5), (6) 34 (3.5 / 25)
3. Exhaust manifold
4. Distance tube(spacer) nuts (7), (8) 34 (3.5 / 25)
Inspection
1. Inspecting the exhaust manifold
5 3 4 6
1 2
7 8
LNW71BSH008901 LNW71ESH001501
2. Install the EGR cooler. 5. Install the A/C compressor harness connector.
Refer to "EGR valve and EGR cooler" in Section 6. Install the turbocharger assembly.
1F, Emission Control (4HK1). Refer to "Turbocharger Assembly" in Section 1J,
3. Install the A/C compressor bracket. Induction (4HK1).
• Install the A/C compressor bracket to the 7. Install the exhaust adaptor.
cylinder head, and tighten at the specified Refer to "Turbocharger Assembly" in Section 1J,
torque. Induction (4HK1).
LNW21BSH001801
4. Install the A/C compressor to the bracket, and

tighten at the specified torque.
Timing Gear Train

Components
2
1
4
14 13
15
5
12
6
11
16
10
17
19 8
9
20
7
21
18
22
LNWA1BLF001201
Legend
1. Power steering oil pump 12. Plug
2. Idle gear B shaft 13. Flywheel housing
3. Idle gear A 14. Slinger
4. Idle gear B 15. Stiffener (RH)
5. Power steering oil pump idle gear 16. Stiffener (LH)
6. Power steering oil pump idle gear cover 17. Crankshaft position sensor
7. Clutch pressure plate (M/T vehicle) 18. Crank end spacer (Smoother vehicle)
8. Clutch disk (M/T vehicle) 19. Supply pump
9. Flexible plate (Smoother vehicle) 20. Supply pump bracket
10. Flywheel (M/T vehicle) 21. Vacuum pump
11. Rear oil seal 22. Oil pan
Removal 2. Remove the rocker arm shaft assembly.

Refer to "Rocker Arm Shaft Assembly" in this
1. Remove the cylinder head cover.
Section.
Refer to "Cylinder Head Cover" in this Section.

3. Remove the camshaft assembly.
Refer to "Camshaft Assembly" in this Section.
4. Remove the cylinder head assembly.
Refer to "Cylinder Head" in this Section.
5. Remove the clutch pressure plate and clutch disk. 4
1
6. Remove the supply pump (1) and coupling (3). 3
• Remove the supply pump (including the 2
bracket) tightening bolt, and remove it from the
vacuum pump (4).
• Remove the coupling (3) and O-ring. 5
6
MFW41BSH033101
Legend
1. Supply pump
2. Key
4 3. O-ring
3 4. Supply pump bracket
2 5. Nut
6. Coupling
1 7. Flange bolt
LNW71BSH002301 8. Remove the vacuum pump (1).

Legend • Remove the bolt and the nut to remove the
1. Supply pump (including bracket) vacuum pump (1).
2. O-ring 9. Remove the gear (4) from the vacuum pump (1).
3. Coupling
4. Vacuum pump
1
2
7. Remove the supply pump bracket (4).
3
• Tighten the 2 bolts in the coupling (6) screw
holes for turning prevention, and remove the 4
nut. 5
• Remove the 2 tightened bolts in the coupling
(6) screw holes via the gear puller to remove
the coupling (6).
LNWA1CSH000401
Legend
1. Vacuum pump
2. Key
3. O-ring
4. Gear
5. Nut

10. Remove the flywheel (the flexible plate for 13. Remove the power steering oil pump idle gear
Smoother vehicles). cover.
• Install the crankshaft stopper to the flywheel 14. Remove the power steering oil pump idle gear.
housing starter, and make sure the crankshaft
does not rotate.
NOTE:
Check that the stopper securely meshes into the ring
gear and that it is installed.
Special Tool
Crankshaft stopper: 5-8840-2230-0
LNW81BSH003601
15. Remove the stiffener (LH/RH).
1 4 5 2
LNW21BSH007701
• Slowly loosen the bolts in the order shown in

the diagram to remove the crankshaft stopper.
Then remove the flywheel (the flexible plate for
Smoother vehicles).
3 3
LNW91BSH006601
1 4
Legend
6 7 1. Stiffener (RH)
2. Stiffener (LH)
3 2 3. Flywheel housing mounting bolt
4. Cylinder block installation bolt A
8 5 5. Cylinder block installation bolt B
LNW71BSH008801
11. Remove the rear oil seal and slinger.

Refer to "Crankshaft Rear Oil Seal" in this Section.
12. Remove the power steering oil pump.

16. Remove the rubber spacer. 21. Remove the idle gear B shaft.
3
1 2 3
LNW91BSH006701 LNW81BSH004901
Legend
1. Rubber spacer
2. Stiffener (RH Inspection
3. Flywheel housing mounting bolt 1. Measurement of idle gear backlash.
4. Stiffener (LH) • Touch the dial indicator to the idle gear tooth to
be measured, and gently move the gear left
and right to read the inconsistency on the dial
indicator. (Always fasten the other gear)
17. Remove the oil pan.
• Replace the idle gear if the measured value
18. Remove the flywheel housing.
exceeds the limit.
• Do not forget to remove the bolt indicated by
the arrow in the diagram.
Timing gear backlash mm(in)
Standard
0.100 - 0.170 (0.00394 - 0.00669)
values
Limit 0.300 (0.0118)
• Measure idle gear backlash before removing

the idle gear A.
LNW21BSH053601
19. Remove the idle gear A.

20. Remove the idle gear B.
LNW21BSH003301

2. Measurement of play of the idle gear in the axis
direction.
• Insert a thickness gauge into the gap between
the idle gear and thrust collar to measure the
gap.
• Replace the idle gear or thrust collar if the
measured value exceeds the limit.
Play of the idle gear in the axis direction mm(in)

Standard
0.080 - 0.155( 0.00315 - 0.00610)
values
Limit 0.200 (0.00787)
• Measure idle gear play in the axis direction

before removing idle gear B.
LNW21BSH003501
4. Clearance between the idle gear and the idle gear

shaft.
• Measure the inner diameter of the idle gear
bush to calculate the gap between the idle gear
and the idle gear shaft.
• Replace the idle gear or shaft if the measured
value exceeds the limit.
Gap between the idle gear and shaft mm(in)

Standard
0.020 (0.0008) - 0.062(0.0024)
values
Limit 0.200 (0.0079)
LNW21BSH003401
3. Outer diameter of the idle gear shaft.

• Use a micrometer to measure the outer
diameter of each idle gear shaft.
• Replace the shaft if the measured value
exceeds the limit.
Outer diameter of the idle gear shaft mm(in)

Standard
29.959 - 29.980 (1.1795 - 1.1803)
values
Limit 29.800 (1.1732)
LNW21BSH003601
Installation
1. Install the idle gear B shaft.

• Tighten the idle gear B shaft at the specified • Rotate the crankshaft in the forward direction to
torque. align the 1st cylinder piston to the top dead
Apply Loctite #962T to thread part. (three bolt) center.
Tightening torque: 31 N⋅m (3.2 kg m/23 lb⋅ft) • Align the crankshaft gear (6) and idle gear A (9)
alignment marks and install to the cylinder
• After installing, apply engine oil to the shaft. block.
• Apply engine oil to the threaded portion and
seat surface of the bolt, and to both sides of the
washer.
Before assembling, be sure to confirm that the
threaded portion and seat surface of the bolt
and both sides of the washer are completely
covered in engine oil.
• Tighten the mounting bolt at the specified
torque.
LNW81BSH004601
2. Install the idle gear B (1).

• Install the idle gear B to the direction shown in
the drawing, and tighten the mounting bolt (3)
LNW81BSH005301
LNW21BSH003801
Legend
1. Idle gear B
2. Thrust collar
3. Bolt
3. Install the idle gear A.

1 2
9 3
0
L 0
5
7 6
LNW21BMF000101
Legend
1. Idle gear C 6. Crankshaft gear
2. Camshaft gear 7. Oil pump drive gear
3. Idle gear B 8. Supply pump gear
4. Power steering oil pump gear 9. Idle gear A
5. Power steering oil pump idle gear
• As shown in the diagram, uniformly apply liquid

4. Install the flywheel housing. gasket (TB1207B) to the inside of the bolt hole
(excluding the bolt hole at the arrow).
• Especially, clean the excessive liquid gasket
that comes out when the crankcase is installed.
LNWA1BSH000401
Bolt : (2) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)

• Position the cylinder block knock pin to install Bolt : (3) 38 N⋅m (3.9 kg⋅m/38 lb⋅ft)
the flywheel housing.
• Tighten the one marked "(3)" from the cylinder
block side.
Flywheel housing tightening torque
Bolt : (1) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
1
1
LNW91BMF001901
• After applying the liquid gasket, install the oil

5. Install the oil pan. pan within 5 minutes.
• Apply a bead of liquid gasket (TB1207B) to 3
mm(0.118 in) in the joints of the cylinder block,
front cover and flywheel housing.
LNW21BSH004601

• Assemble the gasket (3) using the flywheel
housing, front cover and crankcase stud as a
guide, and place the oil pan (2).
Next, place the rubber assembly (1) on the oil
pan, and tighten with the nuts and bolts. 1 2
2
4
3
1
LNW21BSH013801
6. Install the rubber spacer between flywheel hausing

and stiffener.
3 2
LNW21BMH000101 4
Legend
1. Rubber assembly
2. Oil pan
3. Gasket
3
1 2 3
LNW91BSH006701
• After tightening the oil pan at (1), (2, (3), and
(4), tighten the others. (No particular order is Legend
required.) 1. Rubber spacer
2. Stiffener (RH
Tightening torque: 11 N⋅m (1.1 kg⋅m/95 lb⋅in) 3. Flywheel housing mounting bolt
4. Stiffener (LH)
7. Install the stiffener (LH/RH).
Tightening torque
Bolt (3) 76 N⋅m(7.7 kg⋅m/56 lb⋅ft)
Bolt A (4) 48 N⋅m(4.9 kg⋅m/35 lb⋅ft)
Bolt B (5) 76 N⋅m(7.7 kg⋅m/56 lb⋅ft)
1 4 5 2
3 3
Legend
1. Stiffener (RH) 9. Install the power steering oil pump idle gear cover
2. Stiffener (LH) to the flywheel housing.
3. Flywheel housing mounting bolt
• Install the O-ring to the cover, and tighten the
4. Cylinder block installation bolt A
bolts at the specified torque.
5. Cylinder block installation bolt B
8. Install the power steering oil pump idle gear.

• Apply engine oil to the gear assembly sections
of the idle gear shaft.
• Assemble the idle gear and shaft, install as
shown in the drawing, and tighten at the
specified torque.
LNW81BSH003701
10. Install the rear slinger and oil seal.

11. Install the flywheel.
• Align to the crankshaft knock pin, install the
flywheel, and tighten at the specified torque in
the order shown in the diagram.
LNW21BSH053701
Tightening torque
1st time 78 N⋅m(8.0 kg⋅m/58 lb⋅ft)
2nd time 120 – 150°

With HBB
1 4
6 7
3 2
8 5
LNW71BSH008801 2
LNW46ASH000801
Legend
12. Install the Power steering oil pump.
• Install the power steering oil pump and tighten it 2. Cylinder block section bolt
at its specified torque.
13. Install the gear (4) to the vacuum pump (1).

Tightening torque
• Install the key (2) to the shaft of the vacuum
Flywheel mounting pump (1).
43 N⋅m(4.4 kg⋅m/32 lb⋅ft)
bolt (1)
• Insert the gear (4) into the shaft and tighten the
Cylinder block nut (5) at the specified torque.
44 N⋅m(4.5 kg⋅m/35 lb⋅ft)
installation bolt (2)
Without HBB
1
2
3
4
5
LNWA1CSH000401
LNW41BSH001501
Legend
Legend 1. Vacuum pump
1. Flywheel housing mounting bolt 2. Key
2. Cylinder block installation bolt 3. O-ring
4. Gear
5. Nut

14. Rotate the crankshaft in the forward direction to
align the 1st cylinder piston to the compression top
dead center (BTDC 0°).
1
23
6 5
LNW71BSH002701
Legend
1. Casting burr
LNW71BSH002801
2. Slit
3. Slit location before insertion
15. Remove the plug (viewing hole). 4. Slit location after insertion
5. Viewing hole
16. Install the vacuum pump to the cylinder block.
6. Vacuum pump
• Install the O-ring to the vacuum pump.
• Align the vacuum pump side casting burr (1)
and gear slit (2).
• Use the cylinder block stud bolt as a guide to • After assembling the vacuum pump (2), the
assemble to the vacuum pump. assembly is correct if a line joining the center of
the claw (4), as shown in the drawing, is angled
• Look through the viewing hole (5) in the approximately 15° to the level surface of the
flywheel housing to check that the gear slit (4) engine, when looking from the engine front
is near the center of the hole. side.
CAUTION:
If the slit is mis-positioned, redo this. 1
LNW71BSH002501
Legend
1. Cylinder block
2. Vacuum pump
3. Approximately 15°
4. Claw

• Fit in the coupling (3) with the damper to the
• Tighten the vacuum pump at the specified vacuum pump (4).
torque.
CAUTION:
Check that the coupling (3) rubber dampers are
Tightening torque assembled facing alternately.
M10 : nut 40 N⋅m(4.1 kg⋅m/30 lb⋅ft) • Place the O-ring (2) on the fuel supply pump
M10 : bolt 48 N⋅m(4.9 kg⋅m/35 lb⋅ft ) (1), align the supply pump (1) with the coupling
and groove of the vacuum pump (4) and install
M12 : bolt 76 N⋅m(7.7 kg⋅m/56 lb⋅ft)
them to the vacuum pump (4).
CAUTION: NOTE:
Tighten in diagonal order. • Confirm there is no gap between the supply pump
(1) and the vacuum pump (4) before tightening the
17. Assemble the units of the supply pump (1) and
mounting bolts.
supply pump bracket (4).
• It is not necessary to align the alignment marks,
• Insert an O-ring (3) into the supply pump (1)
etc., to insert the fuel supply pump and the coupling.
and assemble to the supply pump bracket (4).
• Tighten the bolts (7) in diagonal order. • Tighten the bolts in diagonal order at the
specified torque.
• Insert the key (2) into the supply pump shaft
and install the coupling (6).
• Tighten the 2 bolts in the coupling (6) screw
holes to fasten and tighten the nut (5) at the
specified torque.
4 4
1 3
3
2 2
5
6 LNW71BSH002301
Legend
1. Supply pump
7
2. O-ring
3. Coupling
4. Vacuum pump
MFW41BSH033101
Legend
1. Supply pump 19. Install the plug (1) to the viewing hole, and tighten
2. Key it at the specified torque.
3. O-ring Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
4. Supply pump bracket
5. Nut
6. Coupling
7. Flange bolt
18. Install the supply pump (1) to the vacuum pump

(4).

• Thinly apply engine oil to the O-ring (2) for
assembly.
1
2
LNW71BSH002601
Legend
1. Plug
2. O-ring
20. Remove the clutch disk and clutch pressure plate.

21. Install the cylinder head assembly.
22. Install the camshaft assembly.
23. Install the rocker arm shaft assembly.
Section.
24. Install the cylinder head cover.

a
b
d
c
e
f
g
j
h
r
k
t i
s q
m
p n
u
v
o
LNWA1BLF001301
(s) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(a) 43 N⋅m (4.4 kg⋅m / 32 lb⋅ft) (t) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) (u) 51 N⋅m (5.2 kg⋅m / 38 lb⋅ft)
(c) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) M10: 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(v)
(d) 31 N⋅m (3.2 kg⋅m / 23 lb⋅ft) M12: 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(e) 110 N⋅m (11.2 kg⋅m / 81 lb⋅ft) (w) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
(f) 157 N⋅m (16.0 kg⋅m / 116 lb⋅ft)
(g) 134 N⋅m (13.7 kg⋅m / 99 lb⋅ft)
(h) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(i) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(j) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(k) 76 N⋅m (7.7 kg⋅m / 56 lb⋅lb)
(l) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(m) 96 N⋅m (9.8 kg⋅m / 71 lb⋅ft)
(n) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) → 120° – 150°
(o) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) → 120° – 150°
(p) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(q) 76 N⋅m (7.7 kg⋅m / 56 lb⋅lb)
(r) 76 N⋅m (7.7 kg⋅m / 56 lb⋅lb)
Valve Stem Seal and Valve Spring

Components
8
7
LNW21BLF003501
Legend
1. Camshaft bearing cap 6. Valve spring
2. Camshaft bearing 7. Spring upper seat
3. Camshaft assembly 8. Split collar
4. Rocker arm shaft assembly 9. Bridge
5. Valve stem oil seal
Removal CAUTION:
Be very careful not to drop the bridge cap into the
1. Remove the cylinder head.
cylinder head rear-side gearcase or front side oil return
hole.
2. Remove the bridge cap (1).
3. Remove the bridge (2). NOTE:
Store the removed bridge and bridge cap so that they
can be returned to their original positions.

NOTE:
Do not reuse the removed oil seal.
MFW61BSH000401
Legend
1. Bridge cap
LNW21BSH056801
2. Bridge
Inspection
4. Remove the split collar.
• Compress the valve spring and remove the split Inspect the valve springs
collar using a replacer. NOTE:
Visually inspect the valve spring for damage or excess
Special Tool wear. Replace if necessary.
Valve spring replacer: 5-8840-2621-0
Pivot: 5-8840-2808-0 1. Free length
• Measure the spring free length. If it is lower
than the specified limit, replace the spring.
Free length of valve spring mm(in)

Inlet Exhaust
Standard values 59.9(2.3583) 70.3(2.7677)
Limit 56.9(2.2402) 67.3(2.6496)
LNW21BSH031401
5. Remove the spring upper seat.

• Remove the special tool and remove the upper
seat.
6. Remove the valve spring.
Organize the removed valve springs in the order of
the cylinder number.
7. Remove the valve stem oil seal.
• Remove the oil seal using pliers. LNW21BSH017001
2. Degree of perpendicular condition

• Measure the degree of perpendicular condition
with a right-angle gauge. Replace the valve
spring if the measured value exceeds the limit.
Degree of perpendicular condition of valve spring

Limit: 1.0 mm(0.0394 in)
LNW21BSH056701
Installation
1. Install the valve stem oil seal.
• Apply engine oil to outer edge of the valve
guide and install the oil seal using the valve
stem seal setting tool.
NOTE:
LNW21BSH017101
After installing the valve stem oil seal, check that it is
securely inserted all the way in, and that the oil seal is
not inclined or that the garter spring will not come
3. Tension loose.
• Using a spring tester, compress the spring to
the installation height. Measure the com-
pressed spring tension. If the measured tension Special Tool
is lower than the limit, replace the spring. Valve stem seal installer:
5-8840-2625-0
Valve spring tension N (kg/lb)
Inlet Exhaust
Installation
47 mm(1.85 in) 47 mm(1.85 in)
height
Standard 333(34.0/74.97) 490(50.0/110.25)
values
Limit 315(32.2/71.001) 463(47.3/104.297)
LNW21BSH031901
2. Install the valve spring.


• Install either the side with the paint mark (2) or • Using a replacer, compress the valve spring to
narrower spring pitch (2) to the lower side install the split collar.
(cylinder head side).
Special Tool
Paint mark
Pivot: 5-8840-2808-0
Inlet Blue
Exhaust Red
LNW21BSH031401
2
5. Apply engine oil to the bridge (2) for assembly.
LNW21BSH016701
NOTE:
Legend Move it up and down to confirm that it moves smoothly.
1. Spring pitch
2. Paint mark 6. Apply engine oil to the bridge cap (1) for assembly.
CAUTION:
3. Install the spring upper seat. Be very careful not to drop the bridge cap into the
4. Install the split collar. cylinder head rear-side gearcase or front side oil return
hole.
MFW61BSH000401
Legend
1. Bridge cap
2. Bridge
7. Install the cylinder head.

Rocker Arm Shaft Assembly

Components
5
4
3
2
1
6
LNW21BLF003701
Legend
1. Camshaft bracket 5. Rocker arm bracket
2. Rocker arm 6. Camshaft bracket
3. Wave washer 7. Rocker arm shaft
4. Rocker arm
Removal
2. Remove the rocker arm shaft assembly.
• Remove the rocker arm shaft assembly
together with the camshaft bracket.

• The bolt in the drawing is for fastening the 6. Remove the camshaft bracket (6), and remove the
rocker arm shaft and does not need to be shaft.
removed.
5
4
3
2
1
6
7 LNW21BSH058101
LNW21BSH030201
Legend
1. Camshaft bracket
CAUTION: 2. Rocker arm
Be very careful not to drop the bridge cap into the 3. Wave washer
cylinder head rear-side gear case or front side oil return 4. Rocker arm
hole. 5. Rocker arm bracket
6. Camshaft bracket
7. Rocker arm shaft
Disassembly
1. Remove the camshaft bracket (1).
2. Remove the rocker arm (2).
Inspection
3. Remove the wave washer (3).
1. Inspect for clogging in the oil hole of the camshaft
4. Remove the rocker arm (4). bracket (rear side).
5. Remove the rocker arm bracket (5).
• Disassemble in the order of (2) to (4) hereafter.
LNW21BSH018901
2. Inspect the rocker arm shaft for bending.

• Set the rocker arm shaft on the V-block.
• Touch the dial indicator to the center of the
shaft to inspect for bending while rotating the
shaft.

• If the bending is minor in the measurement,
correct it using the press (when cooled).
• Replace the shaft if the measured value of the
bending in the shaft exceeds the limit.
Rocker arm shaft runout mm(in)

Limit 0.3(0.0118)
LNW21BSH019101
4. Inspect the gap between the rocker arm and rocker

arm shaft.
• Use a cylinder gauge to measure the inner
diameter of the rocker arm bush and measure
the gap with the shaft outer diameter.
• Replace the rocker arm and shaft if the
LNW21BSH056601
Clearance between the rocker arm and mm

3. Inspect the rocker arm shaft for wear. rocker arm shaft (in)
• Use a micrometer to measure the rocker arm
sliding portion at 8 places. Standard 0.010 - 0.056
values (0.0004 - 0.0022)
• Replace the shaft if the measured value is
under the limit. Limit 0.2(0.0079)
Outer diameter of the rocker arm shaft mm

(in)
Standard 21.979 - 22.000
values (0.8653 - 0.8661)
Limit 21.85(0.8602)
LNW21BSH019201
5. Inspect the gap between the rocker arm roller and

rocker arm pin.

a. Pass a cord through the gap between the • Assemble in the reverse order of disassembly.
rocker arm and roller, and pull firmly in the
direction of the arrows to measure the level
difference between the rocker arm and roller
with the roller raised. (In the diagram (1))
b. After applying a mark at the measurement
point, pull out the cord. Measure the level of the
mark position with the roller pushed all the way
in. (In the diagram (2))
c. The difference in dimension measured at a. and
at b. is the gap between the roller and the
rocker arm pin. Replace the rocker arm if the
gap exceeds the limit.
Clearance between the roller and rocker mm

arm pin (in)
Standard 0.068 - 0.100
values (0.00268 -0.00394) LNW21BSH033101
Limit 0.2(0.00787)
2. Install the rocker arm.
• Apply engine oil to the inner diameter of the
rocker arm, roller and rocker arm pin, and then
install to the rocker arm shaft.
1 2
LNW21BSH019301
Reassembly LNW21BSH019801
1. Install the camshaft bracket to one side of the

rocker arm shaft side. At this time, temporarily 3. Install the wave washer (3) between the rocker
tighten. After installing the rocker arm shaft arms.
assembly to the cylinder head, tighten.
4. Install the rocker arm bracket (5).
• Be careful of the direction of bracket assembly
to assemble to the rocker arm shaft (7).
5. Lastly, install the camshaft bracket to the opposite
side.

• Install the camshaft bracket (1) to the rocker
arm shaft (7). At this time, temporarily tighten
bolt indicated by the arrow. After installing the
rocker arm shaft assembly to the cylinder head,
tighten it. 1
2
5
4
3
2
1
6
MFW61BSH000401
Legend
1. Bridge cap
2. Bridge
7 LNW21BSH058101
Legend
1. Camshaft bracket • Loosen the rocker arm adjust screw and apply
2. Rocker arm engine oil to the rocker arm roller, and then
3. Wave washer install to the cylinder head.
4. Rocker arm • Slightly loosen the bolt indicated by the arrow to
5. Rocker arm bracket make installation easier.
6. Camshaft bracket
7. Rocker arm shaft
Installation
• If the bridge cap (1) is removed, apply engine
oil to the inside of the bridge cap, and assemble
to the bridge (2).
CAUTION:
cylinder head rear-side gear case or front side oil return
hole.
LNW21BSH030201
• Apply engine oil to the threaded portions of the

bolt and nut.

• Temporarily tighten the rocker arm assembly
tightening bolts (2), and (3). Gradually tighten
the whole rocker arm assembly to become
level, in the order of nut (1) of the rocker arm
side.
Tightening torque
Bolt (3) 56 N⋅m(5.7 kg⋅m/41 lb⋅ft)
Nut (1) 27.5 N⋅m(2.8 kg⋅m/20 lb⋅ft)
Bolts (2), (4) 27.5 N⋅m(2.8 kg⋅m/20 lb⋅ft)
1
2
3
1
2
4
LNW21BSH059201
Legend
1. Nut
2. Bolt
3. Bolt
4. Bolt
2. Adjust valve clearance.


LNW71BMF002201
(a) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(b) 56 N⋅m (5.7 kg⋅m / 41 lb⋅ft)
(c) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
Camshaft Position Sensor

Removal
1. Disconnect the camshaft position sensor con-
nector.
2. Remove the camshaft position sensor.
LNW71BSH007301
Installation
1. Install the camshaft position sensor and tighten at
the specified torque.
LNW71BSH007301
2. Connect the camshaft position sensor connector.

Camshaft Assembly
Components
LNW71BLF001501
Legend
1. Bearing cap 3. Knock pin
2. Bearing 4. Camshaft gear
Removal NOTE:
Organize the removed bearings according to the
cylinders using tags, etc.
Section.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
5. Remove the camshaft assembly.
6. Remove the bearing lower.

• Inspect the camshaft journal and cam for wear
and damage. Replace if there are
abnormalities.
LNW21BSH030301
Disassembly LNW21BSH020201
1. Remove the camshaft gear.

• Remove the camshaft gear installation bolt, 2. Inspect the clearance of the camshaft in the axis
sandwich wood piece in the pullers and remove direction.
the camshaft gear. • Insert a thickness gauge to measure the gap
between the camshaft gear and camshaft
bracket in the axis direction.
• Replace the camshaft gear or camshaft if the
1
Clearance of the camshaft in the axis
direction mm(in)
Standard 0.05 - 0.17
values (0.00197 - 0.00669)
Limit 0.25(0.00984)
LNW21BSH056201
Legend
1. Piece of wood
2. Remove the knock pin.
Inspection
1. Visually inspect the camshaft.
LNW21BSH020301
3. Inspect the cam lobe for wear.


• Measure the height of the cam lobe using a
micrometer.
• Replace the camshaft if the cam lobe height is
under the limit.
Cam lobe height mm(in)

Inlet Exhaust
Standard 52.8(2.079) 54.5(2.146)
values
Limit 51.8(2.0394) 53.5(2.106)
LNW21BSH020501
5. Inspect the camshaft for bending.

• Place the camshaft in the V-block and use a
dial indicator to measure any bending.
• Slowly rotate the camshaft to measure
deflection of the dial indicator. Replace the
camshaft if the deflection exceeds the limit.
Runout of the camshaft mm(in)

Limit 0.05(0.00197)
LNW21BSH020401
4. Inspect the camshaft journal for wear.

• Measure the diameter of the camshaft journal
and uneven wear using a micrometer.
• Replace the camshaft if the wear exceeds the
limit.
Outer diameter of the camshaft journal mm(in)

Standard 39.950 - 39.975
values (1.5728 - 1.5738)
Limit 39.850(1.5689)
Disproportionate wear of the camshaft
journal mm(in)
Limit 0.05(0.00197)
LNW21BSH020601
6. Measure the camshaft journal oil clearance.

a. Measure the inner diameter of the camshaft
bearing using the cylinder gauge.
b. Read the difference of the inner diameter of the
camshaft bearing and diameter of the camshaft
journal.
Replace the camshaft bearing if the measured
oil clearance exceeds the limit.
Clearance of journal mm (in)

Standard 0.025 - 0.087
values (0.0010 - 0.0034)
Limit 0.15(0.0059)
LNW21BSH020301
Installation
1. Rotate the crankshaft in the forward direction to
align the 1st cylinder piston to the compression top
dead center.
LNW21BSH054601
Reassembly
1. Install the knock pin.
2. Install the camshaft gear.
• Put the side of the camshaft gear center boss
that is projected to the camshaft side, and align
it to the knock pin. Then install the camshaft
gear.
NOTE:
When tightening the gear, be careful not to damage the
cum and journal.
LNW71BSH002801
2. Install the camshaft bearing lower.

• Apply engine oil to the camshaft bearing lower
and assemble to the cylinder head.

• Assemble the camshaft assembly so that the "
B " marks on the camshaft gear end and top
surface of the cylinder head are aligned.
LNW21BSH030901
LNW71BSH010601
Section.
NOTE:
After tightening, check again that the " • " marks are 7. Install the cylinder head cover.
aligned. Refer to "Cylinder Head Cover" in this Section.
4. Install the bearing upper to the bearing cap.

5. Install the bearing cap.
• Apply engine oil to the bearing upper.
• Face the bearing cap front mark to the engine
front side, and assemble in numbered order to
the cylinder head.
LNW21BSH055801

tighten the bearing cap at the specified torque.

LNW71BLF003301
(a) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(b) 142 N⋅m (14.5 kg⋅m / 105 lb⋅ft)
Cylinder Head
Components
1
4
2
18 5
6
7
3
8
9
10
11
17
12
16
15
13
14
LNWA1BLF001401
Legend
1. Bridge cap 10. Idle gear C cover
2. Bridge 11. Idle gear C
3. Bridge guide 12. Glow plug
4. Split collar 13. Inlet and exhaust valve
5. Spring upper seat 14. Cylinder head
6. Valve spring 15. Engine hanger
7. Valve stem oil seal 16. A/C compressor bracket
8. Spring lower seat 17. Thermostat
9. Valve guide 18. Water outlet pipe
Removal • Refer to "Exhaust Pipe" in Section 1G, Engine

Exhaust (4HK1).
1. Drain the coolant.
3. Remove the air duct from the turbocharger.
brake assembly. • Remove the PCV hose (2) from the air duct.

• Loosen the air duct tightening clamp (5) at the
turbocharger inlet.
4. Remove the air intake hose(4).
clamp(3). 1
5. Disconnect the connector (6) from the
turbocharger actuator. 2
4
3
LNW71BSH006801
1
5 13. Remove the A/C compressor.

6
• Remove the A/C compressor harness con-
nector, remove the compressor from the A/C
compressor bracket, and fasten to a suitable
LNW81JSH000801 position together with the hoses using a wire,
etc.
6. Remove the engine harness.

7. Remove the radiator upper hose.
8. Remove the oil level gauge and oil level gauge
guide tube.
Refer to "EGR Valve and EGR Cooler" in Section
10. Remove the cooling water pipe and oil pipe eyebolt
from the turbocharger.
Induction (4HK1).
11. Remove the exhaust adaptor
Induction (4HK1).
12. Remove the A/C compressor drive belt.
LNW71ESH001501
• Loosen the tension pulley nut (1) and adjust
bolt (2), and remove the drive belt.
15. Alternately and evenly loosen the injector terminal
nuts (3), and remove the terminal.
16. Loosen the injector harness bracket bolts, remove
the inside connector (2), and remove the harness
bracket (1).
NOTE:
The injector ID code identifies the injectors. Do not
remove the injector ID codes from the injectors.

17. Remove the nozzle leak-off pipe (4). 21. Remove the water bypass hose from the cylinder
head side.
3 1
2 4
LNW21DSH003901
LNW71BSH007001
18. Remove the leak-off hose.

19. Remove the leak-off pipe (2) 22. Disconnect the camshaft position sensor
connector.
1
2
LNWA1CSH000501
LNW71BSH007301
Legend
1. High pressure pipe
2. Leak-off pipe
20. Disconnect the engine coolant temperature sensor Section.
connector. 24. Remove the camshaft assembly.
25. Remove carefully so that the bridge cap does not
fall into the engine.
26. Remove the bridge.
NOTE:
Store the removed bridge and bridge cap so that they
can be returned to their original positions.
27. Disconnect the glow plug connector.


28. Remove the glow plug. CAUTION:
• The injector ID code identifies the injectors. Do not
confuse between other injector QR plates.
• When the injector assembly is replaced, use the
scan tool to register the ID code to the ECM.
For details on writing, refer to "Programming" in
Section 1A, Engine Control System.
• When a special tool is used to pull out the injector,
make sure that the injector sleeve does not come off
while working on it.
LNW21BSH055301
2
29. Remove the injection pipe clip (2), and remove the
injection pipe (1).
2
2
LNW46CMH000301
Legend
LNWA1CSH000601 1. Sliding hammer
2. Injector remover
3. Injector assembly
30. Disconnect the common rail pressure sensor
connector. NOTE:
31. Remove the common rail. Store the removed injector with the cylinder number on
32. Remove the injector bracket. it.
Take sufficient care not to hit the injection hole.
33. When it is difficult to remove the injector, set an
injector remover (2) on the injector (3) leak-off pipe
installation section, and then pull the injector
upward using a sliding hammer (1).
Special Tool
Injector remover: 5-8840-2826-0
Sliding hammer: 5-8840-0019-0

CAUTION:
If you grip the actuator rod to lift the turbocharger, it will
be deformed and cause improper operation. Do not
grip the rod.
2. Remove the exhaust manifold.
LNW91BSH004401
34. Remove the cylinder head assembly.

• Evenly loosen the cylinder head bolts in the
order shown in the diagram. LNW91BSH008501
NOTE: Legend
(1) and (2) are tightened to the flywheel housing by 1. Cylinder head
M10 bolts, so do not overlook them. 2. Gasket
3. Exhaust manifold
• Remove the cylinder head gasket. 4. Distance tube(spacer)
NOTE:
Do not reuse the removed cylinder head gasket. 3. Remove the throttle valve assembly.
Refer to "Throttle Valve Assembly" in this Section.
4. Remove the inlet cover outer.
7 15 18 10
3 11 19 14 6 2
1
4 12 20 13 5
8 16 17 9
3
2
1
LNW21BSH030401
LNW91BSH007801
Disassembly Legend
1. Remove the turbocharger assembly and gasket.
2. Gasket
3. Inlet cover
Induction (4HK1).

5. Remove the inlet cover. • As shown in the drawing, lightly tap the sealing
• There is 1 bolt on the throttle valve Assembly cup outer perimeter with the leading end of the
installation section (arrow) in the inlet cover. Be screwdriver, turn the sealing cup over and pull it
careful not to forget to remove it. out using pliers.
• Carefully remove the fluid gasket.
LNW21BSH054701
LNW91BSH008001
10. Remove the idle gear C.

6. Remove the A/C compressor bracket.
7. Remove the water outlet pipe. 1 2
8. Remove the thermostat.
4
3
LNW61BSH003901
Legend
1. Idle gear C
2. Idle gear shaft
LNW21BSH056501
3. Washer
4. Bolt
9. Remove the idle gear C cover.
11. Remove the split collar.

12. Remove the spring upper seat.
13. Remove the valve spring.
• Compress the valve spring and remove the split
collar using a replacer.
Special Tool
Pivot: 5-8840-2808-0

• Remove the upper seat and valve springs. • Remove the oil seal using pliers.
Organize the removed valve springs in the
order of the cylinder number.
LNW21BSH056801
LNW21BSH031401
16. Remove the spring lower seat.
17. Remove the valve guide.
14. Remove the inlet valve and exhaust valve.
• Use the valve guide replacer to tap out the
• Organize the removed valves according to the valve guide from the lower side of the cylinder
cylinders using tags, etc. head.
Special Tool
Valve guide replacer: 5-8840-2628-0
LNW21BSH016801
15. Remove the valve stem oil seal.

LNW21BSH055701
18. Install the nozzle sleeve remover to the bottom

surface of the head and tap to pull out the nozzle
sleeve (1).
Nozzle sleeve remover: 5-8840-2623-0
NOTE:
• Be careful not to damage the bottom surface of the
head.
• Do not reuse the removed nozzle sleeve.

• Carefully remove any drill powder in the cylinder • Install a metal plate from the inside of the head
head screws. to tap and remove.
1
LNW21BSH056401
LNW21BSH056301
Legend
1. Nozzle sleeve Inspection
1. Inspect the valve guide.
19. Remove the bridge guide. NOTE:

• Electrically weld (1) the nut to the top of the If there are scratches or abnormal wear on the inner
bridge guide, attach the sliding hammer to diameter of the valve stem or valve guide, replace it
remove the bridge guide. together with the valve guide.
a. Measure the valve guide clearance.

• Measure the diameter of the valve stem
using the micrometer.
If the diameter of the valve stem is smaller
than the limit, replace the valve and valve
1
guide together.
mm
Outer diameter of the valve stem
(in)
Standard values Limit
8.946 - 8.961 8.88
Inlet valve
(0.3522 - 0.3528) (0.3496)
Exhaust 8.921 - 8.936 8.80
valve (0.3512 - 0.3518) (0.3465)
LNW21BSH058201
20. Remove the oil seal.


• Use a dial indicator to measure the contact
surface of the bridge cap and rocker arm.
• Replace the bridge cap if wear exceeds the
limit or if there is abnormal wear (band-shaped
wear).
Wear of the bridge cap mm(in)

Limit 0.1(0.0039)
LNW21BSH017301
• Use a dial indicator to measure the gap

between the valve guide(2) and valve
stem(1) within a range of 10 mm(0.3937
in)(a) from the valve guide.
• Replace the valve and valve guide together
as an assembly if the measured value
exceeds the limit.
LNW21BSH019401
Gap between the valve guide and mm

valve stem (in) 3. Inspect the valve.
Standard values Limit Valve thickness
• Measure the thickness of the valve.
0.039 - 0.071 0.20
Inlet valve • Replace the valve and valve guide together as
(0.0015 - 0.0028) (0.0079)
an assembly if the measured value exceeds the
Exhaust 0.064 - 0.096 0.25 limit.
valve (0.0025 - 0.0038) (0.0098)
Valve thickness mm(in)
Inlet valve 1.71(0.0673) 1.3(0.0512)
Exhaust valve 1.75(0.0689) 1.3(0.0512)
BLW51BSH005801
2. Inspect the bridge cap for wear.

Exhaust 45°
3
2
LNW21BSH017801
Valve seat MFW51BSH003501

• Remove the carbon and water deposit on the Legend
bottom surface of the cylinder head. 1. Contact length width
Install the valve to the cylinder head. 2. Sinking amount
Use a depth gauge or simple straight ruler to 3. Contact surface angle
measure the sinking amount of the valve from
the bottom surface of the cylinder head.
Replace the valve and insert if it exceeds the
limit. Repair of the seat surface.
• Remove the carbon from the valve seat insert
top surface.
Sinking amount of the valve mm(in)
• Use a seat cutter to minimize the scratches and
Standard values Limit other uneven parts, and return the touching
0.73 - 1.10 2.3 width to the standard value.
Inlet Inlet valve
(0.0287 - 0.0433) (0.09)
1.16 - 1.54 2.8 1
Exhaust
(0.0457 - 0.0606) (0.11)
• Measure the touching width of the valve seat.

Repair or replace when there are scratches on
the seat touching surface, or it is rough, or if the
touching surface wear exceeds the limit.
Touching width of the valve seat mm(in)

Inlet valve 2.7(0.1063) 3.2(0.1260)
Exhaust valve 2.7(0.1063) 3.2(0.1260)
• Measure the contact surface of the valve seat.

If the valve seat contact surface is improper, LNW76BSH005501
repair or replace together as an assembly with Legend

the valve, valve guide and valve seat. 1. 119°45’
Contact surface angle

Inlet 30°

NOTE:
Exhaust valve After fitting, remove all applied compound.
LNW76BSH005401
Legend LNW21BSH031801
1. 89°45’
Replacement of the valve seat insert

NOTE: Removal of the valve seat insert
Get rid of only the scratches and uneven portions, but
• Arc weld the entire inner circumference (1) of
be careful not to over-cut.
the valve seat insert (2).
Use an adjustable valve cutter pilot.
The valve cutter pilot should not be allowed to scrape • Cool the valve seat insert for 2 to 3 minutes.
inside the valve guide. Cooling makes it easier to remove the valve
seat insert due to contraction.
• Remove the valve seat insert using a
screwdriver (3). At this time, be careful not to
damage the cylinder head.
LNW21BSH056101
• Add compound to the valve seat insert. LNW21BSH056001
• Insert the valve into the valve guide.

• Add compound to the valve seat surface and Installation of the valve seat insert.
gently tap the valve while turning it to check that
it is touching evenly around the entire • Be careful when placing the dolly block (1)
circumference. (smaller outer diameter than the valve seat
insert) over the valve seat insert (2).

• Use the press (3) to gradually apply pressure to • Inspect for cracks between the valve seat
the dolly block and push in the valve seat insert. and exhaust port of the cylinder head.
Replace the cylinder head if there is
NOTE: damage or cracks. Perform a collar check
Do not apply excessive pressure with the press. as necessary.
Add compound to the valve seat surface and gently tap
the valve while turning it to check that it is touching
evenly around the entire circumference.
LNW21BSH032401
c. Flatness of the cylinder head bottom surface.

LNW21BSH018601 • As shown in the diagram, measure the 4
sides and diagonal line with a simple
straight ruler and thickness gauge. Replace
4. Inspect the cylinder head assembly.
if the limit is exceeded.
• Completely remove the varnish-like matter and
soot on the metal surfaces. Use a metal brush
for the gasket installation surfaces. Be careful Deformation on the bottom surface of the mm(in)
not to scratch the seal surface. cylinder head
• If the cylinder head seal surface is leaking, Standard values 0.05(0.0020) or less
corroded or blown out, and the gasket is
defective, check the following possible causes. Limit 0.20(0.0079)
- Incorrect installation
- Improper cylinder head tightening
- Warping of the cylinder head bottom surface
and cylinder block top surface
a. Screw surface damage caused by over-
tightening, and stretched cylinder head bolts.
NOTE:
Replace dubious bolts.
b. Combustion chamber, glow plug holes.
LNW21BSH032501
d. Flatness of the installation surface of the

exhaust manifold and inlet cover

• As shown in the diagram, measure the 4
sides and diagonal line with a simple
straight ruler and thickness gauge. Replace
if the limit is exceeded.
Strain on the installation surface of the mm(in)

manifold and cover
Standard values 0.05(0.0020) or less
Limit 0.2(0.0079)
LNW71BSH009001
5. Bridge
• There should be no strain in the bridge (1) and
bridge guide (2).
• Measure the gap between the bridge (1) and
bridge guide (2).
Gap mm(in)
0.020 - 0.056
Assembly standard
LNW21BSH032601 (0.0008 - 0.0022)
0.1
e. Flatness of the exhaust manifold Limit for use
(0.0039)
• Measure flatness using a simple straight
ruler and thickness gauge. Replace the
exhaust manifold if it exceeds the limit.
Deformation of the exhaust manifold mm(in) 1
Standard values 0.3(0.0118) or less 2

Limit 0.5(0.0197)
LNW21BSH059101
Reassembly
1. Install the oil seal.
• Install to the injection pipe insertion surface.
• Uniformly tap the seal so that it is not slanted.

CAUTION:
Be careful not to damage the lip section.
Special Tool
Oil seal installer: 5-8840-2627-0
a
MFW81BSH001401
(a) 37.5 mm(1.47 in)

(b) 122.5 mm(4.82 in)
LNW21BSH056401
3. Install the nozzle sleeve.

• Install the O-rings (1), (2) to the nozzle sleeve
1 and apply engine oil.
2
• Apply Loctite No. LT290 to the tapered section
(3) of the nozzle sleeve.
LNW21BSH058301
Legend
1. Cylinder head
2. Oil seal installer
2. Install the bridge guide.

• Apply engine oil to the outer circumference of
the guide. Use a setting tool to tap the guide up
to finished depth of the cylinder head hole.
(Reference: The height of the bridge guide is
approximately 37.5 mm(1.47 in) from the top
surface of the head).
Special Tool
Bridge guide setting tool: 5-8840-2626-0

• Apply engine oil (4) to the injector sleeve Special Tool
contact surface of the cylinder head. Nozzle sleeve setting tool: 5-8840-2624-0
1
3
2
6
5 3
4
4
MFW61BMH000101
LNW21BMH001001
Legend
1. O-ring (white paint) Legend
2. O-ring 1. Punch bar
3. Loctite application area 2. Ball
4. Engine oil application area 3. Guide sleeve
4. Nozzle sleeve
5. Clamp
6. Bolt
• Install the nozzle sleeve (4) to the cylinder
head, and insert the guide sleeve (3) included
in the nozzle sleeve setting tool (5-8840-2624- 4. Install the valve guide.
0). • Use the valve guide replacer to tap the valve
• Insert with the guide sleeve (3) so that the guide from the upper surface side of the
nozzle sleeve securely attach to the bottom cylinder head.
surface of the cylinder head.
• Fasten the guide sleeve (3) with the clamp (5) NOTE:
and bolt (6). When replacing the valve guide, replace as a set with
the valve.
• Insert a ball (2) (bearing steel ball 9.525
mm(0.3740 in)) into the guide sleeve (3) and
attach a punch bar (1), then hammer the ball (2)
through.
NOTE:
• Allow the cylinder head to float so that the ball
comes out from the bottom surface.

Special Tool NOTE:
Valve guide replacer: 5-8840-2628-0 After installing the valve stem oil seal, check that it is
Valve guide installer: 5-8840-2930-0 securely inserted all the way in, and that the oil seal is
not inclined or that the garter spring will not come
loose.
Special Tool
Valve stem seal installer: 5-8840-2625-0
LNW21BSH031601
The height from the upper surface of the

cylinder head to the end surface of the valve
guide (a): 17.1 - 17.9 mm(0.6732 - 0.7047 in) LNW21BSH031901
7. Install the inlet valve and exhaust valve.

• Apply engine oil to the valve stem and install
the valve.
NOTE:
After assembling the valve, check that the assembly is
correct.
a
LNW71BSH001701
5. Install the spring lower seat.

6. Install the valve stem oil seal.
• Apply engine oil to outer circumference of the
valve guide and install the oil seal using the
valve stem seal setting tool.
LNW21BSH018801
8. Install the valve spring.

• Install either the side with the paint mark (2) or
narrower spring pitch (2) to the lower side
(cylinder head side).
Paint mark
Inlet side Blue
Exhaust side Red
1 LNW21BSH031401
11. Install the thermostat.

2
• Install the thermostat (1) to the position shown
in the diagram.
LNW21BSH016701
Legend
1. Spring pitch
2. Paint mark
9. Install the spring upper seat. 1

10. Install the split collar.
• Using a replacer, compress the valve spring to
install the split collar.
• After installation, lightly tap the top of the valve
stem with a rubber hammer to stabilize the split 1
collar.
Special Tool
LNW21BSH021901
Pivot: 5-8840-2808-0
Legend
NOTE: 1. Thermostat
Check that the split collar is securely in the valve stem
groove.
12. Install the water outlet pipe.
• Tighten the water outlet pipe at its specified
torque.
Legend
13. Install the A/C compressor bracket and tighten the 1. Liquid gasket
bolt at the specified torque.
LNW91BSH007901
• Tighten in the order of the numbers in the

LNW21BSH001801
diagram.
Tightening torque: 23.5 N⋅m(2.4 kg⋅m/17 lb⋅ft)
14. Install the inlet cover.

• Align to the inlet cover groove, and apply liquid
gasket (TB-1207C) to 2.5 - 5.5 mm(0.098 -
0.217 in) width.
• After applying the liquid gasket, install it within 5
minutes.
NOTE:
• Be careful not to forget tightening the bolt indicated
by the arrow.
• Tighten the stud along with the common rail.
3 7 1
6 2
2 1 7
3 5 4
5 4 6
15. Install the inlet cover outer. 16. Install the intake throttle valve assembly and
• Install the gasket and inlet cover outer, and gasket, and tighten at the specified torque.
tighten at the specified torque. Refer to "Intake Throttle Valve" in this Section.
17. Install the exhaust gasket.
18. Install the exhaust manifold.
• Install the distance tube(spacer), disc
spring(washer) and nut in that order to the stud
on the cylinder head.
1 2
3
2
1
LNW91BSH007801
Legend
2. Gasket
3. Inlet cover
MFW81BSH000601
Legend
• Tighten in the order of the numbers in the 1. Distance tube(spacer)
diagram. 2. Disc spring(washer)
3. Nut
• Tighten the exhaust manifold at the specified

torque in the order of numbers in diagram.

• The measuring positions of the piston head and
reference points on the cylinder block side are
Tightening torque N⋅m(kg⋅m/lb⋅ft)
shown in the diagram below.
Bolts (1), (2), (3), (4), (5), (6) 34 (3.5/25)
nuts (7), (8) 34 (3.5/25)
NOTE:
Since it will expand or contract due to the heat of the
manifold, do not over-tighten.
5 3 4 6
1 2
7 8
LNW21BSH068001
Measurement Piston head Points (2)

points and (3)
Reference Cylinder block top
Point (1)
Points: surface
LNW71BSH008901
NOTE:
19. Install the turbocharger assembly. In the table below, there are 3 selections for the piston
Refer to "Turbocharger Assembly" in Section 1J, protrusion amount on the head gasket, so be careful.
Induction (4HK1).
• Calculate the average value (Ti) for the
protrusion amount of piston for each cylinder.
Installation • Find the maximum value (Ti-max.) of the
1. Install the cylinder head gasket. average value (Ti) for each cylinder.
• Select the cylinder head gasket.
• Clean the piston head and cylinder block top
surface.
• Measure the protrusion amount of piston using
a dial indicator. Perform the measurement in 2
places on each cylinder.

• Select the gasket of the appropriate grade
using the Ti-max.
a
c
3
b
d
1
2
LNWA6ASH016601
Legend
MFW81BSH001501
1. Grade identification hole
Legend
1. Cylinder block top surface
2. Piston head
3. Piston head • Apply liquid gasket.
4. a :50 deg. • As shown in the diagram, apply liquid gasket
5. b :20 deg. (TB1207B) to about 3 mm(0.118 in) width to the
6. c :70 mm(2.76 in) aligning surface (mating surface) (1) of the
7. d :100 mm(3.94 in) cylinder block and flywheel housing.
• After applying the liquid gasket, install the
cylinder head within 5 minutes.
Protrusion amount of
Gasket
Identification the piston (Ti-max.)
Grade 1
mm(in)
0.439 - 0.519
A No hole
(0.0173 - 0.0204)
0.519 - 0.589
B 1 hole
(0.0204 - 0.0232)
0.589 - 0.669)
C 2 holes
(0.0232 - 0.0263)
LNW21BSH015501
Legend
1. Liquid gasket application position
• Install the cylinder head gasket.


• Set the side of the head gasket marked with the • Tighten the head blots in the order shown in the
part number facing upward, position and install diagram using a torque wrench and angle
the cylinder head rear side gear case and gauge.
dowel together.
Cylinder head tightening torque

M14 1st time 98 N⋅m(10.0kg⋅m/72 lb⋅ft)
2nd time 147N⋅m(15.0kg⋅m/108 lb⋅ft)
(1 - 18)
3rd time 30° - 60°
M10
38 N⋅m(3.9kg⋅m/28 lb⋅ft)
(19,20)
Use a stud bolt for (16).
Special Tool
Angle gauge: 5-8840-0266-0
LNWA6ASH016901
14 6 3 11
2. Install the cylinder head assembly. 18 10 2 7 15 19
• Gently install the cylinder head while aligning
with the cylinder block dowel.
20
NOTE: 17 9 1 8 16
When installing, be careful not to damage the head 13 5 4 12
gasket.
LNW21BSH030701
3. Apply engine oil to the bridge (2) for assembly.
NOTE:
Move it up and down to confirm that it moves smoothly.
4. Thinly apply engine oil to the bridge cap (1) inner

surface and install it.
CAUTION:
cylinder head rear-side gearcase or front side oil return
hole.
LNW21BSH007901
• Apply molybdenum disulfide to the threaded

portion of the M14 head bolt and seat surface,
and apply engine oil to the threaded portion of
the M10 head bolt and seat surface.

NOTE:
When disassembling the idle gear C, assemble it while
paying attention to the following points because it is
1 difficult to position the idle gear C shaft.
1. Position the marked line on the crank pulley

(2) and the alignment mark on the front
2 cover (1) and set to compression top dead
center of the 1st cylinder.
MFW81BSH002301 2
Legend
1. Bridge cap
2. Bridge
5. Insert the gasket into the injector (1) and install to

the cylinder head.
MFW71BSH004401
6. Apply molybdenum disulfide to the threaded
portion and seat surface of the injector clamp bolt
(2), and temporarily tighten.
2. With the idle gear B assembled, insert the
idle gear C from above the cylinder head.
• Apply engine oil to the inner
circumference of the idle gear C bush
2 3 and the thrust bearing surface.
3. Apply engine oil to the outer circumference
4
of the shaft and pass from the cylinder head
1 rear surface hole to the gear center hole.
BLW71BSH020401
Legend
1. O-ring
2. Injector
3. Injector clamp bolt
4. Injector clamp
5. O-ring
6. Gasket
7. Install the idle gear C.

a. Assembly of the idle gear C.

4. Apply engine oil to the 2. Assemble the camshaft with the gear
both surfaces of the thrust collar, and installed to mesh with the idle gear C
molybdenum disulfide to the threaded installed to the cylinder head.
portion of the bolt and seat surface. At this time, when the marked line on the
Assemble the bolt which is installed to the crank pulley and alignment mark on the front
thrust collar. cover are positioned compression top dead
However, the bolt should be tightened at a center of the first cylinder, install so that the
torque of 40 N⋅m(4.1 kg⋅m/30 lb⋅ft), and alignment mark B on the camshaft gear
loosen by 30° to 90° after tightening. matches the top surface of the cylinder
(Confirm that the idle gear C moves.) head.
1
2 3
LNW71BSH010601
3. Set the cam bearing upper to the camshaft

cap, and apply engine oil to the bearing
inner circumference.
4. Assemble the #2, #3, #4 and #5 caps (1).
BLW71BMH000501
Apply engine oil to the threaded portion and seat
surface
Legend
1. Insertion direction Tightening torque
2. Shaft Cap bolts 27.5N⋅m (2.8 kg⋅m/20 lb⋅ft)
3. Thrust collar Cap nuts 27.5N⋅m (2.8 kg⋅m/20 lb⋅ft)
4. Bolt
5. Idle gear C
6. Bush NOTE:
Do not assemble the rocker arm.
b. Installation of the camshaft assembly.

Refer to "Camshaft Assembly" in this section.
1. Set the cam bearing lower to the cylinder
head. Apply engine oil to the bearing inner
circumference.

2. Hold down the camshaft gear by hand and
tighten the idle gear C bolt at the specified
torque.
1
Apply molybdenum disulfide to the threaded

portion and seat surface
Idle gear C bolt
Tightening torque 71 N⋅m(7.2 kg⋅m/52 lb⋅ft)
NOTE:
When tightening, be careful that the idle gear C shaft
position does not move a lot.
3. After tightening the idle gear C, check the

backlash to ensure that it is within the
standard value below.
LNW81BSH005601
Between the idle gear C and camshaft

c. Tightening the idle gear C. gear mm (in)
1. Manually rotate the camshaft gear in the left 0.015 - 0.146 (0.00059 - 0.00575)
direction (when looking from the engine
rear) (2), gently mesh the idle gear C to the If the camshaft gear does not move with
direction of the arrow (1) in the diagram, and rattling when manually moving it, there is the
set the idle gear C shaft position. possibility that that the backlash has
excessively built up. Check the backlash
NOTE: andreadjust.
Be careful as backlash can excessively build up if too
much force is applied when rotating the camshaft gear. NOTE:
If the backlash cannot be adjusted, assemble with the
service idle gear C shaft (8-97186-398-1 ).
4. Remove the cam cap and camshaft.

2 5. Use a flat-blade screwdriver (large size),
etc., to check the backlash of the idle gear C
1 while holding down the idle gear B.
1
Between the idle gear C and idle gear B mm (in)
2 0.015 - 0.217 (0.00059 - 0.00854)
6. Repeat Step b. 1 to 4.
7. Remove the camshaft cap end once, and
3
assemble with the rocker arm assembly.
8. Install the idle gear C cover.
• Apply liquid gasket (Loctite 262) to the outer
BLW71BSH009801 circumference of the idle gear C cover, and
Legend then use the sealing cup setting tool to tap in to
the dimensions(a :1.5 - 2.5 mm (0.059 - 0.098
(1) Lightly engage the idle gear C.
in)) shown in the diagram.
(2) Rotate the camshaft gear counterclockwise.
1. Camshaft gear Special Tool
2. Idle gear C Sealing cup installer: 5-8840-2222-0
3. Idle gear B
2
2
MFW81BSH000901 LNWA1CSH000601
9. Install the camshaft assembly. 13. Tighten the injector clamp (1) (temporarily
Refer to "Camshaft Assembly" in this Section. tightened earlier) at the specified torque.
10. Install the rocker arm shaft assembly. Tightening torque: 30 N⋅m (3.1 kg⋅m/22lb⋅ft)
Section. 14. Tighten the injection pipe (2) at the specified
11. Install the common rail. torque.
Tightening torque Tightening torque

Nuts side 22 N⋅m( 2.2 kg⋅m/16 lb⋅ft) Injector side 30 N⋅m( 3.1 kg⋅m/22 lb⋅ft)
Bolts side 24 N⋅m( 2.4 kg⋅m/17 lb⋅ft) Common rail side 25 N⋅m( 2.5 kg⋅m/19 lb⋅ft )
• Install the common rail pressure sensor

connector.
12. Install the injection pipe (1). 1
• Thinly apply engine oil to the outer
circumference of the injector side sleeve nut
and install it. 2
• Lightly tighten the sleeve nut with spanner so
that it is airtight to the injector and common rail
side.
• Tighten the injection pipe clip (2) at the
specified torque.
2
LNWA1CSH000701
Legend
1. Clamp bolt
2. Injection pipe
15. Install the glow plug.


NOTE: 19. Install the leak-off pipe.
Do not over-tighten. There is the possibility of damage
by tightening beyond the standard. Tightening torque: 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
20. Install the leak-off hose.
16. Install the glow plug connector and tighten at the
specified torque. • Install the leak-off hose to the leak-off pipe and
fasten with the clips.
Tightening torque: 1.2 N⋅m (0.12 kg⋅m/10 lb⋅in) 21. Fit the new gasket onto the injector leak-off pipe,
17. Install the camshaft position sensor and tighten at and install leak-off pipe.
the specified torque. Tightening torque
Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in) Injector side: 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)
Cylinder head side: 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
LNW71BSH007301
LNW21DSH003401
18. Install the water bypass hose.

22. Install the injector harness connector from the
• Install the engine coolant temperature sensor
inside, and tighten the harness bracket at the
connector to the thermostat housing.
specified torque.
2
MFW71BSH003701
Legend
1. Water bypass hose
LNW91DSH000801
2. Engine coolant temperature sensor

23. Install the terminal nut (3) to the injector (1). • Install the A/C compressor harness connector.
NOTE:
• Alternately tighten the terminal nuts so that not only
1 side is tightened because this is an integrated
part.
• As the terminal stud can be damaged if the nut is
over-tightened, never over-tighten the nut.
LNW71ESH001501
27. Install the A/C compressor drive belt and adjust the
belt tension.
2 • Refer to "Drive Belt" in Section 1C, Engine
Cooling (4HK1).
28. Install the exhaust adaptor.
1 Refer to "Turbocharger Assembly" in Section 1J,
Induction (4HK1).
LNW71DSH003601
29. Install the water pipe and oil pipe to the
Legend turbocharger.
1. Injector Refer to "Turbocharger Assembly" in Section 1J,
2. Harness Induction (4HK1).
3. Terminal nut 30. Install the EGR cooler.
Refer to "EGR Valve and EGR Cooler" in Section
Refer to "Cylinder Head Cover" in this Section. 31. Install the oil level gauge and guide tube.
25. Install the radiator upper hose. 32. Install the radiator upper hose.
Radiator hose clip Radiator hose clip
Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in) Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
26. Install the A/C compressor. 33. Install the charge air pipe on the left and right of
the engine to the intercooler.
• Install the A/C compressor to the A/C
compressor bracket, and tighten at the
specified torque. 34. Install the intake hose (4) to the turbocharger, and
tighten the hose clamp (3) at the specified torque.
NOTE:
torque.
Tightening torque: 7.5 N⋅m(0.76 kg⋅m/66 lb⋅in)

NOTE:
torque.
• Tighten the turbocharger inlet air duct

tightening clamp (5) at its specified torque.
Tightening torque: 8 N⋅m(0.8 kg⋅m/69 lb⋅in)
• Install the PCV hose (2) to the air duct.
36. Install the connector (6) to the turbocharger
actuator.
4
3
5
6
LNW81JSH000801

assembly and tighten it at the specified torque.
• Refer to "Exhaust Pipe" in Section 1G, Engine
Exhaust (4HK1).
38. Install the engine harness.
39. Pour in the coolant.

d
a
g
f
LNWA1BMF001401
(a) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(d) 71 N⋅m(7.2 kg⋅m / 52lb⋅ft)
(e) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(f) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(g) 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →147 N⋅m (15 kg⋅m / 108 lb⋅ft) → 30° - 60°
Crankshaft Position Sensor

Removal
1. Disconnect the crankshaft position sensor harness
connector.
2. Remove the crankshaft position sensor.
• This is sensitive to shocks so do not throw or
drop.
LNW71BSH007501
Installation
1. Install the crankshaft position sensor and tighten at
LNW71BSH007501
2. Connect the crankshaft position sensor harness

connector.
Flywheel
Components
3
4
6
7
8
9
LNW81BMF001801
Legend
1. Crankshaft position (CKP) sensor 6. Clutch disk (M/T vehicle)
2. Flywheel housing 7. Pressure plate (M/T vehicle)
3. Flywheel Assembly (M/T vehicle) 8. Flexible plate (Smoother vehicle)
4. Washer 9. Crank end spacer (Smoother vehicle)
5. Pilot bearing (M/T vehicle)
Removal
1. Remove the starter.
• Disconnect the starter ground cable.

• Disconnect the front frame harness connector • Remove the pressure plate mounting bolts in
near the transmission control box and remove the order numbered in the diagram.
each of the clips fastening the harness. • Remove the pressure plate from the flywheel.
1 5
7
3
9
10
4
8
6 2
4. Remove the clutch disk.

• Remove the 2 bolts (upper and lower) attaching
the starter, and remove the starter from the • Remove the clutch disk from the flywheel along
clutch housing. with the clutch aligner (1).
• Fasten with a wire etc. to a position where it will
not interfere with the removal of the
transmission.
LNW21BSH002601
Legend
1. Clutch aligner
LNW21BSH011601
2. Remove the transmission Assembly. • Install the crankshaft stopper to the flywheel
Refer to "Smoother Transmission Assembly" in housing starter, and make sure the crankshaft
Section 5B, Automatic Transmission for details on does not rotate.
Refer to "Transmission Assembly" in Section 5C, NOTE:
Manual Transmission for details on M/T vehicles. Check that the stopper securely bites into the ring gear
3. Remove the clutch pressure plate. and that it is installed.
• Insert the clutch aligner in the spline of the
clutch disk.

Special Tool • For A/T vehicles, after loosening the flywheel
Crankshaft stopper: 5-8840-2230-0 mounting bolts, remove the washers, flexible
plate, flywheel and sleeve in that order.
1 4
6 7
3 2
8 5
LNW21BSH007701
LNW71BSH008801
5. Remove the crankshaft position (CKP) sensor.

• When removing the flywheel, remove to 8. Remove the pilot bearing.
prevent interference or damage. • Remove the pilot bearing from the flywheel.
• This is sensitive to shocks so do not throw or
drop.
LNW21BSH029301
Legend
LNW71BSH007501 1. Washer
2. Pilot bearing
3. Flywheel
6. Remove the washer.
7. Remove the flywheel.
• Gradually loosen the flywheel mounting bolts in 9. Remove the ring gear.
the order shown in the drawing while making
sure that the flywheel does not rotate.
• Loosen all bolts, then remove the stopper, and
the flywheel.

• Install a rod to the ring gear and remove it by Depth: From pressure plate installation surface
tapping with a hammer. to friction surface (1).
LNW21BSH012001 MFWB1BSH002501
Inspection Installation
1. Visual inspection 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks, • Tap the ring gear onto the flywheel after
wear, and damage. Repair or replace if there uniformly heating using a gas burner.
are abnormalities. Heating temperature should be less than
• Inspect the ring gear tooth surfaces. Replace 200°C(392°F).
the ring gear if it shows damage or is • When shrink-fitting the ring gear and cooling,
significantly worn. apply a load of 68.6 kN (7,000 kg/15,435 lb)
2. Measurement of friction surface and hold evenly.
• Measure the depth of the flywheel friction NOTE:
surface.
• Install it with the chamfered side of the ring gear
• Repair the flywheel if the measured value is facing the front.
within the standard value and limit value and if it
can be repaired by polishing or sanding. • After shrink-fitting, check that the ring gear is airtight
against the flywheel.
• Replace the flywheel if the measured value
exceeds the limit.
Flywheel friction surface depth mm (in)

Standard values 19(0.74)
Limit 20(0.79)
LNW21BSH012101

2. Install the flywheel. Smoother specifications
3. Install the washer. • Align to the crankshaft knock pin to install the
M/T Specifications spacer.
• Align to the crankshaft knock pin, install the • Align to the flexible plate to the spacer center
flywheel, and tighten in the order shown in the holes and knock pin and install.
diagram. • Align the washer to the knock pin to install.
• Apply molybdenum disulfide to the bolt
threaded portion and seat surface.
• Install the crankshaft stopper to the flywheel
housing starter installation section.
Tightening torque
2nd time 120° - 150°
1 4
6 7
3 2
8 5
LNW71BSH008801
LNW21BSH007701

• Tightening is the same as M/T specifications.
5 4
LNW41BMF001701
Legend
1. Flexible plate 4. Spacer
2. Washer 5. Crankshaft
3. Bolt
5. Tap in the pilot bearing until it touches the crank

4. Install the CKP sensor and tighten at the specified end surface.
torque. 6. Install the clutch disk.
LNW71BSH007501

• Install the clutch disk to the flywheel using the 9. Install the starter to the clutch housing with a bolt,
clutch aligner (1). and tighten at the specified torque.
LNW21BSH002601
Legend
1. Clutch aligner LNW21BSH011501
7. Install the clutch pressure plate. • Install the starter ground cable.
• Align the pressure plate installation hole to the • Connect the front frame harness connector.
knock pin in the flywheel and install the
pressure plate to the flywheel.
• Tighten the pressure plate in the order shown in
the diagram.
1 5
7
3
9
10
4
8 LNW21BSH011601
6 2
LNW21BSH002501
8. Install the transmission Assembly.

the Smoother vehicles.

LNW81BMF001901
(a) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) → 120° - 150°

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(c) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) → 120° - 150°
(d) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
Front Cover
Components
16
3
15
10 4
12 11
13 5
14
6
7
8
LNWA1BLF000501
Legend
1. Adjust plate (50A generator only) 10. Water pump assembly
2. Generator 11. Drive belt
3. Front cover 12. Water pump pulley
4. Oil pan gasket 13. Set plate
5. Oil pan 14. Drive belt adjust pulley assembly (80A generator
6. Rubber assembly only)
7. Front slinger 15. Fan assembly
8. Front oil seal 16. Adjust plate (80A generator only)
9. Crankshaft pulley
Removal 2. Remove the oil pan.

Refer to "Oil Pan" in Section 1H, Engine
1. Remove the front oil seal.
Lubrication (4HK1).
Refer to "Crankshaft Front Oil Seal" in this Section.

3. Remove the water pump. 5. Remove the drive belt adjust pulley assembly (80A
Refer to "Water Pump" in Section 1C, Engine generator only)
Cooling (4HK1).
4. Remove the front cover.
• Remove the generator adjust plate.
LNW81BSH002301
LNW81BSH005001 6. Remove the oil cooler bypass valve.

• Remove the oil cooler bypass valve from the
cylinder block.
• Remove the oil relief valve (arrow) and loosen
the front cover installation bolt to remove the
front cover.
LNW81BSH004801
LNW81BSH003801

Installation
1. Install the oil cooler bypass valve.
• Insert the oil cooler bypass valve(1) to the
position of the arrow on the cylinder block. At
this time, be careful not to mistake the insertion
direction.
1
1
LNW21BSH058701
Legend
1. O-ring
• Align to the cylinder block knock pin to install

LNW81BSH004701
the front cover.
2. Install the front cover. NOTE:

At the same time as the front cover, install the water
• Clean the cylinder block front side. Especially, pump Assembly (before the liquid gasket dries).
clean the liquid gasket that oozes out when the
crankcase is installed. Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
• Install the O-rings (2 pcs.) and apply liquid • The (a) bolt should be tightened together with
gasket (TB1207B) to the groove in the front the generator adjust plate.
cover installation surface.
• Tighten the oil relief valve (5) at the specified
torque.
1.5 - 5 mm
Bead width Tightening torque: 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
(0.059 - 0.197 in)
From aligning surface:
Bead height 0.3 - 1.5 mm 1 2
(0.0118 - 0.059 in)
(1)
• After applying the liquid gasket, install it within 5 a

35
minutes. 4
(2)
5
NOTE: 3
25
Apply the liquid gasket without applying it on the O-ring 2
(1). (3)
2
65
(4)
30
1
LNW81BSH002401

3. Install the drive belt adjust pulley assembly. (80A 5. Install the oil pan.
generator only) Refer to the "Oil Pan" in Section 1H, Engine
Lubrication (4HK1).
6. Install the front oil seal.
4. Install the water pump. Refer to "Crankshaft Front Oil Seal" in this Section.
Refer to "Water Pump" in Section 1C, Engine
Cooling (4HK1).
LNW81BLF002001
(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
Crankshaft Front Oil Seal

Components
3
2
1
LNW81BSF000401
Legend
1. Crankshaft pulley 3. Crankshaft front slinger
2. Crankshaft front oil seal
Removal • Fix it using wires, etc. in a place where it will not

interfere with the work.
2. Remove the starter.
• Disconnect the starter ground cable.
• Disconnect the front frame harness connector
LNW21BSH011601
3. Disconnect the air charge pipe connected to the

intercooler.
4. Remove the radiator upper hose at the engine
LNW21BSH011501
side.
5. Remove the coolant reserve tank hose at the
radiator side.
• Remove the 2 bolts (upper and lower) installing 6. Remove the radiator lower hose at the engine side.
the starter, and remove the starter from the 7. Remove the brackets on the left and right sides of
clutch housing. the radiator (with fan guide) to remove the radiator.

8. Remove the fan assembly. • Be careful not to damage the front cover oil seal
• Remove the 4 installation nuts to remove the installation section and shaft. Use a screwdriver
fan assembly. to pry only the oil seal to remove it.
9. Remove the fan belt.
LNW21BSH002801
LNW71CSH002001 Legend
1. Felt
2. Slinger
10. Remove the crankshaft pulley. 3. Oil seal
• Install the crankshaft stopper to the installation
section of the flywheel housing starter, and
loosen the pulley nut while making sure that the 12. Remove the crankshaft front slinger.
crankshaft does not rotate. • Pull out the slinger using a puller.
(It is easier to pull out by fastening the outer
NOTE: circumference of the puller with a clip band.)
Check that the stopper securely bites into the ring gear Special Tool
and that it is installed. Slinger puller: 5-8840-2360-0
Special Tool
Crankshaft stopper: 5-8840-2230-0
LNW71BSH007601
LNW21BSH012301
Installation
1. Install the front slinger.
11. Remove the crankshaft front oil seal.

• Firmly fit the slinger using the oil seal installer • Cover the sleeve over the adaptor and tighten,
kit. and then firmly fit in the washer to the center
blot all the way to the end until the installation
sleeve touches the adaptor.
4
1
2 5
3 6
LNW21BSH073201
Legend
LNW81BSH003901
1. Front slinger
2. Adaptor (front)
3. Fixing bolt
4. Sleeve (front) • After firmly fitting in the slinger, measure the
5. Washer (front) dimension from the crankshaft end to the oil
6. Center bolt seal lip touching surface. Also check for
fluctuations in the slinger (4 directions).
Special Tool
Oil seal installer kit: 5-8840-2703-0 Slinger press-fitting measurement
(Use the parts in the table below for the front oil (front) mm(in)
seal.)
40.2 - 40.8
Assembly Standard
(1.583 - 1.606)
Oil
No. Parts number Part Name Slinger
seal NOTE:
1 5-8840-2704-0 Sleeve (front) { { Be careful not to mistake the slinger assembly direction
and the front and rear. There is a right, 4-thread screw
Adaptor cut at the rear side, and a left, 4-thread screw cut at the
2 5-8840-2705-0 { {
(front) front side. Always replace the slinger and oil seal as a
Adaptor ring set.
3 5-8840-2706-0 - {
(front)
Washer
4 5-8840-2707-0 { {
(front)
5 5-8840-2713-0 Center bolt { {
6 5-8840-2714-0 Fixing Bolt { {
• Insert the slinger to the leading end of the front

adaptor and install the adapter to the
crankshaft.

• Install the adaptor (1) to the crankshaft with the
fixing bolt.
1
4
5
1
3 2
LNW71BSH011701
Legend
LNW81BSH004001
1. Adaptor
2. Sleeve Legend
3. Slinger 1. Adaptor
4. 40.2 - 40.8 mm (1.583 - 1.606 in)
5. 33.9 - 34.1 mm (1.335 - 1.343 in)
• Thinly apply engine oil to the oil seal (1) lip

2. Install the front oil seal. section, and set to the front adaptor.
• Firmly fit the oil seal using the oil seal installer
NOTE:
kit.
Always apply oil to the lip section of the oil seal.
• Put the front adaptor ring (2) into the sleeve (3)
and set to the adaptor using the center bolt and
washer (4).
5
2 4
7
1 3 6
LNW21BSH073301
Legend
1. Oil seal
2. Adaptor (front)
3. Adaptor ring (front)
4. Fixing bolt
5. Sleeve (front)
6. Washer (front)
7. Center bolt

• Tighten until the sleeve touches the adaptor
and firmly fit the front oil seal.
4 1
1 2 3 4
2
a
3
MFW81BSH001101
Legend
LNW81BSH004101
1. Adaptor ring
Legend 2. Sleeve
1. Oil seal 3. Adaptor
2. Adaptor ring 4. Oil seal
3. Sleeve 5. a:30.7 - 31.3 mm(1.21 - 1.23 in)
4. Washer
3. Install the crankshaft pulley.

• Apply engine oil to the threaded portion of the
tightening bolt.
• Align to the crankshaft knock pin, and install the
crank pulley.
• Tighten in the order shown in the diagram.
3 4
LNW81BSH003901
2
• After firmly fitting the front oil seal, measure the
dimension from the crankshaft end surface to
the oil seal surface. Also check for fluctuations
in the oil seal (4 directions).
LNW71BSH007701
Oil seal press-fitting measurement

(front) mm(in) 4. Install and adjust the fan belt.
Refer to "Drive Belt" in Section 1C, Engine Cooling
30.7 - 31.3
Assembly Standard (4HK1).
(1.21 - 1.23)

5. Install the fan assembly and tighten it at its
specified torque.
LNWA1BSH000301
7. Install the radiator lower hose.

LNW71CSH002001
Radiator hose clip

6. Install the radiator.
• Be careful not to scratch the radiator fins 8. Install the coolant reserve tank hose.
withthe fan blades.
9. Install the radiator upper hose.
• Install the radiator bracket to the frame side
Radiator hose clip
Frame side bracket from radiator bracket Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
10. Install the air charge pipe to the intercooler.
• When removing the frame side bracket, tighten 11. Install the starter to the housing with a mounting
at the specified torque. bolt, and tighten it at the specified torque.
Frame from frame side bracket • Install the starter ground cable.

• Connect the front frame harness connector. 12. Refill the coolant.
LNW21BSH011601
LNW81BSF000501
(a) 200N⋅m (20.4kg⋅m / 148 lb⋅ft)

Crankshaft Rear Oil Seal

Components
7
6
9 8
LNW81BLF002501
Legend
1. Starter 6. Crankshaft rear oil seal
2. Transmission Assembly 7. Crankshaft rear slinger
3. Clutch pressure plate (M/T vehicle) 8. Flexible plate (Smoother vehicle)
4. Clutch disk (M/T vehicle) 9. Crank end spacer (Smoother vehicle)
5. Flywheel (M/T vehicle)
Removal 3. Remove the rear oil seal.

1. Remove the transmission assembly.
Refer to "Flywheel" in this Section.

• Be careful not to damage the flywheel housing • Firmly fit the slinger using the oil seal installer
oil seal installation section and shaft. Use a kit.
screwdriver to pry only the oil seal to remove it.
3
1 3
2
2
5
6 4
LNW21BSH073401
LNW21BSH002801
Legend
Legend 1. Rear slinger
1. Felt 2. Fixing bolt
2. Slinger 3. Center bolt
3. Oil seal 4. Sleeve (rear)
5. Collar (rear)
6. Adaptor (rear)
4. Remove the rear slinger.
• Pull out the slinger using a puller. Special Tool
(It is easier to pull out by fastening the outer Oil seal installer kit: 5-8840-2703-0
circumference of the puller with a clip band.)
Special Tool No. Parts number Part Name Slinger Oil seal
Slinger puller: 5-8840-2360-0 Sleeve
1 5-8840-2708-0 { {
(rear)
Adaptor
2 5-8840-2709-0 { {
(rear)
3 5-8840-2710-0 Collar (rear) { {
Adaptor
4 5-8840-2711-0 - {
Ring (Rear)
5 5-8840-2713-0 Center bolt { {
6 5-8840-2714-0 Fixing Bolt { {
NOTE:
An engine sleeve (5-8840-2712-0) for engines before
'93.5 models is included in the oil seal installer kit, but it
will not be used with this engine.
LNW21BSH002901
Installation
1. Install the rear slinger.

• Insert the slinger to the leading end of the rear • After firmly fitting in the slinger, measure the
adaptor (3), install the collar (1) to the fixing bolt dimension from the crankshaft end to the oil
(3), and install the adapter to the crankshaft. seal lip touching surface. Also check for
fluctuations in the slinger (4 directions).
Slinger press-fitting measurement (rear) mm (in)

17.0 - 17.6
1 Assembly Standard
(0.6693 - 0.6929)
NOTE:
Be careful not to mistake the slinger assembly direction
2 and the front and rear. There is a right, 4-thread screw
cut at the rear side, and a left, 4-thread screw cut at the
front side. Always replace the slinger and oil seal as a
set.
3
LNW21BSH014501
1
Legend
1. Collar
2. Fixing bolt 2
3. Adaptor
3
4
5
• Cover the slinger over the adaptor and tighten

the center bolt all the way to the end until the 6
sleeve touches the adaptor and firmly fit the
7
slinger.
LNW21BSH014301
Legend
1. Crankshaft
2. Adaptor
3. 17.0 - 17.6 mm(0.6693 - 0.6929 in)
4. 10.7 - 10.9 mm(0.4213 - 0.4291 in)
5. Slinger
6. Sleeve
7. Collar
2. Install the rear oil seal.
LNW21BSH014701

• Firmly fit the oil seal using the oil seal installer • Thinly apply engine oil to the oil seal lip section,
kit. and set the rear oil seal to the rear adaptor.
NOTE:
Always apply oil to the lip section of the seal.
• Put the rear adaptor ring (2) into the sleeve (1)
and set to the adaptor and install the center
1 2 3 bolt.
7 6 5 4
LNW21BSH073501
Legend
1. Adaptor (rear)
2. Fixing bolt 2
3. Center bolt
4. Sleeve (rear)
5. Collar (rear) LNW21BSH014601
6. Adaptor ring (rear)
7. Oil seal Legend
1. Sleeve
2. Adaptor ring
• Install the collar (1) to the fixing bolt (2), and

install the adaptor (3) to the crankshaft.
• Tighten the center bolt all the way to the end
until the sleeve touches the adaptor, and firmly
fit the oil seal.
LNW21BSH014501
Legend
1. Collar LNW21BSH014701
2. Fixing bolt
3. Adaptor

• After firmly fitting the oil seal, measure the
dimension from the crankshaft end surface to
the oil seal surface. Also check for fluctuations
in the oil seal (4 directions).
Oil seal press-fitting measurement (rear) mm (in)

7.5 - 8.1
Assembly Standard
(0.2953 - 0.3189)
1
2
7
3
6
5
LNW21BSH014801
Legend
1. Crankshaft
2. Oil seal
3. 7.5 - 8.1 mm(0.2953 - 0.3189 in)
4. Collar
5. Adaptor ring
6. Sleeve
7. Adaptor

Refer to "Flywheel" in this Section.
the Smoother vehicles.
Piston and Connecting Rod

Components
1 2
2
3
6
4
MFW71BLF000601
Legend
1. Piston ring 5. Connecting rod cap
2. Snap ring 6. Connecting rod
3. Piston 7. Piston pin
4. Bearing
Removal 4. Remove the camshaft assembly.

Refer to the "Oil Pan" in Section 1H, Engine Refer to "Cylinder Head" in this Section.
Lubrication (4HK1).
6. Remove the connecting rod cap.
Refer to "Cylinder Head Cover" in this Section. NOTE:
3. Remove the rocker arm shaft assembly. Organize the removed bearings according to the
Refer to "Rocker Arm Shaft Assembly" in this cylinders using tags, etc.
Section.

Disassembly
1. Remove the piston ring.
• Remove the piston ring using the ring pliers.
NOTE:
When reusing the piston rings, organize them
according to the order of the cylinders so that other
cylinder pistons and piston rings do not get mistaken.
LNW21BSH004901
7. Remove the piston and connecting rod.

• Remove carbon from the top of the cylinder
liner using a scraper.
• Pull out the piston and connecting rod out to the
cylinder head side.
NOTE: LNW21BSH005101
When pushing out the connecting rod, be careful not to

damage the oil jet and cylinder liner.
2. Remove the snap ring (1).
3. Remove the piston pin.
NOTE:
Organize the disassembled piston pin, piston and
connecting rods according to the cylinders.
LNW21BSH005001
1
8. Remove the connecting rod bearing.
NOTE:
When reusing the bearing, organize them according to MFW41BSH016101
the order of the cylinders so that other cylinder
bearings do not get mistaken.
4. Remove the connecting rods from the pistons.
5. Piston

• Carefully clean carbon from the piston heads
and piston ring grooves.
NOTE:
Do not use a wire brush to clean the pistons.
Visually inspect the pistons for cracks, seizure or other
excessive wear. If there is an abnormality, replace the
piston.
6. Remove the bush.

• Set the collar (6), connecting rods (2) and collar
(4) on the setting bar (1) as shown in the
diagram.
• Tighten the nut (3).
2 1
LNW21BSH010001
1
Legend
1. Fixing bolt
2. Base
2
4 Inspection
1. Measure the gap between the piston and the inner
5 diameter of the cylinder liner.
Inner diameter of cylinder liner
• Use the cylinder bore gauge to measure the
6 liner inner diameter in the thrust direction and
3 the radial direction at the specified position.
LNW46ASH005001
• Measuring position (From top surface of the
Legend cylinder block)
1. Setting bar 1) 20 mm(0.79 in), 2) 110 mm(4.33 in), 3) 190
2. Connecting rod mm(7.48 in)
3. Nut
• Find the liner inner diameter according to the
4. Collar
average value of the 6 locations actually
5. Bush
measured.
6. Collar
Inner diameter of cylinder liner mm(in)
• Place the connecting rod bush replacer base 115.031 - 115.050 (4.52877 - 4.52952)
(2) on the bench press and tighten the fixing
bolts (1).
• Use the bench press to remove the bushing.
Special Tool
Connecting rod bush replacer:
5-8840-2340-0
2
3
2. Replace the piston

Piston outer diameter
• There is only 1 type of grade of the piston and
• Use a micrometer to measure the piston pin of
the inner diameter of the cylinder liner. There is
the specified position and the outer diameter of
no need to select the grade.
the piston at the perpendicular direction.
However, when replacing the cylinder liner,
• Measuring position (From top surface of the there are 2 types of liner outer diameters (1x,
piston) 85 mm(3.35 in) 3x), so it is necessary to select for the cylinder
blocks (1, 2, and 3).
Piston outer diameter mm(in) • Refer to section "Cylinder Block" for repla-
cement of the cylinder liner.
114.944 - 114.979
Standard values
(4.52535 - 4.52672) NOTE:
Grades A, B, and C are marked on the top of the piston
when shipped from the factory.
Gap between the inner diameter of the piston mm
and cylinder liner (in)
0.052 - 0.106
Standard values
(0.00205 - 0.00417)
NOTE:
• The dimensions above are of the liner and piston for
service replenishment.
• If the measurement reveals that the gaps between
the pistons and cylinder liners exceed the standard
values, replace the pistons or cylinder liners.
LNW46ASH004501
Legend
1. Front mark

3. Inspect the piston ring. 0.27 - 0.56 1.20
Measurement of the piston ring joint (remove the Oil ring
(0.01063 - 0.02205) (0.04724)
carbon from the ring joint)
• Insert the piston ring into the cylinder liner. Measure the clearance between the piston ring
• Push the ring into the lower end of the cylinder groove and the piston ring.
liner using the piston. • Remove all carbon in the piston ring groove.
• Insert the piston ring into the piston ring groove,
and measure the gap with the thickness gauge.
• If the clearance between the piston ring groove
and the piston ring exceeds the standard value,
replace the piston or piston ring.
NOTE:
The No.1 compression ring cannot be measured
because of the half keystone ring.
Clearance of the piston ring and ring mm

groove: (in)
Piston ring: Standard values Limit
NO.1 Compression
– –
ring
LNW21BSH009301
NO.2 Compression 0.015 - 0.055 0.15
• Use a thickness gauge to measure the ring joint
ring (0.00059 - 0.00217) (0.00591)
gap.
0.03 - 0.07 0.15
Oil ring
(0.00118 - 0.00276) (0.00591)
LNW61BSH000901
• Replace the piston ring if the measured value

exceeds the limit.
LNW21BSH009501
mm
Piston ring joint gap
(in)
4. Inspect the piston pin.
Piston ring: Standard values Limit • Visually inspect the piston pin for cracks,
NO.1 Compression 0.27 - 0.46 1.20 scratches or other damages, and replace it as
ring (0.01063 - 0.01811) (0.04724) necessary.
NO.2 Compression 0.37 - 0.61 1.20 • Use a micrometer to measure the outer
ring (0.01457 - 0.02402) (0.04724) diameter of the piston pin. Replace the piston
pin if the measured value exceeds the limit.
Piston pin outer diameter mm(in) Clearance of connecting rod small end and mm
piston pin outer diameter (in)
39.995 - 40.000
Standard values
(1.57460 - 1.57480) 0.012 - 0.027
Standard values
(0.00047 - 0.00106)
Limit 39.970(1.57362)
Limit 0.05(0.00197)
LNW21BSH009601
LNW21BSH009801
• Inspect for a certain degree of resistance when

the piston pin is lightly pushed in, when the 5. Measure the clearance between the piston and the
piston is at room temperature. piston pin.
• Replace the piston or the piston pin if they feel • Apply engine oil to the piston pin. Then,
loose at room temperature. manually push it into the piston hole and rotate
it. If the pin rotates smoothly without any
looseness, the clearance is normal. If there is
looseness, measure the clearance. Replace the
piston and piston pin if the clearance exceeds
the limit.
mm
Clearance between piston and piston pin
(in)
0.009 - 0.022
Standard values
(0.00035 - 0.00087)
Limit 0.04(0.00157)
6. Measure the connecting rod alignment.

• Use the connecting rod aligner to measure the
LNW21BSH009701 twisting of the large end hole and small end
hole, and the degree of parallelization. Make
replacements if the measured value exceeds
the limit.
• Measure the inner diameter of the connecting
rod small end bush. If the clearance between
the bush inner diameter and pin outer diameter, Connecting rod alignment mm
replace the bush or the connecting rod for 100 mm (3.937 in) (in)
assembly, and pin.
Twisting 0.05 0.20

(0.00197) (0.00787)
Degree of 0.05 0.20
parallelization (0.00197) (0.00787)
LNW21BSH010501
- Remove the cap.

- Measure the widest width area of the
plastigauge to find the oil clearance.
LNW21BSH010401
Replace the bearings in sets if the clearance
exceeds the limit.
7. Measure the bearing oil clearance.

Pin oil clearance mm(in)
• Use the following method to measure the oil
clearance between the connecting rod bearing 0.037 - 0.076
Standard values
and crank pin. (0.00146 - 0.00299)
- Remove the connecting rod caps. Set the Limit 0.10(0.00394)
removed caps in the order of the cylinder
number.
- Remove the plastigauge from the bearing
- Clean the bearing and crankshaft pin. and crank pin.
- Inspect the bearing. Replace the bearings in
sets if there is damage or excessive wear.
• Place the plastigauge on the crankshaft pin.
• Install the bearing cap, and tighten the bolt at its
specified torque.
Apply molybdenum disulfide to the threaded
portion and seat surface.
Tightening torque
2nd time Rotating angle 60°
3rd time Rotating angle 30°
NOTE:
Do not rotate the crankshaft.
LNW21BSH010601
8. Select the connecting rod bearing.

• Select the bearing from the table when
installing a new one or replacing a bearing in
use.

• Select the bearing by carefully considering the
grade of the large end diameter of the
connecting rod for installation.
1
1
1
2 3
LNW21BSH010801
Legend
1. Grade identification color
LNW71BSH009101
Legend
1. Front and back side discrimination boss
Reassembly
2. Diameter grade of large end hole mark
3. Cylinder number 1. Installation of the bush
• Place the connecting rod bush replacer base
(2) on the bench press, set the connecting rod,
and tighten the fixing bolts (1).
Bearing selection table
Large end Bearing
hole Identification
Oil clearance
diameter color mm
Grade (in)
0.037 - 0.076
A Green
(0.00146-0.00299)
0.037 - 0.076
B Yellow
(0.00146-0.00299)
2 1
LNW21BSH010001
Legend
1. Fixing bolt
2. Base
• Set the collar (6), new bush (5) and collar (4) on
the setting bar (1) as shown in the diagram.
• Tighten the nut (3).

• Align the connecting rod oil hole and bush oil • Install 1 side of the snap ring using the long-
hole, and use the bench press to install the nose pliers.
bush.
2
4
6
MFW61BSH001601
3
LNW46ASH005001
Legend
1. Setting bar
2. Connecting rod
3. Nut 1
4. Collar
5. Bush
6. Collar
2
• After assembling the new bush, use a grinder to
finish the pin hole so that the pin and clearance
are at the standard value.
LNW81BSH003201
Legend
1. Front mark
2. Convex mark
4. Apply an adequate amount of engine oil to the

piston pin. Then, push it into the piston and
connecting rod small end.
5. Install the snap ring using long-nose pliers.
NOTE:
Check that the snap ring is securely installed in the ring
LNW21BSH010301
groove. Check that the connecting rod slides smoothly.
2. Install the piston.

3. Install the connecting rod.
• Assemble so that the piston head front mark (1)
and connecting rod cast mark (convex) (2) face
same directions.
6. Install the piston ring using the ring pliers. Installation

• Install the oil ring so that the coil expander joint
1. Install the connecting rod bearing.
is 180° in the opposite direction.
• Install the bearing to the connecting rod, and
• The compression ring is installed with the mark
apply engine oil to the bearing.
facing upward, and install in the order of No.2
and No.1 compression rings. 2. Install the piston and connecting rod assembly.
• Thoroughly apply engine oil to the piston ring,
ring groove and piston side surface.
• Shift the piston ring joint in intervals of 120°, as
shown in the drawing, assigning (1) for the ring
No. 1, (3) for the ring No. 2, and (2) for the oil
ring.
1
• Face the piston front mark towards the front,
and insert the piston into the cylinder liner using
2
the setting tool.
NOTE:
3 • When pushing in the piston, firmly attach the setting
tool to the cylinder liner and push in. If the
adherence is inadequate, the ring can be damaged
when pushed.
• When pushing the piston, be careful not to touch the
oil jet against the connecting rod.
MFW61BSH000101
• Be careful not to damage the inner surface of the
Legend liner when inserting the piston.
1. Compression ring No.1
2. Compression ring No.2
3. Oil ring
NOTE:
Check that there is no gap at the position of the arrow
in the diagram when the oil ring coil expander is
installed.

• Apply molybdenum disulfide to the threaded
Special Tool portion of the mounting bolts and seat surface.
Piston setting tool: 5-8840-9018-0 Tighten at the specified torques.
Tightening torque
2
2nd time Rotating angle 60°
3rd time Rotating angle 30°
3
Special Tool
Angle gauge: 5-8840-0266-0
1
NOTE:
4 Check that the crankshaft turns smoothly.
MFW71BSH002601
Legend
1. No.1 compression ring joint
2. No.2 compression ring joint
3. Oil ring joint
4. Front mark
3. Install the connecting rod cap.

• Install the bearing to the connecting rod cap
and apply engine oil.
• Align the cap and the connecting rod number
markings (1, 2, 3, 4) and install the cap.
LNW21BSH011401

1
Section.
1 8. Install the oil pan.
1
2 3 Refer to the "Oil Pan" in Section 1H, Engine
Lubrication (4HK1).
LNW71BSH009101
Legend
1. Front and back side discrimination boss
2. Diameter grade of large end hole mark
3. Cylinder number

MFW71BMF000101
(a) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) → 60° → 30°

Crankshaft
Components
1
3
LNWB1BLF003101
Legend
1. Upper bearing 5. Lower bearing
2. Thrust bearing upper 6. Thrust bearing lower
3. Gear 7. Crankcase
4. Crankshaft
Removal 4. Remove the oil pan.

Refer to the "Oil Pan" in Section 1H, Engine
1. Remove the engine assembly from the vehicle.
Lubrication (4HK1).
Refer to "Engine Assembly" in this Section.
5. Remove the water pump.
Cooling (4HK1).
3. Remove the supply pump.
6. Remove the front cover.
Refer to "Supply Pump" in Section 1D, Engine Fuel
Refer to "Front Cover" in this Section.
(4HK1).
7. Remove the timing gear train.
Refer to "Timing Gear Train" in this Section.

8. Remove the crankshaft front oil seal. 16. Remove the thrust bearing upper.
Refer to "Crankshaft Front Oil Seal" in this Section. 17. Remove the upper bearing.
9. Remove the crankshaft rear oil seal.
10. Remove the oil pump.
Refer to "Oil Pump" in Section 1H, Engine
Lubrication (4HK1).
11. Remove the piston and connecting rod.
Refer to "Piston and Connecting Rod" in this
Section.
12. Remove the crankcase.
• Gradually loosen the crankcase installation bolt
in the order shown in the drawing, and use the
3 replacer holes (at the arrows in the diagram)
to remove it.
3 7 11 15 16 12 8 LNW21BSH023801
1
4
Disassembly
18 22 26 25 21
1. Remove the gear.
• Use the gear puller to remove it.
19 23 27 24 20
Special Tool
Crankshaft gear puller: 8-9439-6818-0
2 6 10
14 17 13 9 5
LNW21BSH023601
13. Remove the thrust bearing lower.

14. Remove the crankshaft lower bearing.
LNW21BSH023901
Reassembly
1. Install the gear.
• Warm the gear to 170 - 250°C(338 - 482°F) and
align the gear side groove with the pin position
at the backside of the crankshaft and install
them.
LNW21BSH023701
15. Remove the crankshaft assembly.


• When installing, face the alignment mark "S" (1)
of the gear edge surface towards the outside
and insert at once up to the rim. When it is
cooling, use the installer to tap into until it
touches the end.
Special Tool
Crankshaft gear installer: 8-9439-6819-0
LNW21BSH024001
2. Main bearing clearance

• Remove the crankcase.
The removed main bearing should be lined in
the order of the number.
• Remove the crankshaft. Remove the main
LNW21BSH025101 bearing.
Legend • Clean the crankshaft journal and top/bottom
1. Alignment mark (S) bearings.
• Inspect the bearings for damage and excess
wear.
Inspection If damage and excess wear is found during the
inspection, replace the bearings in sets.
1. Thrust clearance
• Set the upper bearing and crankshaft to the
• As shown in the diagram, set a dial indicator cylinder block. Install the crankshaft to be level.
and measure the crankshaft thrust clearance.
• Replace the thrust bearing in sets if the thrust NOTE:
clearance exceeds the limit. Turn the crankshaft approximately 30° to stabilize the
bearing.
Play in the crankshaft axis direction mm
(in)
0.040 - 0.205
Standard values
(0.00157 - 0.00807)
NOTE:
Measure the thrust clearance prior to disassembly.
LNW21BSH024101

• As shown in the diagram, place the plastigauge
on the crankshaft journal.
• Set the lower bearing to the original position of
the crankcase. 25 21 17 13 12 16 20
27
24
10 6 2 3 7
9 5 1 4 8
26 22 18
14 11 15 19 23
LNW21BSH022601
Tightening torque
LNW21BSH024201 M14 (1) to (10)
1st time 98 N⋅m (10.0 kg⋅m/72 lb⋅ft)
• Install the crankcase and tighten the bolt at the 2nd time 132 N⋅m (13.5 kg⋅m/98 lb⋅ft)
specified torque. 3rd time 30° - 60°
• Use a torque wrench and angle gauge to M10 (11) to (27)
tighten the crankcase in the order shown in the 4th time 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
diagram.
• Tighten the 1 to 10 bolts (M14) in the tightening
direction. Check that they are tightened at a
torque beyond 167 N⋅m (17 kg⋅m/123 lb⋅ft).
Special Tool
Angle gauge: 5-8840-0266-0
NOTE:
After tightening the crankcase, do not turn the
crankshaft.
• Loosen the bolts and gently remove the

crankcase.
• Measure the maximum width portion of the
plastigauge crushed by tightening the
crankcase to determine clearance.
LNW21BSH024301
Journal oil clearance mm(in)
Standard values
No.1,2,4,5 0.039 - 0.070(0.0015 - 0.0028)
No.3 0.053 - 0.084(0.0021 - 0.0033)
• Replace all sets of main bearings or the 4. Measure the journal and crank pin diameter and
crankshaft if the oil clearance exceeds the limit. uneven wear.
• Remove the plastigauge from the bearing and • Use a micrometer to measure the journal and
crankshaft. pin outer diameters to calculate difference of
the maximum and minimum. Measure in 4
Inspection of the crankshaft sections on the journal and on the pin.
• Inspect the crankshaft journal and crank pin
surface for wear and damage. Inspect the oil
seal installation surface for excess wear and
damage.
• Inspect the oil port for clogging.
3. Crankshaft runout
Carefully set the crankshaft to the V-block. Slowly
rotate the crankshaft to measure runout. Replace
the crankshaft if the crankshaft runout exceeds the
limit.
Crankshaft runout mm(in)

LNW21BSH024601
Crankshaft outer diameter mm(in)

Standard values
81.905 - 81.925
Journal #1,#2,#4,#5
(3.2246- 3.2254)
81.891 - 81.911
Journal #3
(3.2241 - 3.2248)
72.902 - 72.922
Pin
(2.8702 - 2.8709)

NOTE: • Do not let any inspection liquid get in your eyes, on
Repairs must not be done because TUFFTRIDE (soft your hands or cloths. If some of the liquid gets in
nitriding) is implemented to increase the strength of the your eyes, wash them immediately with large
crankshaft. volumes of fresh water and seek medical
treatment.
Inspection of the TUFFTRIDE layer of the
crankshaft Selection of the crankshaft bearing
1. Use an organic detergent to thoroughly clean the • Refer to the bearing selection table to install a new
crankshaft. Completely remove the oil from the test crankshaft bearing or to replace one in use.
locations. • Be careful of the journal hole inner diameter grade
2. Prepare a solution of copper chloride ammonium of the cylinder block and the crankshaft journal
of 5 to 10% (diluted with diluting water). diameter grade in selecting a new bearing.
3. Use an oil drop to apply the solution to the test • The journal numbers are #1 to #5 from the left in
locations. Maintain the inspection surface at a the direction that the characters are read.
complete level so that the solution does not flow.
2
1
LNW21BSH024701
LNW21BSH038001
Legend
1. Drip prohibited area
2. Test liquid drop section
3. Pin or journal moving surface
NOTE:
Do not allow the solution to approach the oil port.
Determination
• Wait 30 to 40 seconds.
• If the color does not change after 30 or 40
seconds, the crankshaft can be used. If the color
changes (test surface turns copper-colored)
(indicating a residual layer of TUFFTRIDE),
replace the crankshaft.
CAUTION:
• The inspection liquid is highly corrosive, so when LNW21BSH024801
finished, wipe it away with a cloth immediately and

clean with water or steam. NOTE:
Be careful not to mistake the bearing shape when
installing.
1 2
3
4
6
LNW21BSH024901
Legend
1. Upper bearing
2. Oil hole
4. Oil groove
5. Lower bearing
Bearing selection table

Grade combination Oil clearance mm(in)
Cylinder block Crank journal Bearing
#1,2,4,5 #3
Grade Grade identification color
0.041 - 0.068 0.055 - 0.082
1 1 Black
(0.00161 - 0.00268) (0.00218 - 0.00323)
0.039 - 0.065 0.053 - 0.079
1 2 Brown
(0.00154 - 0.00256) (0.00209 - 0.00311)
0.043 - 0.070 0.057 - 0.084
2 1 Blue
(0.00169 - 0.00276) (0.00224 - 0.00331)
0.041 - 0.067 0.055 - 0.081
2 2 Black
(0.00161 - 0.00264) (0.00217 - 0.00319)
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing to the cylinder block
and apply oil.
NOTE:
When replacing the crankshaft bearing, select the
grade upon referring to the selection of the crankshaft
bearing grade. Do not apply oil to the cylinder block
bearing installation surface or the outer circumference
of the bearing.

NOTE:
Install so that the oil groove of the thrust bearing
touches the crankshaft.
LNW21BSH025201
2. Install the thrust bearing upper.

• Install the thrust bearing upper to the cylinder LNW21BSH025401
block No.5 journal section front side. When
doing so, it is acceptable to use grease to
adhere the bearing upper to the cylinder block. 4. Install the crankshaft lower bearing.
However, wipe away any excess grease. 5. Install the thrust bearing lower.
• Install the thrust bearing lower to the crankcase
NOTE: No. 5 journal rear side.
Install so that the oil groove of the thrust bearing
• Install so that the oil groove of the thrust
touches the crankshaft.
bearing touches the crankshaft.
LNW21BSH025501
LNW21BSH025301
6. Install the crankcase.

3. Install the crankshaft assembly.
• Apply engine oil to the crankshaft journal and
gently place it on the cylinder block.
• Push the installed crankshaft against the rear
side, and insert the thrust bearing upper to the
cylinder block No.5 journal section rear side.

• Apply liquid gasket (TB1207B) to the cra-
nkcase in a width of approx. 3 to 4 mm(0.12 to
0.16 in).
25 21 17 13 12 16 20
27
24
10 6 2 3 7
9 5 1 4 8
26 22 18
14 11 15 19 23
1 2
LNW21BSH022601
LNW81BSH002001
7. Install the piston and connecting rod.
Legend Section.
1. 2 - 3 mm(0.08 - 0.12 in)
8. Install the oil pump.
2. 3 - 4 mm(0.12 - 0.16 in)
Lubrication (4HK1).
9. Install the timing gear train.
• After applying the liquid gasket, install it within 5 Refer to "Timing Gear Train" in this Section.
minutes. 10. Install the crankshaft rear oil seal.
• Gently place the crankcase on the cylinder Refer to "Crankshaft Rear Oil Seal" in this Section.
block. 11. Install the front cover.
• Apply molybdenum disulfide to the threaded Refer to "Front Cover" in this Section.
portion of the M14 bolt and seat surface, and 12. Install the crankshaft front oil seal.
tighten at the specified torque in the numbered Refer to "Crankshaft Front Oil Seal" in this Section.
order in the diagram. 13. Install the water pump.
• Do not apply engine oil to the M10 bolt. Refer to "Water Pump" in Section 1C, Engine
Cooling (4HK1).
14. Install the oil pan.
Tightening torque
M14 bolts (1) to (10) Lubrication (4HK1).
1st time 98 N⋅m(10.0 kg⋅m/72 lb⋅ft) 15. Install the supply pump.
2nd time 132 N⋅m(13.5 kg⋅m/98 lb⋅ft) Refer to "Supply Pump" in Section 1D, Engine Fuel
(4HK1).
3rd time 30° - 60°
M10 bolts (11) to (27) Refer to "Cylinder Head" in this Section.
4th time 38 N⋅m(3.9 kg⋅m/28 lb⋅ft) 17. Install the engine assembly to the vehicle.
• Tighten the 1 to 10 bolts (M14) in the tightening
direction. Check that they are tightened at a
torque beyond 167 N⋅m(17 kg⋅m/123 lb⋅ft).
Special Tool
Angle gauge: 5-8840-0266-0
NOTE:
Check that the crankshaft turns smoothly.

LNW71BLF002201
(a) M14: 98 N⋅m (10.0 kg⋅m / 72 lb⋅ft)→132 N⋅m (13.5 kg⋅m / 98 lb⋅ft)→30° - 60°
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
Cylinder Block
Components
LNW81BLF002101
Legend
1. Cylinder liner 2. Cylinder block
Removal 5. Remove the water pump.

1. Remove the engine assembly from the vehicle.
Cooling (4HK1).
Refer to "Engine Assembly" in this Section. 6. Remove the front cover.
2. Remove the cylinder head. Refer to "Front Cover" in this Section.
Refer to "Cylinder Head" in this Section. 7. Remove the timing gear train.
3. Remove the supply pump. Refer to "Timing Gear Train" in this Section.
Refer to "Supply Pump" in Section 1D, Engine Fuel 8. Remove the oil pump.
(4HK1). Refer to "Oil Pump" in Section 1H, Engine
4. Remove the oil pan. Lubrication (4HK1).
Refer to the "Oil Pan" in Section 1H, Engine 9. Remove the piston and connecting rod.
Lubrication (4HK1). Refer to "Piston and Connecting Rod" in this
Section.

10. Remove the crankshaft. • Inspect the inner surface of the liner for
Refer to "Crankshaft" in this Section. scratches or damage.
11. Remove the piston oil jet. • For the liner inner diameter, measure the
maximum wear (much wear in rotation
direction) of approximately 15 to 20 mm(0.59 to
0.79 in) position from the liner surface with the
cylinder block installed. Replace the liner if that
exceeds the use limit.
LNW21BSH026401
12. Remove the cylinder liner.
Inspection
LNW61BSH004001
1. Gently remove foreign materials such as water
deposit adhering to the top surface of the cylinder
block. Inner diameter of cylinder liner mm(in)
• Be careful not to damage the cylinder block.
Standard 115.021 - 115.050
2. Gently remove the liquid gasket on the crankcase values (4.52838 - 4.52952)
installation surface.
115.20
3. Clean the cylinder block. Limit
(4.53542)
4. Visually inspect the cylinder block.
• Perform the collar check and water pressure (or NOTE:
air pressure) test, and replace the cylinder There is only 1 type of replacement cylinder liner bore
block if cracks or other damage is found. (inner diameter). There is no need to select the grade.
6. Measure the flatness.

• Pull out the cylinder liner and remove all water
deposit on the top of the cylinder block.
• Use a simple straight ruler and thickness gauge
to measure the 4 sides of the cylinder block top
surface and 2 locations in a diagonal line.
• Replace the cylinder block if the measured
value exceeds the limit.
Deformation on the cylinder block top

surface mm (in)
Limit 0.20(0.0079)
LNW81BSH004501
5. Measurement of cylinder liner wear

Cylinder block Inner 118.001 - 118.020

diameter (4.64570 - 4.64645)
Lining outer diameter 117.981 - 118.000
(4.64491 - 4.64566)
Grade (3) • (3X)
Cylinder block Inner 118.021 - 118.030
diameter (4.64649 - 4.64684)
Lining outer diameter 118.001 - 118.010
(4.64570 -4.64605)
(Reference)
When replacing the liner, replenishment with
the "liner set" can be performed by replenishing
the liner with piston grade that matches the
inner diameter of the liner, per cylinder, if the
LNW21BSH026901 liner outer diameter grade is specified.
2. Install the cylinder liner.
• Install straight into the cylinder block.
Installation
• Do not tap or apply excessive force when
1. Selection of the cylinder liner grade inserting the liner.
• The cylinder block inner diameter grades are
marked at the arrows in the diagram of the NOTE:
cylinder block. Select the liner depending on Thoroughly clean the cylinder block and cylinder liner
the outer diameter grade of that. and install them after air-blowing.
• Matching grades for cylinder block and liner
outer diameter
Cylinder block (marked) 1,2 3

Lining outer diameter 1X 3X
LNW21BSH027101
3. Protrusion amount of the cylinder liner

Use a dial indicator to measure the protrusion
amount of cylinder liner.
The difference of protrusion amounts of adjacent
LNW81BSH004401 cylinder liner should not exceed 0.03 mm(0.00118
in).
Cylinder block inner diameter, liner grade

Projection amount of the cylinder liner mm (in)
(reference) mm(in)
0.05 - 0.10
Grade (1,2) • (1X) Standard values
(0.00197 - 0.00394)

NOTE: 8. Install the timing gear train.
After replacing the cylinder liner, always measure the Refer to "Timing Gear Train" in this Section.
protrusion amount of the cylinder liner. 9. Install the front cover.
Refer to "Front Cover" in this Section.
10. Install the water pump.
Cooling (4HK1).
Lubrication (4HK1).
12. Install the supply pump.
Refer to "Supply Pump" in Section 1D Engine Fuel
(4HK1).
14. Install the engine assembly to the vehicle.
LNW21BSH026801
4. Install the piston oil jet.

• Align the oil jet knock pin to the cylinder block
pin hole and tighten with a check valve.
NOTE:
Be careful not to deform or damage the oil jet nozzle.
LNW21BSH065701
5. Install the crankshaft.

Refer to "Crankshaft" in this Section.
6. Install the piston and connecting rod.
Section.
7. Install the oil pump.
Lubrication (4HK1).

LNW71BSF000801
(a) 21 N⋅m (2.1 kg⋅m / 15 lb⋅ft)

Engine Cooling (4HK1) 1C-1
ENGINE
Engine Cooling
(4HK1)
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1C-2
Functional and Operational Description . . . . . . 1C-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . 1C-6
Failure Symptom List . . . . . . . . . . . . . . . . . . . 1C-10
Phenomenon:The Engine has Overheated. . . 1C-11
Phenomenon:The Engine has Overcooled. . . 1C-12
Primary Specifications. . . . . . . . . . . . . . . . . . . 1C-12
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
List of Tightening Torques . . . . . . . . . . . . . . . . 1C-17
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Engine Coolant Temperature Sensor . . . . . . . . . 1C-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-26
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-28
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-29
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-30
List of Tightening Torques . . . . . . . . . . . . . . . . 1C-32
1C-2 Engine Cooling (4HK1)
Cooling System
Maintenance Precautions Functional and Operational Description
WARNING: Coolant System
Do not loosen or remove the radiator cap when the The coolant system is a force-circulation type system,
coolant is hot. Steam and boiling water can burst out and its main components are a water pump, thermostat
from the radiator possibly causing burns or heat related and radiator. Note that the ATF is cooled by the coolant
injuries. When opening the radiator cap, place a thick in the radiator.
cloth over the cap when the coolant is cooled, and turn
it gradually to release the pressure before opening it.
10
11
12
9 15
8
13
16
14
7
1
3
5 2
LNW41CLF000201
Legend
1. Water jacket 9. Reserve tank
2. Oil cooler 10. Air removal plug
3. Water pump 11. Water outlet pipe
4. Heater core 12. Thermostat (2 units)
5. Drain plug 13. Thermometer unit
6. Radiator 14. Bypass pathway
7. Cooling fan 15. Turbo charger
8. Radiator cap 16. EGR cooler

Water pump
The water pump is a centrifugal impeller type pump. It
is driven by the engine fan belt.
Since the water pump cannot be disassembled, replace
the water pump Assembly when there is an
abnormality.
2
6
LNW71CMF001101
Legend
1. Fan center 4. Seal unit
2. Fan pulley 5. Impeller
3. Bearing 6. Liquid gasket application groove

Thermostat
The thermostat is a wax pellet type and there is a total
of two used. One is used (bottom bypass type) for an
opening valve temperature of 82°C (180°F), and the
other is used for an opening valve temperature of 85°C
(185°F). This structure enables fine water temperature
adjustments. The thermostat is installed in the
thermostat housing.
2 2
5
5
4 4
3
3
LNW71CMF001501
Legend
1. Jiglu valve 4. Gasket
2. Open valve temperature marking 5. Piston
3. Valve

Radiator
The radiator is a tube type with a corrugated fin. To
raise the boiling point of the coolant, a pressurized
radiator is attached.
LNWA1CSH000101

Functional Inspection
Engine coolant level detection • Inspect the radiator hose and heater hose for
• Inspect the coolant level in the reserve tank. If the damage or wear. Check that the hose clamps are
level is within its maximum (upper limit) and not loose.
minimum (lower limit), (the amount is appropriate.
In addition, open the radiator cap and check if the
coolant is filled up to the radiator filler. Coolant
level should be checked only after the engine has
cooled down). Note that if there is insufficient
coolant, remove the reserve tank cap and pour in a
mixture of tap water and engine coolant at the
appropriate proportion and fill the tank to the MAX
line.
Reference Value
Coolant 18 liters (3.96 Imp⋅gal) (between
Amount MIN and MAX level)
Replacement
Every 2 years
Period
LNW41CSH000101
Coolant concentration inspection

1. Engine coolant concentration
1
• The concentration of the engine coolant affects
its freezing temperature. Therefore, the
concentration should be set to the lowest
2 temperature.
• Use genuine Isuzu engine coolant.
• If the mixing ratio of the engine coolant is higher
than 60%, it overheats easily. If it is less than
30%, it will not be sufficient to prevent
corrosion.
3 • When diluting the coolant, use the distilled or
deionized water.
LNWA1CSH000201
• When it is used at the temperature of -30°C (-
Legend 22°F) or below, make the concentration to 55%.
1. Reserve tank
2. MAX line (upper limit)
Coolant
3. MIN line (lower limit) Region where used
Concentration
General regions, regions where the
lowest temperature is -12°C (10.4°F) 30%
Coolant Leaks Inspection or above
• Add 200 kPa (2.0 kg/cm2 /29 psi) pressure using
Cold regions, regions where the
the radiator cap tester to inspect for leaks in the
lowest temperature is -30°C (-22°F) 50%
following locations.
or above
- Radiator assembly
Regions where the lowest
- Water pump assembly
temperature is -30°C (-22°F) or 55%
- Radiator hose below
- Heater hose

CAUTION: • After measuring the temperature and relative
• For the coolant, make sure to use the products density, find the concentration from the table
specified (recommended) by Isuzu. below.
• If the coolant specified (recommended) by Isuzu is
not used, the engine, radiator or heater core may be 1.100
damaged.
1.090
• Never use the coolant which contains borate or
silicate. The engine, radiator or heater core may
1.080 50%
corrode, causing a water leakage. 1.070
SPECIFIC GRAVITY
1.060
1.050 30%
2. Measurements of engine coolant concentration
Hydrometry
1.040
• Use an antifreeze hydrometer to measure the
1.030
specific gravity and coolant temperature. 1.020
If you remove the cap when the engine is hot, 1.010
be careful because the coolant will burst out. 1.000
• Use a container that is deeper than the length
of the hydrometer. 0 10 20 30 40 50 60 70
TEMPERATURE
MFW91CSH001001
Coolant Scope Method

• Measure the concentration using a coolant
1 scope.
Reference
Coolant filling procedures (when replacing all of the
2 coolant)
1. Check that the engine is cool.
2. Open the radiator cap.
WARNING:
Do not loosen or remove the radiator cap when the
coolant is hot. Steam and boiling water can burst out
from the radiator possibly causing burns or heat related
LNW46BSH001001 injuries. When opening the radiator cap, place a folded
Legend thick cloth over the cap when the coolant is cooled, and
1. Density gauge turn it gradually to release the pressure before opening
2. Radiator it.
• The temperature of the coolant should be within

0°C - 50°C (32°F - 122°F) for measurement.

5. Drain the coolant from the reserve tank.
6. Tighten the drain plugs for the radiator and engine.
7. Remove the air bleeder plug from the engine.
Radiator cap Air bleeder plug
Radiator cap LNW71BSH016601
3. Remove the engine coolant drain plug on the

radiator and drain the coolant.
LNW71BSH016201
Front 8. Fill with engine coolant of the specified
concentration up to the filler neck.
CAUTION:
• Fill slowly to prevent air from entering the system.
• For EGR coolers with air bleeder plugs, remove the
EGR cooler air bleeder plug and refill with an
amount of coolant equivalent to the level between
the remaining coolant and the radiator inlet. Then
reattach the air bleeder plug.
Loosen
Air bleeder plug A

EGR cooler
Drain plug
LNW71BSH016401
4. Remove the engine coolant drain plug for the

engine and drain the coolant.
Drain plug LNW71BSH016301
9. Tighten the air bleeder plug for the thermostat

housing.
10. While manually pressing the radiator upper hose
several times to remove air from inside the hose,
refill with an amount of coolant equivalent to the
level between the remaining coolant and the filler
neck.
MFW71BSH016401

11. Repeat the procedure above until the coolant level 17. After the warm up switch shuts OFF, increase
no longer decreases. engine speed to around 2,000 r/min and continue
12. Close the radiator cap. this for 5 minutes once the needle of the engine
coolant temperature gauge reaches the center.
18. With the engine idling, confirm that the thermostat
is open by touching the radiator upper hose to see
if it is warm.
CAUTION:
Confirm this not only by checking the engine coolant
temperature gauge and the warm air following from the
heater, but also by touching the radiator upper hose to
see if it is warm. If the radiator hose is not warm, return
to step 17 of this procedure.
Radiator cap LNW71BSH016601
13. Fill the reserve tank with coolant until the MAX line,
and then close the reserve tank cap.
LNW71CSH005001
2
19. Idle the engine for 5 minutes.
20. Stop the engine and refill with coolant up to the
filler neck once the engine has sufficiently cooled,
refill the reserve tank with coolant up to the MAX
line.
3
CAUTION:
The following morning, refill the reserve tank with
LNWA1CSH000201 coolant up to the MAX line if the coolant level has
Legend dropped.
1. Reserve tank
3. MIN line (lower limit)
14. Start and idle the engine.
CAUTION:
Idle the engine for 5 minutes or more.
15. Stop the engine and refill with an amount of

coolant equivalent to the level between the
remaining coolant and the filler neck.
16. Close the radiator cap, turn OFF the heater fan
and heat the engine by turning ON the warm up
switch.

• The Engine has Overheated.
• The Engine has Overcooled.

Phenomenon:The Engine has Overheated

The engine has overheated Coolant is insufficient Refill
Defective thermostat Replacement
Defective water pump Replacement
Radiator clogging Clean or replace
Defective radiator cap Replacement
Insufficient engine oil or improper Refill or replace engine oil
engine oil was used
Defective cylinder head gasket Replacement
Looseness of fan belt Adjust or replace
Exhaust system clogging Clean or replace
Excessive fuel injection amount Diagnose engine control system
Fuel injection period is improper Diagnose engine control system
The fuel injection starting pressure is Diagnose engine control system
low
Insufficient engine coolant or improper Refill or replace engine coolant
engine coolant used

Phenomenon:The Engine has Overcooled.

The engine has overcooled Defective thermostat Replacement
Coolant system method Force circulation method

Radiator Tube with corrugated fins
Heat dissipation capacity kW (kcal/h) 127 (109200)
Heat dissipation surface
m2 (ft2 ) 17.65 (189.98)
area
Front surface area m2 (ft2 ) 0.364 (3.918)
Dry mass kg(lb) 18.2 (40.1)(M/T vehicles) / 18.4 (40.6)(Smoother vehicles)
Radiator cap
Open valve pressure kPa(kg/cm2 / psi) 93 - 123 (0.9 - 1.3 / 12.8 - 18.5)
Coolant capacity L (lmp⋅gal) 3.2 (0.704)(M/T vehicles) / 3.1 (0.682)(Smoother vehicles)
Water pump Centrifugal impeller method
Pulley ratio 1.190
Thermostat Wax pellet type
Open valve temperature °C (°F) 85 (185) (With jiggle valve) / 82 (180) (without jiggle valve)
Full-open temperature °C (°F) 100 (212) (With jiggle valve) / 95 (203) (without jiggle valve)
Coolant total capacity
L (lmp⋅gal) 18.0 (3.96)(including radiator)
[reference values]
Water Pump
Components
7
6
5
LNW91CMF000401
Legend
1. Radiator lower hose 5. Water pump pulley
2. Fan guide 6. Drive belt
3. Fan assembly 7. Water pump assembly
4. Set plate
Removal
1. Drain engine coolant.
2. Remove the radiator lower hose at the radiator
side.
3. Remove the fan guide from below.

4. Remove the four installation nuts to remove the fan 6. For AC generator 80A Specifications only.
assembly. At that time, loosen the four water pump Loosen the lock nut (2).
pulley and set plate tightening bolts. Loosen the pulley adjust bolt (1) to remove the
drive belt.
1 4
2
3
2
LNW71CSH002301
LNW81CSH000201
Legend
1. Fan
2. Fan assembly tightening nut
3. Set plate 7. Remove the set plate and water pump pulley.
4. Water pump pulley 8. Insert a screwdriver into the position shown in the
5. Collective-fastening bolt drawing to remove the water pump assembly by
prying it out.
5. For AC generator 50A Specifications only.

Loosen the adjust plate lock nut (2) and bolt (3). 1
Loosen the generator adjust bolt (1) to remove the
2
drive belt.
2
3
LNW71CSH002401
Legend
1. Water pump
1
3 2. Water pump pulley
3. Set plate
LNW71CSH001101
Inspection
1. External inspection
• Inspect the pump body for cracks and damage.
• Inspect the impeller for cracks and corrosion.
• Inspect for water leaks from the seal unit.

• When you find a problem, replace with the • Install the water pump by aligning to the front
water pump assembly. cover stud.
mm (in.)
3-5
(0.12-0.20) 1(0.04) or more
(0.02-0.06)
0.5-1.5
LNW21CSH000901
2. Inspection of the bearing unit LNW71CSH002901
• Rotate the fan while pushing the fan center to

the radius direction and inspect for any notable 2. Temporarily tighten the bolt until the water pump
rattling or abnormal sounds. pulley (1) is seated together with the set plate (2)
• When you find a problem, replace with the on the water pump assembly.
water pump assembly.
LNW71CSH002501
LNW21CSH001001 Legend
1. Fan pulley
2. Set plate
Installation
1. Install the water pump assembly.
3. Install the drive belt, and tighten the generator
• Apply liquid gasket (TB1207B) to about 3 to 5
adjust bolts to adjust the tension of the belt.
mm (0.12 to 0.20 in) width in the groove of the
water pump installation surface. • Refer to "Drive Belt" in this Section.
• See the drawing for the position to apply the
liquid gasket.
• After applying the liquid gasket, install within
five minutes.

After adjusting the drive belt, tighten the lock nut at
Tightening torque
Nut (2) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Bolt (3) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
LNW81CSH000201
Legend
2
1. Adjust bolt
2. Lock nut
6. After adjusting the drive belt, tighten the

1 temporarily tightened fan pulley and set plate at
3
the specified torques.
LNW71CSH001101 Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Legend 7. Install the fan assembly and tighten it at the
1. Adjust bolt specified torque.
2. Adjust plate lock nut
3. Bolt Tightening torque: 24 N⋅m (2.4kg⋅m/17 lb⋅ft)

After adjusting the drive belt, tighten the lock nut at 1 4
the specified torque. 2
Nut (2)
LNW71CSH002301
Legend
1. Fan assembly
2. Fan tightening nut (4 pieces)
3. Set plate
4. Fan pulley
5. Collective-fastening bolt

9. Install the radiator lower hose. Radiator hose clip
10. Pour in the engine coolant.
a a
b c
LNW81CLF000101
(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(d) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(e) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(h) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Thermostat
Components
LNW41CMF000201
Legend
1. Radiator upper hose 3. Thermostat
2. Water outlet pipe 4. Gasket
Removal
1. Drain engine coolant. Prepare a container for drain
and use it for filling when installing the thermostat.
The amount of coolant to be discharged should not
be enough to avoid engine coolant spilling from the
thermostat housing.
2. Remove the radiator upper hose at the radiator
side.
3. Remove the water outlet pipe.
4. Remove the thermostat.
5. Remove the gasket from the thermostat.
1
Inspection
1. Inspect the water outlet pipe for corrosion, etc.
2. Inspect the thermostat.
MFW41CSH001301
• Inspect the thermostat pellet, spring, shaft jiglu
valve (1) and crimped sections for damage.
• Inspect the operation of the thermostat.


• Place the thermostat in water, and gradually NOTE:
raise the water temperature to inspect the Do not mistake the assembly position and direction.
starting temperature, the temperature when full-
open, and the lift amount.
Starting temperature
(without jiglu valve) 80 - 84°C (176 - 183°F)
(with jiglu valve) 83 - 87°C (181 - 189°F)
Full-open temperature
(without jiglu valve) Min. 95°C (203°F)
(with jiglu valve) Min. 100°C (212°F)
Lift amount 8 mm (0.31 in)or more
• Since the heat capacity is high for wax type

thermostats, there is a slight difference in valve 1 2
operations for the fluctuations of water
temperature.
LNW21CSH000201
Legend
1. Thermostat
2. Cylinder head
1 2
2. Install the water outlet pipe.
3
Radiator hose clip
LNW61BSH003501
Legend
1. Stirring rod
2. Thermometer
2. Piece of wood
NOTE:
Place a plate on the bottom of the container so that the
thermostat is not directly heated, or lift it up. At this
time, constantly stir the hot water so that there is no
difference in temperature.
3. Check the gasket for cracks and damage.
Installation
LNW21CSH000401
1. Install the gasket to the thermostat, and install to
the position in the drawing.
• Securely insert so that the thermostat gasket
does not ride up outside of the cylinder head
side housing.

4. Fill the coolant stored when drained, and check
that the coolant is at the specified level.
LNWA1CSH000201
Legend
1. Reserve tank
3. MIN line (lower limit)
Engine Coolant Temperature Sensor

Removal
1. Disconnect wiring connector.
2. Remove the engine coolant temperature sensor.
Inspection
ECM engine coolant temperature sensor is a thermistor
type whose characteristic is that the electrical
resistance decreases as the temperature rises.
1 2
MFW71KSH000201
Resistance value at a certain temperature(app-

roximate value)
1 2
Engine coolant
Resistance value
temperature
3
20 °C (68 °F) 2.45 kΩ
MFW71CSH000601 50 °C (122 °F) 0.81 kΩ
Legend 80 °C (176 °F) 0.32 kΩ
1. Indicates the wiring
3. ECM thermistor NOTE:
Be careful not to allow water to get into the terminal
section. Wipe off the water droplets on the sensor after
the inspection.
• Place the temperature sensor portion of the engine If any abnormality is found in the inspection results,
coolant temperature sensor into water, and inspect replace it with a normal one.
whether the resist value changes as in the graph
while changing the water temperature.
• Example of how to measure the thermistor
characteristics.
Thermistor characteristic
30
20
10
7.0
)
5.0
Resistance value(k
3.0
2.0
1.0
0.7
0.5
0.3
0.2
0.1
-20/-4 0/32 20/68 40/104 60/140 80/176 100/212 120/248
Engine coolant temperature( )
LNW91CMH000201
Installation
1. Apply Loctite 262 or 962 or equivalent to the
engine coolant temperature sensor threaded
portion and tighten at the specified torque.
2
LNW81CSH000501
Legend
1. Engine coolant temperature sensor
2. Loctite application area
2. Install the wiring connector.

Radiator
Components
1
2
4
3
LNWA1CLF000101
Legend
1. Coolant reserve tank hose 4. Fan guide
2. Radiator upper hose 5. Intercooler
3. Radiator 6. Radiator lower hose
Removal
1. Loosen the radiator drain plug, and completely
drain the coolant.
• After draining, securely tighten the drain plug.

2. Remove the intake hose, and the turbocharger 4. Remove the intake hose, and the throttle side,
side, intercooler side and intake pipe bracket intercooler side and intake duct bracket between
between the turbocharger and the intercooler. the intercooler and throttle valve.
LNW71CSH004301 LNW71CSH004501
3. Remove the harness connector of the boost 5. Remove the upper hose at the radiator side.
sensor (1). 6. Remove the lower hose at the radiator side.
7. Remove the coolant reserve tank hose from the
radiator side.
8. Remove the fan guide from below.
LNW71CSH004401

9. Remove the radiator together with the intercooler.
Be careful not to damage the radiator core with the
fan blades. Remove the bracket tightening nuts on
the left and right sides of the radiator to remove the
radiator.
LNW21BSH000201
2. Inspect the condition of the negative pressure

valve in the center of the cap valve seat side. If the
valve seat is not operating smoothly because of
rust or foreign matter, clean or replace the radiator
cap.
Radiator core
1. Remove dirt or other foreign matter.
Also, if the radiator fins are deformed, this can lead
to a drop in heat dissipation and cause
overheating. Repair the fins. When repairing, be
careful not to damage the base of the fins.
LNW71CMH000701
Cleaning the radiator

10. Remove the intercooler from the radiator. 1. Clean the inside of the radiator and coolant path
with water. Clean away all scales and rust.
a. Cleaning the radiator core and intercooler core.
Inspection
1. Cooling efficiency is compromised when
Radiator cap there is dirt or dust plugging air passages in
1. Use the radiator cap tester to inspect the open the radiator core and intercooler core.
valve pressure. Replace the radiator cap if the This can also cause corrosion of these
open valve pressure is not at the standard value. cores. Periodically wash the radiator core
with tap water.
Open valve pressure
93 - 123 kPa(0.95 - 1.25 kg/cm2/13.5 - 17.8 psi) CAUTION:
• Make sure to turn the engine off and remove the key
from the starter switch before cleaning cores.
• The engine, exhaust pipe and radiator will be hot
immediately after the vehicle is driven.
Be careful around these parts to prevent burns.
Clean the engine when it is cold.
CAUTION:
• Do not clean the radiator(1), intercooler(2) and their
surrounding areas using water that is supplied
under high pressure. Doing so may cause damage.
• When cleaning the radiator core(3) and intercooler
core(4), do not crush or damage the fins(5).

• The fins are very fragile so be careful not to bend • When removing the frame side bracket, tighten
them out of shape. at the specified torque.
If they become deformed, their cooling efficiency will
be impaired.
Frame from frame side bracket
LNW91CSH001501
LNWA1BSH000301
4 • Install the intercooler.

3
• Securely install the fan cover (1) to the bracket
in the center of the fan ring (2).
5
LNW91CSH001601
Installation
1. Install the radiator and intercooler.
• Be careful not to scratch the radiator fins with
the fan blades.
• Install the radiator bracket to the frame side
Frame side bracket from radiator bracket


NOTE:
torque.
• Install the bracket of the intake duct.
Tightening torque
Clamp (1) 8 N⋅m(0.8 kg⋅m/69 lb⋅in)
Nut and bolt (2) 22.8 N⋅m(2.32 kg⋅m/16.8 lb⋅ft)
Clamp (3) 7.5 N⋅m(0.76 kg⋅m/66 lb⋅in)
1
2
1
LNW71CMH000401
2
1
3. Install the coolant reserve tank hose to the
radiator.
4. Install the radiator lower hose.
LNW81CSH001401
Radiator hose clip

1
1
Radiator hose clip

3
6. Install the intake hose between the intercooler and
the throttle valve.
NOTE:
misalignment, and tighten the clamp to the specified 2
torque.
• Use a new clamp. LNW81CSH001501
7. Install the intake hose between the intercooler and

the turbocharger. 8. Install the harness connector of the boost sensor.
9. Pour in the coolant.
• Refer to "Cooling System" section when
referring to the coolant filling procedures.
Drive Belt
Components
50A specifications
1 2
3
4
5
6
7
8
13
12
11
10
4 10
LNW71CMF000601
Legend
1. A/C compressor 8. Tension pulley adjust bolt
2. Adjust plate lock nut 9. Crank pulley
3. Adjust plate 10. Drive belt
4. A/C compressor drive belt 11. Generator tightening bolt
5. Water pump pulley (fan pulley) 12. Generator
6. Tension pulley lock nut 13. Adjust bolt
7. Tension pulley

80A specifications
3
4
6
12
11
7 2 7
10
8
9
LNW81CMF000101
Legend
1. A/C compressor 7. Drive belt
2. A/C compressor drive belt 8. Crank pulley
3. Water pump pulley (fan pulley) 9. Tension pulley
4. Tension pulley lock nut 10. Tension pulley lock nut
5. Tension pulley 11. Adjust bolt
6. Tension pulley adjust bolt 12. Generator
Inspection
Inspect the drive belt for wear and damage. Replace it Between the radiator pulley and fan pulley (2)
if necessary.
5 - 7 mm (0.20 - 0.28 in)
Also inspect belt tension. Adjust the tension if
Amount of flex (when using a new belt)
necessary.
of the belt 6 - 8 mm(0.24 - 0.31 in)
Inspection guidelines (when reusing the belt)
Press on the specified position on the belt with 98 N (10
kg/22 lb) of pressure to inspect the amount of belt flex.
Between the tension pulley and A/C compressor (1)

18 - 23 mm(0.71 - 0.91 in)
Amount of flex (when using a new belt)
of the belt
24 - 27 mm(0.94 - 1.06 in)
(when reusing the belt)

Reference
a NOTE:
1 A V-rib belt is used for the drive belt. It is necessary to
adjust to a more accurate tension than conventional V
2 belts.
If the tension is improper, the belt life will be reduced, or
the belt can squeak. Always take care to set the exact
tension.
A method for checking whether the precise tension has
been set is to use a sonic tension meter.
LNW81CMH000101
Legend
(a) 50A specifications
(b) 80A specifications
Amount of flex Frequency of vibrations

Belt types
mm(in) (Hz)
Drive belt For a new product 5 - 7(0.20 - 0.28) 208 - 232

(50A specifications) When reused 6 - 8(0.2 4 - 0.31) 178 - 190
Drive belt For a new product 5 - 7(0.20 - 0.28) 187 - 209

(80A specifications) When reused 6 - 8(0.24 - 0.31) 161 - 173
A/C For a new product 18 - 23(0.71 - 0.91) 59 - 73
Compressor
Drive belt When reused 24 - 27(0.94 - 1.06) 51 - 59
Adjustment 2. Loosen the adjust plate lock nut and through bolt.
When adjusting the tension of the drive belt, do so for 3. Turn the adjust bolt to adjust the drive belt.
both the drive belt and the compressor drive belt. 4. After adjusting, tighten the adjust plate lock nut
and trough bolt at their specified torques.
NOTE:
After adjusting the drive belt, adjust the compressor
drive belt. Tightening torque
Lock nut 24 N⋅m(2.4 kg⋅m/17 lb⋅ft)
50A specifications drive belt adjustment
Through bolt 40 N⋅m(4.1 kg⋅m/30 lb⋅ft)
1. Loosen the A/C compressor drive belt tension
pulley lock nut and adjust bolt to free the belts.

80A specifications drive belt adjustment
1. Loosen the A/C compressor drive belt tension
pulley lock nut and adjust bolt to free the belts.
2. Loosen the drive belt tension pulley lock nut.
3. Turn the drive belt tension pulley adjust bolt to
adjust the drive belt.
4. After adjusting the drive belt, tighten the drive belt
tension pulley lock nut at its specified torque.
Lock nut
Adjusting the A/C compressor drive belt

1. Loosen the tension pulley lock nut.
2. Turn the tension pulley adjust bolt to adjust the
belt.
3. After adjusting, tighten the lock nut at the specified
torque.
Lock nut

50A specifications
b
C
LNW71CSF000201
(b) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) (c) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
80A specifications
b
LNW91CSF000201
(a) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(b) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(c) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Engine Fuel (4HK1) 1D-1
ENGINE
Engine Fuel
(4HK1)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 List of Tightening Torques . . . . . . . . . . . . . . . . 1D-50
Maintenance Precautions . . . . . . . . . . . . . . . . . 1D-2 Fuel Rail Pressure (FRP) Regulator. . . . . . . . . . 1D-51
Description of Function and Operation . . . . . . . 1D-2 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-51
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1D-6 Maintenance Precautions . . . . . . . . . . . . . . . . 1D-51
Supply Pump Functional Inspection . . . . . . . . . 1D-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-51
Failure Symptom List . . . . . . . . . . . . . . . . . . . 1D-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-51
Phenomenon: Starting is Difficult . . . . . . . . . . 1D-13 Supply pump relearning . . . . . . . . . . . . . . . . . 1D-52
Phenomenon: Hunching When Idling . . . . . . . 1D-14 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-53
Phenomenon: Insufficient Output . . . . . . . . . . 1D-15 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-53
Phenomenon: Engine Does not Stop . . . . . . . 1D-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-54
Phenomenon: Exhaust Gas is Blue or Black . 1D-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-55
Fuel System Check . . . . . . . . . . . . . . . . . . . . . 1D-18 List of Tightening Torques . . . . . . . . . . . . . . . . 1D-56
Primary Specifications. . . . . . . . . . . . . . . . . . . 1D-23 Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-58
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . 1D-24 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-58
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-24 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-61
Fuel Filter Assembly. . . . . . . . . . . . . . . . . . . . . . 1D-26 Fuel Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-62
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-26
Water Sedimenter Switch. . . . . . . . . . . . . . . . . . 1D-27
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-27
Pre-fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-28
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-28
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-32
List of Tightening Torques . . . . . . . . . . . . . . . . 1D-35
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-36
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-38
List of Tightening Torques . . . . . . . . . . . . . . . . 1D-41
Fuel Pressure Sensor (Common Rail) . . . . . . . . 1D-42
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-42
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-43
Pressure Limiter (Common Rail) . . . . . . . . . . . . 1D-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-44
Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . 1D-45
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-47
1D-2 Engine Fuel (4HK1)
Fuel System
Maintenance Precautions Working procedures
Including the inside of the injector, the holes and gaps • When the fuel pipe, injection pipe, injector, supply
that are the fuel paths for the fuel system have an pump, and common rail have been removed,
extremely precise finish. Therefore, because there is quickly apply a seal to the fuel opening.
the possibility of damage if foreign material becomes • Store the eyebolt and gasket in a clean parts box
mixed in, cover the cap after removing parts, etc. to with a cover so that foreign material does not
prevent the entry of foreign material. install to them.
The injector ID plate is specific to that injector. Do not • Leaking fuel is the cause of fires. Therefore, after
confuse other injector ID plates. completing the work, wipe away any leaked fuel,
When the injector assembly is replaced, use the scan and check for fuel leaks after starting the engine.
tool to write the ID code to the ECM. For details on
writing, refer to "Repair Instructions" in Section 1A,
Engine Control System (4HK1). Description of Function and Operation
The fuel moisture removal agent has a nature of
absorbing moisture into diesel oil and is the cause of
rust. Therefore, do not use moisture removal agents in
the fuel tank.
Fuel system diagram
6
5
3 8
1 2 4
9
10
14
13 12 11
LNWA1DSF000101
Legend
1. Common rail (Fuel rail) 8. Fuel tank
2. Pressure limiter 9. Breather valve
3. Leak-off pipe 10. Pre-fuel filter (with sedimenter)
4. Injector 11. Priming pump
5. Fuel cooler 12. Fuel filter (with sedimenter)
6. Fuel return pipe 13. Recirculation valve
7. Fuel feed pipe 14. Supply pump

Common rail
RTW76CLF000601
Legend
1. Pressure limiter 2. Fuel pressure sensor

Supply pump
3
MFWA1DLF000601
Legend
1. Fuel temperature sensor 3. High pressure pipe
2. Fuel rail pressure (FRP) regulator / Suction 4. Camshaft key
control valve (SCV)

Injector Fuel filter
2
1
3
6
3 1
5
4
6 5
4
LNW71DSH002401
Legend
1. Element
2. Recirculation valve
3. Filter body
4. Element case
5. Drain plug
6. Switch connector
LNW46CMH000201
Pre-fuel filter
Legend
1. Terminal stud
2. Fuel outlet port
3. O-ring
4. Fuel inlet port 1
5. Identification code (the last 4 digits of Denso
parts number)
6. ID plate 2
LNW81DSH002501
Legend
1. Mounting head
2. Cartridge
3. Bowl
4. Drain plug

Air removal (when fuel is exhausted) a. Install a vinyl hose, etc. to the air removal plug
1. Before starting engine (2) on the fuel filter and prepare a fuel pan
under the vinyl hose.
a. Install a vinyl hose, etc. to the air removal plug
(2) and prepare a fuel pan under the vinyl hose.
1
1
2
LNW71DSH002601
LNW71DSH000501
b. Sufficiently loosen the plug and press the

priming pump until there is no more fuel mixed
b. Sufficiently loosen the plug and push the
with air.
priming pump (1) until there is no more fuel
containing air. c. Sufficiently tighten the plug, wipe away the
excess fuel in the vicinity and press the priming
c. Sufficiently tighten the plug, wipe away the
pump 20 times or more to feed air in the fuel
excess fuel in the vicinity and press the priming
system from the supply pump to the return
pump 10 times or more to feed air in the fuel
hose.
system from the supply pump to the return
hose. d. Turn the ignition switch to start the engine.
d. Turn the ignition switch to start the engine.
2. After starting the engine
2. After starting the engine a. Turn the ignition switch to start the engine
without depressing the accelerator pedal.
a. Turn the ignition switch to start the engine
without depressing the accelerator pedal. b. After starting, allow the vehicle to idle for 5
seconds.
b. After starting, allow the vehicle to idle for 5
seconds. c. Depress the accelerator pedal all the way to rev
the engine to its maximum speed.
c. Depress the accelerator pedal all the way to rev
Repeat this several times.
the engine to its maximum speed.
Repeat this several times. NOTE:
When the removal of the air is insufficient, there is the
NOTE:
possibility of engine trouble, so always follow these
When the removal of the air is insufficient, there is the
procedures after starting the engine.
possibility of engine trouble, so always follow these
procedures after starting the engine.
Air removal (when the fuel filter was replaced) Moisture removal
1. Before starting engine If more than the specified amount (approximately 160
cc/0.0352 lpm⋅gal) of water builds up in the sedimenter,
the warning light will turn on. In such cases, use the
following procedures to remove the water.
1. Install a plastic hose, etc. to the end of the drain
plug.

2. Prepare a container at the end of the vinyl hose
attached to the drain plug.
3. Loosen the drain plug.
1
4. Press the priming pump several times to discharge
the water.
5. After discharging, tighten the drain plug.
6. Press the priming pump several times to check
that no fuel is leaking.
7. Check that the warning light is extinguished.
NOTE:
Fuel is included in the discharged water, so follow
processing regulations established by your local area
when discarding the water. 2
Fuel system vacuum check

Use this procedure to measure the vacuum (negative
pressure) discharge side the fuel system.
NOTE:
The fuel pressure/vacuum gauge set (gauge (1)) and
the fuel pressure/vacuum gauge adaptor (adaptor (5))
must be cleaned before connect to the fuel line.
4
Otherwise, foreign material adherent to the tools may 5
damage the fuel supply pump.
3
LNW71DMH000201
Legend
1. Fuel Pressure/Vacuum Gauge set
2. Fuel Pipe (Intake Side)
3. Fuel Filter
4. Fuel Pipe (Discharge Side)
5. Fuel Pressure/Vacuum Gauge Adaptor
1. Disconnect the fuel hose from the fuel filter

housing (fuel supply pump side).
2. Install the adaptor.
Special tool
Fuel Pressure/Vacuum Gauge Set:
5-8840-2844-0
3. Connect the gauge (1) with hose to the adaptor
(5).
Special tool
Fuel Pressure/Vacuum Gauge Set:
5-8840-2844-0
4. Loosen the air bleeding plug on the supply pump.
5. Use your hand to operate the fuel filter priming
pump. Operate the pump until all the air has been
bled from the system.
6. Start the engine and allow it to idle.
7. Note the gauge (1) reading. If the reading is
normal, go to Step 8. If the fuel vacuum is greater
than the specified value, there is a problem in the
fuel system. Perform the procedures outlined
below.
Standard fuel vacuum: Less than 17 kPa (0.17 kg/cm2/
2.42 psi)

• Replace the cartridge fuel filter element.
• Check the fuel delivery pipe. If it is clogged, it must
be replaced.
• Remove the fuel pipe at the fuel filter inlet. Use
high-pressure air forced through the fuel pipe to
clean the fuel system.
CAUTION:
• Remove the fuel filler cap before applying high-
pressure air.
• Do not perform this procedure if the fuel tank is
nearly full (fuel approaching or flowing into the fuel
filler neck). The forced air will spray fuel from the
fuel filler neck.
8. Remove the gauge (1) and hose from the adaptor

(5).
9. Remove the adaptor (5).
10. Connect the fuel hose.
11. Use your hand to operate the fuel filter priming
pump. Operate the pump until all the air has been
bled from the system.
12. Start the engine and allow it to idle.
13. Inspect the fuel system for fuel leakage.

Supply Pump Functional Inspection
Inspection description
The supply pump functional inspection is a systematic
method for checking problems that arise due to
functional failures in the fuel supply system.
The supply pump functional inspection is a starting
point for diagnoses of complaints caused by a fuel
system failure.
Understanding and correctly using this diagnostic chart
reduces diagnostic time, and prevents the replacement
of good parts.
Step Action Value(s) Yes No

Inspect the fuel amount.
1 — Add fuel and go to
Is the fuel amount sufficient? Go to Step 2 Step 2
1. Check whether there is fuel leakage from the
fuel piping.
2. Check whether the fuel piping shows
2 abnormalities such as collapsing, bending, —
cracking, or looseness. Repair the fuel
piping and go to
Fuel piping OK? Go to Step 3 Step 3
While cranking the engine for 5 seconds, observe
the Fuel Rail Pressure display on the scan tool.
3 30 MPa
Does the scan tool display a value more than the
specified value while cranking the engine? Go to Step 10 Go to Step 4
1. Bleed air from the fuel piping. Refer to "Fuel
System" in this section for the air bleeding
method.
2. While cranking the engine for 5 seconds,
4 observe the Fuel Rail Pressure display on the 30 MPa
scan tool.

1. Remove each glow plug from the cylinder
head.
5 2. Disconnect each injector harness connector. —

3. Crank the engine.
Does fuel spout from the glow plug holes? Go to Step 6 Go to Step 7
1. Replace any injectors which were found to be
leaking fuel in Step 5. Refer to "Injector" in this
section.
IMPORTANT:
Be sure to program any replaced injectors.
6 30 MPa
observe the Fuel Rail Pressure display on the
scan tool.


1. Replace the fuel filter element and pre-fuel
filter. Refer to "Fuel Filter Element" and "Pre-
fuel Filter" in this section.
scan tool.

1. Replace the SCV. Refer to "Fuel Rail Pressure
(FRP) Regulator" in this section.
scan tool.

1. Replace the fuel supply pump. Refer to "Fuel Go to "Rough,
Supply Pump" in this section. Unstable, or
2. While cranking the engine for 5 seconds, Incorrect Idle and
observe the Fuel Rail Pressure display on the Stalling" in
9 scan tool. 30 MPa "Symptoms - Engine
Controls" in the
Does the scan tool display a value more than the section 1A Engine
specified value while cranking the engine? Control System
Go to Step 10 (4HK1)
1. Clear the DTC with the scan tool. Go to "Rough,
2. Turn OFF the ignition switch and wait for 30 Unstable, or
seconds. Incorrect Idle and
Stalling" in
3. Start the engine.
10 — "Symptoms - Engine
Does the engine start? Controls" in the
section 1A Engine
Control System
Go to Step 11 (4HK1)
1. Reconnect all of the disconnected harness Go to "Lack of
connectors and components. Power,
2. Operate the accelerator pedal and check that Sluggishness, or
the fuel rail pressure and engine speed Sponginess" in
11 respond accordingly. — "Symptoms - Engine
controls" in the
Do the fuel rail pressure and engine speed respond section 1A Engine
accordingly? Control System
System OK (4HK1)

Fuel piping inspection
LNWA1DSF000201
Legend
1. Inspection parts
Engine speed (fuel rail pressure) response verification method
10sec 5sec 10sec 10sec

3500
3000
5sec 10sec 5sec
2500
Engine Speed (r/min)
2000
1500
1000
500
0
0 10 20 30 40 50 60 70 80
Time (sec)
LNW71BMF006901

• Starting is Difficult
• Hunching When Idling
• Insufficient Output
• Engine Does not Stop
• Exhaust Gas is Blue or Black

Phenomenon: Starting is Difficult

Starting is difficult Fuel tank is empty Refill the fuel
Fuel is frozen Pour hot water to warm up the fuel filter
and supply pump
Clogging of the fuel tank breather Clean the fuel tank breather
Air entering into the fuel Remove the air
Clogging of or damage to the fuel line. Repair or replace the fuel line
Loose fuel line connection Repair of the hoses
Clogging of the fuel filter element Replace the element (excluding when
fuel is frozen)
Feed pump problem Replace the supply pump
Regulating valve is open Replace the regulating valve
Locking of the injector nozzle Replace the injector

Phenomenon: Hunching When Idling

Hunching when idling Fuel is frozen Slowly warm up the engine and raise
the engine return fuel temperature
Clogging of the fuel tank breather Clean the fuel tank breather
Air mixture in the fuel system Remove the air in the fuel system
Leak or clogging of fuel system Repair or replace the fuel system
Water mixture in the fuel system Replace the fuel
fuel is frozen)
Injector opening valve pressure drop, Replace the injector
atomizing problem
Feed pump malfunction Replace the supply pump

Phenomenon: Insufficient Output

Insufficient output Clogging of the fuel tank breather Clean the fuel tank breather
Air mixture in the fuel system Remove the air in the fuel system
Leak or clogging of fuel system Repair or replace the fuel system
Water mixture in the fuel system Replace the fuel
fuel is frozen)
Engine control problem Diagnose engine control system

Phenomenon: Engine Does not Stop

Engine does not stop Engine control system problem Diagnose engine control system

Phenomenon: Exhaust Gas is Blue or Black

Exhaust gas is blue or black Diesel particulate diffuser (DPD) Cleaning or replacing the filter
problem
Injector opening valve pressure drop, Replace the injector
atomizing problem

Fuel System Check
Description • The engine cranking speed is normal.
The common rail fuel system is comprised of two fuel • There is adequate fuel in the fuel tank.
pressure sections: a suction side between the fuel tank • There is no air in the fuel line.
and the fuel supply pump and a high-pressure side • Fuse and slow blow fuse are normal.
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and Diagnostic Aids
then pumped into the fuel rail by two plungers, all of
which are internal to the fuel supply pump. • The fuel system from the fuel tank(s) to the fuel
This high pressure is regulated by the ECM using the supply pump is under a slight vacuum with the
suction control valve (SCV) dependant upon values engine running. As a result, air can enter the fuel
from the FRP sensor attached to the fuel rail. system if these connections are not tight. Air in the
In case of fuel rail overpressure, a pressure limiter fuel system will cause fuel rail pressure
valve threaded into the fuel rail will open to release fluctuations especially at high engine speed and
overpressure and return fuel back to the fuel tank. load.
The Fuel System Check diagnostic table directs the • If the fuel tank is empty or near empty, air might be
service technician to the appropriate fuel system allowed to go into the fuel system. With air in the
diagnosis. fuel system, smooth flow of fuel into the supply
The diagnostic table assumes the following conditions pump is interrupted and this DTC may set. Perform
are met: bleeding of fuel system after refilling.
• The battery is completely charged and terminals
are cleaned and tight. Schematic Reference:
Fuel System Routing Diagram
Circuit / System Testing Fuel System Check

1. Install a scan tool.
2. Turn OFF the ignition switch for 30 seconds.
3. Turn ON the ignition switch, with the engine
1 OFF. —
4. Monitor the DTC Information with a scan tool.
Refer to Applicable
Does the scan tool display any DTCs that failed this DTC in Engine
ignition? Control Section Go to Step 2
1. Perform the Injector Force Drive with a scan
tool.
2. Command each injector ON and verify clicking
nose (solenoid operating noise).
2 —
Is there an injector that does not create a clicking
noise (solenoid operating noise), contains an
interrupted noise or abnormal noise when
commanded ON? Go to Step 17 Go to Step 3

1. Inspect the high pressure side between the
fuel supply pump and the fuel injectors for fuel
leakage. The following components may
contain an external leak.
• Fuel supply pump
• Fuel rail
• Pressure limiter valve
• Fuel rail pressure (FRP) sensor
• Fuel pipe between the fuel supply pump
and fuel rail
3 • Fuel pipe between the fuel rail and fuel —
injectors
• Each fuel pipe sleeve nuts
CAUTION:
Fuel may leak under the cylinder head cover from
the inlet high pressure line. In such case, the
engine oil level will rise. Inspect for fuel leakage
into the engine oil.
2. Repair any fuel system leaks as necessary.
Did you find and correct the condition? Go to Step 20 Go to Step 4

1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
CAUTION:
The fuel system from the fuel tank(s) to the fuel
supply pump is under a slight vacuum with the
engine running. As a result, air can enter the fuel
system if these connections are not tight. Air in the
fuel system will cause fuel rail pressure fluctuations
especially at high engine speed and load, which
may set this DTC.
2. Pump the priming pump until it becomes firm.

If there is a leak on the suction side of the fuel
4 system between the priming pump and the —
fuel supply pump, the priming pump will not
build up sufficient firmness and fuel leakage
ay occur.
3. Start the engine and check for high side fuel
system leaks at the fuel supply pump and fuel
rail.
CAUTION:
Fuel may leak under the cylinder head cover from
the inlet high pressure line. In such case, the
engine oil level will rise. Inspect for fuel leakage
into the engine oil.
4. Repair any fuel system leaks as necessary.


1. Make sure the fuel tank(s) have adequate fuel
and the fuel quality is good (take a sample).
2. Bleed the air from the fuel system as
necessary.
3. Start the engine and let idle. If the engine does
not start, continue to crank. ±5 MPa (±51
5 kg/cm2 / ±725
4. Observe the Actual Fuel Rail Pressure and
psi)
Desired Fuel Rail Pressure parameter with a
scan tool while cranking over the engine or
running the engine.
Is the differential pressure within the specified

value? System OK Go to Step 6
1. Turn OFF the ignition switch.
2. Disconnect the fuel injector in-line harness
connector from the cylinder head cover case
in order to disable injection.
3. Remove the rubber fuel hose from the fuel
filter housing (fuel supply pump side). Use a
pan to catch the fuel from the removed fuel
line.
CAUTION:
The fuel pressure/ vacuum gauge connector and
the adaptor hose must be cleaned before
connecting to the fuel line. Otherwise, foreign
material internal to the tools line may damage the
fuel supply pump.
4. Connect the gauge adaptor (5-8840-2844-0)

with fuel pressure/ vacuum gauge set (5-
8840-2844-0) in series with the filter housing
and the disconnected fuel hose. Ensure the
6 service tool and fuel line connections are tight. 8 inHg
5. Bleed the fuel system by priming the priming
pump until it becomes firm, then crank over
the engine for a maximum of 5 seconds.
Perform procedure three times.
6. Fully clamp off a fuel hose as close to the fuel
tank as possible (this will draw vacuum on the
fuel system). You can also disconnect a fuel
line and plug it.
7. Crank over the engine (for no longer than 15
seconds) while monitoring the fuel pressure/
vacuum gauge.
NOTE:
Release the clamp or open the plug when the
gauge is likely to be more than 8 inHg during the
test.
Can a vacuum of at least the specified amount be

pulled on the fuel system? Go to Step 9 Go to Step 7

1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
2. Draw fuel from the fuel tank at the fuel line
going to the fuel pickup tube to verify a clean
7 stream of fuel comes out (use the hand-held —
vacuum pump (5-8840-0279-0) with a clear
hose or equivalent). This will ensure the fuel
pickup tube is not cracked drawing air into the
fuel line.
3. Repair or replace as necessary.

1. Replace the fuel filter cartridge. Refer to Fuel
Filter Cartridge Replacement.
2. Retest the fuel system vacuum test described
8 in Step 5. 8 inHg
Can a vacuum of at least the specified amount be

pulled on the fuel system? Go to Step 20 Go to Step 19
1. Unclamp or unplug the fuel line from Step 5
and reconnect the fuel line.
2. Prime the priming pump until firmness is felt.
3. Crank over the engine for 5 seconds.
4. Repeat steps 2 and 3 three times to bleed the
9 fuel system. 5 inHg
5. Crank over the engine (for no longer than 15
seconds at a time) while monitoring the fuel
pressure/ vacuum gauge.
Does the pressure/ vacuum gauge ever indicate

larger than the specified value? Go to Step 20 Go to Step 11
1. Inspect the fuel lines between the fuel supply
pump and fuel tank for being crushed or
kinked.
2. Inspect the fuel tank vent hose for a plugged
or kinked condition.
3. Inspect the fuel cap for a plugged or kinked
10 condition. —
4. Inspect inside the fuel tank (if possible) for any
foreign material that may be getting drawn into
the fuel line pickup causing a blocked
condition.
5. Repair the condition as necessary.


1. Turn OFF the ignition switch.
2. Make sure the fuel injector in-line harness
connector is disconnected from the cylinder
head cover case.
3. Remove the eyebolt from the cylinder head
that connects to the leak-off pipe.
4. Connect the fuel adaptor 5-8840-2845-0 with
hose assembly to the cylinder head. Install the
hose into a graduated cylinder from the 5-
8840-2845-0 kit.
5. Remove the eyebolt from the pressure limiter
11 valve that connects to the leak-off pipe. —
6. Connect the fuel adaptor 5-8840-2845-0 with
hose assembly to the pressure limiter valve.
9. Perform 7 and 8 three times to take the
average of the fuel return amount coming from
the cylinder head. Make sure the batteries are
fully charged and the engine is cranking at
normal speed for each test.
Is fuel leaking from the pressure limiter valve? Go to Step 16 Go to Step 12

Is the average fuel return coming from the cylinder 15 ml (0.0033
12
head less than the specified value? Imp⋅gal) Go to Step 13 Go to Step 14
1. Remove each glow plug from the cylinder
head.
2. Inspect for fuel leakage into the combustion
13 chamber. —
Is there a cylinder that fuel leakage into the

combustion chamber? Go to Step 18 Go to Step 19
1. Remove the cylinder head cover and injector
harness in order to connect the fuel adaptor 5-
8840-2845-0 with hose assembly to each
injector leak-off port. Refer to Fuel Injector
Replacement.
NOTE: 3 ml (0.00066
14 Replacement injector must be programmed. lmp⋅gal)
3. Replace the injector(s) that return fuel more
than the specified value. Refer to Fuel Injector
Replacement/ Fuel Injector ID Code Data
Programming.
4. Retest after replacement of the fuel injector(s).
Did you complete the replacement? Go to Step 20 —

Replace the fuel filter cartridge. Refer to Fuel Filter
15 Cartridge Replacement. —
Replace the pressure limiter valve. Refer to Fuel
16 Rail Replacement. —
Did you complete the replacement? Go to Step 20 Go to Step 12

Replacement fuel injector must be programmed.
Replace the appropriate fuel injector that does not
create a clicking noise (solenoid operating noise),
17 contains an interrupted noise or abnormal noise at —
Step 2. Refer to Fuel Injector Replacement/ Fuel
Injector ID Code Data Programming.

Replacement fuel injector must be programmed.
Replace the appropriate fuel injector that was
leaking fuel found at Step 13 and inspect the
engine mechanical for any damage or poor engine
18 compression. —
Refer to Fuel Injector Replacement/ Fuel Injector
ID Code Data Programming and engine
mechanical section.

The fuel supply pump must be timed to the engine
and adjustment value must be learned to the ECM.
19 Replace the fuel supply pump. Refer to Fuel Supply —
Pump Replacement.

1. Reconnect all previously disconnected
harness connector(s) or components.
3. Bleed the air from the fuel system.
±5 MPa (51kg/
20 4. Start the engine and let idle.
cm2 / ±725 psi)
5. Observe the Actual Fuel Rail Pressure and
Desired Fuel Rail Pressure parameter with a scan

tool. Is the differential pressure within the specified
value? System OK Go to Step 1
Fuel pump specifications
Item Specifications
Fuel injection pump type Electronically controlled fuel injection system
(common rail type)
Supply pump type HP-3 (Denso)
Rotation direction Left direction when viewed from drive side
Plunger diameter mm (in) - number 8.5 (0.33) - 2
Regulating valve opening pressure MPa (kg/cm2 / psi) 0.5 (5.1 / 72.5)
Feed pump Trochoid type
Injector specifications
Item Specifications
Injector type DXI 893
Injectionnozzle hole mm (in) - number 0.14 (0.0055) - 7
Fuel Filter Element

Maintenance Precautions
• Replace the fuel filter element every 50,000
km(31,070 miles) or once every 2 years.
11
1
Removal
1. Remove the fuel in the element case.
a. Loosen the drain plug at the bottom of the 2
element case.
b. Loosen the air removal plug on the filter body to
10 3
remove the fuel.
2. Remove the sediment harness connector from the
element case.
4
3. Use a socket wrench 29 mm (1.14 in) or a general- 9
purpose filter wrench to remove the element case.
4. Pull the element downward to remove the O-ring
around the outer surface of the filter body. 8
5. If foreign material has accumulated on inner
surface of the filter body, wipe it with a clean cloth.
NOTE:
Do not use an air blower to remove the foreign 6
7
material. If you do, that foreign material can be blown
into the path on the clean side and cause failure of the 5
supply pump.
LNW71DLH000301
Legend
1. Filter body
2. Element case
3. Drain plug
4. Float
5. Gasket (outside)
6. Gasket (inside)
7. Clean side hole
8. Element kit
9. O-ring groove
10. Socket mounting position
11. Air removal plug
Installation
1. Insert the O-ring into the groove on the outer
circumference of the filter body. Do not let the O-
ring get damaged by the threaded portion of the
body.

2. Apply clean fuel to the gaskets inside and outside
of the element, and insert the element until it
reaches the end.
NOTE:
Do not allow foreign material to get into the 4 holes on
the clean side next to the inner side gasket.
3. Apply clean fuel to the inner circumference of the

element case or to the O-ring, and tighten
clockwise until it reaches the body while
preventing the O-ring from being caught.
If the element insertion does not reach the case,
the element is not completely inserted. Press while
turning the element again.
4. Install the element case, and tighten at the
specified torque.
5. Tighten the drain plug of the element case and
connect the connector of the water warning switch.
Tightening torque: 0.4 N⋅m (0.04 kg⋅m/3.5 lb⋅in)
6. After starting the engine, check each section for no
looseness.
Fuel Filter Assembly

Components
LNW91DMF000801
Legend
1. Fuel feed hose 3. Fuel filter assembly
2. Nut 4. Sedimener harness connector
Removal
1. Disconnect the sediment harness connector.
2. Pull out the feed hose and return hose from the
fuel filter.
• Plug the hoses so that fuel does not spill.
At this time, do not let foreign material get
inside. Do not use rusted bolts etc.
3. Remove the fuel filter installation nut.
4. Remove the fuel filter Assembly.
Installation
1. Install the fuel filter Assembly.
2. Install the fuel filter installation nut.
3. Install the feed hose and the return hose.
4. Install the sediment harness connector.
5. Remove the air.
Refer to "Fuel System" in this section.
Water Sedimenter Switch

Inspection
1. Remove the element case and turn it upside down.
When the float rises, check that there is continuity
between the switch connector terminals.
2. Turn the ignition switch ON, disconnect the engine
harness connector from the water sedimenter
switch connector and connect between the engine
harness connector terminals. Check that the
warning light of the sedimenter lights.
If any abnormality is found in the inspection results,
replace the fuel filter tank, or repair defective
connections or open circuits between the circuits.
2
1
5 LNW76CSH000201
Legend
1. Float
2. Engine harness connector
3. Engine harness
4. Element case
5. Switch connector
Pre-fuel Filter
Component Parts
LNW91DMF000701
Legend
1. Filter head 4. Gasket
2. Gasket 5. Bowl
3. Filter element cartridge 6. Drain plug
Disassembly • The gasket of water separator is exchanging at the

time of decomposition.
1. Loosen the drain plug at the bottom of the bowl to
drain the fuel inside the filter.
2. Remove the filter element cartridge. Reassembly
a. Remove the bowl and the filter element NOTE:
cartridge from the filter head as a single unit. Drain out water, when fuel filter will be covered with
b. Remove the filter element cartridge from the water. If driving is continued not draining, there is a
bowl. possibility of damaging a fuel injection system.
c. Remove the gasket from the bowl and filter In addition, surely use the genuine filter for engine at
head. the time of element exchange.
1. Careful clean the bowl and gasket grooves.

Inspection 2. Install the new gasket to the bowl.
• Check any damage or scratch on the bowl. • Apply a light coat of clean diesel fuel or engine
oil to the new gaskets.
• Check dirt, break and distortion on the filter
element cartridge. • Careful insert the gaskets into the gasket
grooves.
• Check any clog in the through hole of filter head.
3. Install the filter element cartridge.

• Screw the bowl into the new filter element
cartridge with your hand until it is firmly seated.
• Screw the new filter element cartridge into the
filter head with you hand until it is firmly seated.
4. Use a filter wrench and tighten the filter element
cartridge and bowl by 1/2 to 2/3 turns.
Tighten torque
Cartridge and bowl: 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
5. Close the drain plug and bleed air from the fuel
system.
5
6
LNW81DSH002601
Legend
1. Filter head
2. Gasket
3. Gasket groove
4. Filter element cartridge
5. Bowl
6. Drain plug
Injector
Components
3 5
6 7
8
1
4
11
12 14
13
10
14
LNWA1CLF000501
Legend
1. Injector terminal 8. EGR valve gasket
2. Injector harness bracket 9. Injector clamp bolt
3. Noise cover 10. Injector clamp
4. Cylinder head cover 11. Leak-off pipe
5. EGR cooler duct 12. Injector
6. EGR valve 13. Injection pipe
7. Gasket (EGR valve to EGR cooler duct) 14. Clip
Including the inside of the injector, the holes and gaps Removal
that are the fuel paths for the fuel system have an
1. Remove the injector connectors.
extremely precise finish. Therefore, because there is
the possibility of damage if foreign material becomes 2. Remove the EGR cooler.
mixed in, cover the cap after removing parts, etc. to Refer to “EGR valve and EGR cooler” in Section
prevent the entry of foreign material. 1F, Emission Control.
3. Remove the noise cover.

4. Remove the cylinder head cover. 7. Disconnect the injector leak off pipe (4).
3 1
2 2 4
LNW41BSH001001 LNW21DSH003901
Legend Legend
1. Noise cover 1. Harness bracket
2. Cylinder head cover 2. Harness connector
3. Terminal nut
4. Leak-off pipe
5. Alternately and evenly loosen the injector terminal
nuts (3) to remove the terminal.
8. Remove the injection pipe clip (2) to remove the
NOTE: injection pipe (1).
ID codes are unique to each injector. Put a
corresponding number tag on each QR plate when 1
storing injectors to avoid mix-up.
6. Loosen the injector harness bracket bolts, and

remove the inside connector (2) to remove the
harness bracket (1).
2
2
LNWA1CSH000601
9. Loosen the injector clamp tightening bolt.

10. When it is difficult to remove the injector, set a
special tool injector remover (2) on the injector (3)
leak off pipe installation. Pull the injector clamp
upward using a sliding hammer (1).
Special Tool
Injector remover: 5-8840-2826-0
Sliding hammer: 5-8840-0019-0

NOTE:
When a special tool is used to pull out the injector,
make sure that the injector sleeve does not fall out
while working on it.
LNW91BSH004401
Installation
1. Install a new gasket and O-rings (5) and install to
3 the cylinder head with the injector clamp
sandwiched as shown in the drawing.
• Apply molybdenum-disulfide to the threaded
portion of the clamp bolt and seat surface, and
temporarily tighten.
LNW71DMH000301
2 3
• Store the removed injector with the cylinder 1

number on it. Be very careful not to bump the
injection hole.
CAUTION: 5
Absolutely never touch the injector solenoids because
that can hinder their performance or cause damage.
6
BLW71BSH020401
Legend
1. O-ring
2. Injector
3. Injector clamp bolt
4. Injector clamp
5. O-ring
6. Gasket
2. Install the injection pipe and fasten with the clips to

the position shown in the drawing.

• Thinly apply engine oil to the outer
circumference of the injector side sleeve nut
and assemble it.
1
• Lightly tighten the sleeve nut with spanner so
that it is attached airtight to the injector and
common rail side.
2
• Tighten the injection pipe clip at the specified
torque.
LNWA1CSH000701
Legend
1. Clamp bolt
2. Injection pipe
2
2
5. Install the injector leak off pipe sandwiching the
new gasket and tighten it at the specified torque.
Tightening torque
Injector side: 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)
LNWA1CSH000601
Cylinder head side: 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Legend
1. Injection pipe
2. Clip
3. Tighten the injector clamp bolt that was temporarily

tightened earlier at the specified torque.
4. Tighten the injection pipe at the specified torque.
Tightening torque
Common rail side 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
Injector side 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
MFW81BSH001701
6. Install the injector harness connector from the

inside and tighten the harness bracket at the
specified torque.

8. Install the cylinder head cover and gasket and
tighten them at their specified torque in the order
shown in the drawing.
5 1 3 7
LNW91DSH000801
6 2 4 8
7. Install the terminal nut to the injector and tighten it

LNW21BSH030101
• This is an integrated part, so alternately tighten
the terminal nuts separately 2 to 3 times to 9. Tighten the noise cover at the specified torque.
prevent only one side is tightened.
CAUTION:
If the nut is over-tightened, the terminal stud can be
damaged. Never over-tighten.
1
2
2
LNW41BSH001001
1 Legend
1. Noise cover
LNW71DSH003601 2. Cylinder head cover
Legend
1. Injector
2. Harness
Refer to “EGR valve and EGR Cooler” in Section
3. Terminal nut
1F, Emission Control.
11. Install the engine harness connectors.
• Check that there is a clicking sound when
installting the connector joints to securely
connect them.

a
c
b
m
l
d
e
i
h
k
i g
LNWA1CLF000801
(a) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)

(b) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(d) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(e) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
(h) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(i) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(j) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(k) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(l) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(m) 15 N⋅m (1.5 kg⋅m / 11 lb⋅ft)
(n) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
Common Rail
Components
7 5
3 4
6
10 9
LNW91DLF001201
Legend
1. Fuel leak-off pipe 6. Injection pipe clip
2. Fuel pipe 7. Injection pipe
3. EGR valve 8. Common rail (Fuel rail)
4. Gasket (EGR valve to EGR cooler duct) 9. Common rail (Fuel rail) bracket
5. EGR cooler duct 10. Oil cooler
Including the inside of the injector, the holes and gaps

extremely precise finish. Therefore, because there is
the possibility of damage if foreign material becomes
mixed in, cover the cap after removing parts, etc. to
prevent the entry of foreign material.

Removal 6. Remove the harness clamp bracket (2).
1. Remove the air intake hose.
2 1 2 3
LNW91DSH002001
LNW81BSH002901 Legend
1. Harness bracket
Legend
2. Harness clamp bracket
1. Air intake hose
3. Common rail (Fuel rail)
2. Boost sensor
4. Harness bracket
2. Disconnect the common rail fuel pressure sensor.

3. Disconnect the fuel leak off hose from the leak off 7. Remove the injection pipe clip (2) and remove the
pipe. injection pipe (1).
• Put a cover over the removed fuel hose and
fasten it facing upward using a wire. 1

Refer to “EGR valve and EGR cooler” in Section
5. Remove the oil level gauge and guide tube.
2
2
LNWA1CSH000601
Legend
1. Injection pipe
2. Clip
8. Remove the fuel pipe (1).


9. Remove the clip, and remove the fuel leak off pipe 11. Remove the common rail bracket (2).
(2).
1
2
1 2
3
LNW91DSH002201
LNWA1CSH000501
Legend
Legend 1. Oil cooler
1. Fuel pipe (high pressure) 2. Common rail (Fuel rail) bracket
2. Fuel leak-off pipe
Installation
10. Remove the common rail (2). 1. Install the common rail bracket (2) and tighten it at
NOTE:
• Avoid the pressure limiter and pressure sensor, and
hold the common rail unit. Tightening torque
• Be careful not to damage the pressure sensor Nuts and bolts 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
connector.
1 2
3
LNW91DSH002201
LNW91DSH002101
Legend
Legend
1. Oil cooler
1. Common rail (Fuel rail) bracket

2. Install the common rail (2) and tighten it at the
specified torque.
Tightening torque
Nuts and bolts 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
2
8 1
1 6
2 5
LNW91DSH002101
Legend
1. Common rail (Fuel rail) bracket 4
3. Install the fuel leak off pipe (1), and then tighten
the eyebolt and clip at their specified torque.
Tightening torque
LNW81DLH000101
(2) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(3) 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
(4) 8 N⋅m (0.8 kg⋅m/69 lb⋅in) 5. Install the injection pipe and clip, and tighten them
at the specified torques.
4. Install the fuel pipe (6) and tighten the sleeve nut at • Thinly apply engine oil to the outer
the specified torque. circumference of the injector side sleeve nut
and assemble it.
Tightening torque
Sleeve nuts tightening torque
(5) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
Common rail side 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(7) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Injector side 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(8) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
Clip 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
NOTE:
The fuel pipe (4) has directionality. Install the common
rail side with the yellow color of the processed surface
side of the sleeve nut, and the green should be
installed at the supply pump side.

10. Check that there is a clicking sound when
1 connecting each connector with the engine
harness to securely connect them.
11. Install the air intake hose.
NOTE:
torque.
2 • Install the connector of the boost sensor.
2
Clamp (2)
Clamp (5)
Tightening torque: 6.4 N⋅m (0.65 kg⋅m/57 lb⋅in) ABA
W4 Stainless clamp
LNWA1CSH000601 Tightening torque: 8.0 N⋅m (0.8 kg⋅m/71 lb⋅in)
Legend NORMA W1 Steel clamp
1. Injection pipe
2. Clip
6. Install the harness clamp bracket (2).

1
4 3
5
LNWB1BSH014801
4 Legend
1. Air intake hose
2. Clamp
3. Boost sensor
4. Air intake duct
1 2 3 5. Clamp
LNW91DSH002001
Legend
1. Harness bracket
2. Harness clamp bracket
4. Harness bracket
7. Install the oil level gauge and guide tube.

9. Install the fuel leak hose to the leak off pipe and
fasten with the clips.

n b
f e
g
h
n m l
p
i
k
j
LNW91DLF001301
(a) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)

(b) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(e) 172 N⋅m (17.5 kg⋅m / 127 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(h) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(i) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(j) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
(k) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(l) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(m) 28 N⋅m (2.9 kg⋅m / 21lb⋅ft)
(n) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(o) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(p) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
Fuel Pressure Sensor (Common Rail)

Components
RTW76CLF000601
Legend
1. Pressure limiter 2. Fuel pressure sensor
Maintenance Precautions • After replacing each sensor, check that the trouble
code is extinguished and the operations are
Precautions for Maintenance
normal with the scan tool.
• With the engine assembled prior to disassembly,
add a cleaning agent to the steam cleaner and
thoroughly clean the sensor and common rail Removal
areas. Fuel pressure sensor
• Completely remove the moisture with an air
1. Remove the harness connector of the fuel
blower.
pressure sensor.
• Start work after checking that all foreign material
has been removed.
• After starting the engine, check to be sure that
there is no fuel leaking.

2. Remove the fuel pressure sensor.
1
1
3 2
3 2
RTW76CSH000101
RTW76CSH000101
Legend
Legend 1. Common rail (Fuel rail)
1. Common rail (Fuel rail) 2. Fuel pressure sensor
2. Fuel pressure sensor 3. Pressure limiter
3. Pressure limiter
2. Install the fuel pressure sensor harness connector.
Installation
Fuel pressure sensor
1. Install the fuel pressure sensor.
• Apply grease to the threaded portion of the
sensor and install it.
• Install so that this does not interfere with the
connector terminals.
Tightening torque: 98 N⋅m (10.0 kg⋅m / 72 lb⋅ft)
NOTE:
• Do not remove the protective cap right until
assembling the sensor.
• Be careful not to allow water or foreign material to
get into the connector.
• Do not allow foreign material to adhere to the
threaded portion. Also, thoroughly check that there
is no foreign material in the installation section.
Pressure Limiter (Common Rail)

Removal
• Remove the pressure limiter.
NOTE:
• Do not reuse the removed sensor and gasket.
1
• When removing the gasket, be careful not to
damage the seat surface.
1
3 2
RTW76CSH000101
Legend
2. Pressure sensor
3. Pressure limiter
3 2
RTW76CSH000101
Legend
2. Fuel pressure sensor
3. Pressure limiter
Installation
• Install the pressure limiter.
NOTE:
• Before installation, thoroughly check that there is
no foreign material in the installation section.
• Tighten using a 19 mm (0.75 in) width across flat
section.
Fuel Supply Pump

Components
9
8
7
6
5
4
LNW91DMF000601
Legend
1. Fuel leak-off pipe 6. Supply pump bracket O-ring
2. Fuel pipe 7. Coupling
3. Supply pump 8. Coupling nut
4. Supply pump O-ring 9. Coupling
Including the inside of the injector, the holes and gaps 2. Remove the fuel feed pipe and hose.
extremely precise finish. For that reason, the sensitivity
to foreign material is high. Since foreign material can
lead to trouble on the road, take every precaution to
prevent foreign material from getting inside.
Removal
1. Disconnect the air charge pipe connected between
the intercooler and intake pipe.
LNWA1CSH000801

6. Remove the fuel pipe bracket ( between the supply
3. Remove the fuel return pipe. pump and common rail).
LNW71DSH000801 LNW71DSH000701
4. Remove the oil level gauge guide tube. 7. Disconnect the fuel temperature sensor and FRP
regulator connector from the supply pump.
5. Remove the fuel pipe (between the supply pump
and common rail). 8. Remove the supply pump.
• Remove the coupling and O-ring.
LNWA1CSH000901
LNW71DSH001301
9. Remove the coupling from the supply pump.

• Tighten the two bolts in the coupling screw
holes and after applying a turn stopper, remove
the nut.
• Put the puller on the two tightened bolts of the
coupling and remove the coupling.
10. Remove the three bolts to remove the supply Installation

pump bracket (3).
1. Install the fuel temperature sensor (1).
• Remove the O-ring (2).
• Install the O-ring to the fuel temperature sensor.
• Tighten the furl temperature sensor at specified
3 torque.
2 Tightening torque : 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
LNW71DSH001501
Legend
1. Supply pump
2. O-ring
LNW91DSH001501
11. Remove the fuel temperature sensor (1). 2. Install the O-ring (2) to the supply pump (1) with
• Disconnect the O-ring from the sensor. the three mounting bolts and tighten to the supply
pump bracket (3) at the specified torque.

• Be careful of the O-ring protruding. CAUTION:
Check that the coupling (3) rubber dampers are
assembled facing alternately.
3
• Place the O-ring (2) on the fuel supply pump
2 (1), align the supply pump (1) with the coupling
and groove of the vacuum pump (4) and install
them to the vacuum pump (4).
1
NOTE:
• Confirm there is no gap between the supply pump
(1) and the vacuum pump (4) before tightening the
mounting bolts.
• It is not necessary to align the alignment marks,
etc., to insert the fuel supply pump and the coupling.
• Tighten the bolts in diagonal order at the

specified torque.
LNW71DSH001501 Tightening torque: 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
Legend
1. Supply pump
2. O-ring
3. Install the alignment coupling to the supply pump

shaft key and tighten the nut at the specified
torque.
• Tighten two bolts to the coupling screw holes as
a turn stopper.
4
3
2
LNW71BSH002301
Legend
1. Supply pump
2. O-ring
3. Coupling
4. Vacuum pump
5. Install the fuel pipe bracket ( between the supply

pump and common rail).
LNW71DSH001401
4. Install the supply pump (1) to the vacuum pump

(4).
• Fit in the coupling (3) with the damper to the
vacuum pump (4).
LNW71DSH000701 LNWA1CSH000801
6. Connect the fuel temperature sensor and FRP 10. Install the fuel pipe (between the supply pump and
regulator connector to the supply pump. common rail).
7. Install the oil level gauge guide tube. Tightening torque: 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
8. Install the fuel return pipe.
Tightening torque
Upper eyebolt 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
Side eyebolt 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
Bracket nut 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
LNWA1CSH000901
11. Install the air charge pipe between the intercooler

and intake pipe.
LNW71DSH000801
9. Install the fuel feed pipe and hose.


a b
d
i g e
h
f
LNWA1CLF000701
(a) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)

(b) 51 N⋅m (5.2 kg⋅m / 38 lb⋅ft)
(c) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(d) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(e) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(f) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(g) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(h) 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(i) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
Fuel Rail Pressure (FRP) Regulator

Component Parts
5
4
3
LNW86CMF000101
Legend
1. Bolt 4. O-ring (large)
2. Fuel rail pressure (FRP) regulator / Suction 5. O-ring (small)
control valve (SCV) 6. Supply pump
3. Gasket
Maintenance Precautions 2. Disconnect the harness connector from the FRP

regulator.
• Add cleaning agent to the steam cleaner and
thoroughly clean the sensor and supply pump 3. Remove the FRP regulator and gasket from the
areas. supply pump.
• Completely remove the moisture with an air
blower. Installation
• Start work after checking that all foreign matter has 1. Install the O-ring to the supply pump.
been removed.
• Clean O-ring groove before installing.
• After starting the engine, check to be sure that
there is no fuel leaking. 2. Install the FRP regulator to the supply pump, and
temporarily tighten two bolts.
• After replacing valves, use a scan tool to check
that the trouble code is cleared and that operations NOTE:
are normal.
• Be careful so as not to pinch the O-ring during
installation.
Removal • Temporarily tighten by hand until the FRP regulator
adheres the supply pump.
1. Remove the band clip.

3. Tighten the FRP regulator to the specified torque.
4. Connect the harness connector to the FRP

regulator.
Supply pump relearning

After replacing FRP regulator, supply pump relearn
must be performed in the following steps.
1. Install a scan tool.
2. Start the engine and let idle until engine coolant
temperature reaches the following figure or higher.
Engine model Temperature

4HK1 70 °C (158 °F)
3. “Fuel Supply Pump Status” in data list changes

from “Not Learned” to “Learned”.
Fuel Tank
Components
100L (22.0 Imp⋅gal) Specifications
5
4
LNW71DLF001201
Legend
1. Fuel tank unit 4. Fuel feed hose
2. Breather hose 5. Band
3. Fuel return hose 6. Fuel tank

140 L (30.8 Imp⋅gal) Specifications
2
1
7 6
MFW81DLF001201
Legend
1. Fuel feed hose 6. Drain plug
2. Fuel return hose 7. Fuel tank
3. Fuel tank bracket 8. Fuel tank unit
4. Fuel tank band 9. Outlet breather hose
5. Fuel filler cap
Removal 3. After the fuel has been drained, tighten the drain
plug at the specified torque.
1. Loosen the fuel filler cap.
2. Drain the fuel from the drain plug.
Tightening torque
100L (22.0 Imp⋅gal)
29.0 N⋅m (3.0 kg⋅m/ 22 lb⋅ft)
specifications
140L (30.8 Imp⋅gal)
73.5 N⋅m (7.5 kg⋅m/ 54 lb⋅ft)
specifications
4. Remove the fuel tank unit connector.


5. Remove the breather hose. Installation
6. Remove the fuel feed hose. 1. Install the fuel tank.
7. Remove the fuel return hose.
• Plug the hose so fuel does not spill, and tie to NOTE:
the frame facing upward. When removing the fuel tank, and the bracket is
removed, install the bracket and tighten at the specified
8. Remove the fuel tank installation band nut and the torque.
leading end of the band on the frame side.
9. Pull the fuel tank to the outside.
Bracket tightening torque
NOTE:
100L (22 Imp⋅gal)
If the fuel tank cannot be pulled out, remove the bracket 47 N⋅m (4.9 kg⋅m/35 lb⋅ft)
Specifications
to pull the fuel tank to the bottom side.
140 L (30.8 Imp⋅gal)
54 N⋅m (5.5 kg⋅m /40 lb⋅ft)
100L (22 Imp⋅gal) Specifications Specifications
NOTE:
When placing the fuel tank on the bracket, securely
place the rubber section attached to the fuel tank on to
the bracket.
2. Install the band to the fuel tank and tighten the nut
NOTE:
Hold the fuel tank band using a suitable tool while
tightening the lock nut, so that the fuel tank band does
not get twisted.
100L (22 Imp⋅gal) Specifications
LNW71DSH003101
Tightening torque: 13 N⋅m(1.3 kg⋅m / 113 lb⋅in)

NOTE:
• Hold the fuel tank band using a suitable tool while
tightening the inner nut, so that the fuel tank band
2
does not get twisted.
1 • Hold the inner nut using a spanner. Then tighten the
3 outer nut to the specified torque.
Tightening torque
Inner nut (3) 27.5 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
Outer nut (4) 27.5 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
MFW81DSH001001
Legend
1. Frame
2. Fuel tank unit
3. Fuel tank band
3. Install the fuel return hose.

4. Install the fuel feed hose.
• The hose should fit more than 25 mm (0.98 in)
into the pipe.
5. Install the breather hose.
• Fill the fuel tank with fuel, and replace the fuel
filler cap.
1 • Connect the battery ground cable.
• After starting the engine, check that there is no
fuel leak from the hose connections.
6. Connect the fuel tank unit connector.
2
4 3
MFW81BSH001801
Legend
1. Fuel tank band
2. Bracket
3. Inner nut
4. Outer nut

100L (22 Imp⋅gal) Specifications
LNW71DMF000701
(c) 29.0 N⋅m (3.0 kg⋅m / 22 lb⋅ft)

(a) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
(b) 47 N⋅m (4.9 kg⋅m / 35 lb⋅ft)

b
c
MFW81DLF001301
(a) 54 N⋅m (5.5 kg⋅m / 40 lb⋅ft)

(b) 27.5 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
(c) 27.5 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
(d) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)
Fuel Tank Unit

Components
LNW71DMF000601
Legend
1. Fuel tank unit connector 2. Fuel tank unit

MFW81DMF000901
Legend
1. Fuel tank unit 2. Fuel tank
Removal Inspection
1. Remove the wiring connector from the fuel tank The fuel tank unit changes the internal resistance by
unit. the float position (the fuel level height) and operates the
2. Remove the installation screws and remove the fuel meter indicator.
fuel tank unit.
NOTE:
When attaching and detaching the fuel tank unit, be
careful of interfering with surrounding parts and do not
deform the arm, etc.
After removing the fuel tank unit, cover the tank so that
foreign material does not get inside.
LNW21DSH002301

1. While moving the float from "E" to "F", inspect the 2. Check that the low fuel level warning light lights up
resistance value between the connector terminals when the float is at the "E" position.
(2) and (3). If any abnormality is found in the inspection
results, replace the meter with a normal one.

Float position F point (h1) 1/2 point (h2) E point (h3) SE point (h4)
Distance from the flange mm (in) 76.0 (2.99) 192.9 (7.59) 313.4 (12.34) 332.3 (13.08)
Tank capacity L (lmp⋅gal) 89.5 (19.69) 51.0 (11.22) 12.0 (2.64) 6.0 (1.32)
Resistance value Ω 14 44 100 110
2
3 1
h1
F
h2
h3
h4
1
2
SE
LNW79EMF000301

F point 3/4 point 1/2 point 1/4 point E point SE point
Float position
(h1) (h2) (h3) (h4) (h5) (h6)
66.0 139.6 215.5 291.5 368.8 379.9
Distance from the flange mm(in)
(2.60) (5.50) (8.48) (11.48) (14.52) (14.96)
129 100.5 71.0 41.5 12 8.0
Tank capacity L(Imp⋅gal)
(28.38) (22.11) (15.62) (9.13) (2.64) (1.76)
Resistance value Ω 14 29 44 72 100 110

2
h1
3 1
F
h2
h3
3/4
h4
h5
h6
1/2
1/4
SE
MFW81ELF000101
Installation
Installation is in the reverse order of removal.
1. Install the fuel tank unit.
2. Connect the wiring connector to the fuel tank unit.
Fuel Cooler
Removal
1. Remove the fuel hose.
2. Remove the fuel cooler.
LNWA1DSH000101
Installation
1. Install the fuel cooler.
2. Install the fuel hose.
Engine Electrical (4HK1) 1E-1
ENGINE
Engine Electrical
(4HK1)
TABLE OF CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2 Functional inspection: . . . . . . . . . . . . . . . . . . . 1E-46
Maintenance Precautions . . . . . . . . . . . . . . . . . 1E-2 Failure Symptom List . . . . . . . . . . . . . . . . . . . 1E-48
Description of Function and Operation . . . . . . . 1E-2 Phenomenon: Warming is not Promoted with
Failure symptom list . . . . . . . . . . . . . . . . . . . . . 1E-5 the Warm-up Switch at ON (when idling;
Phenomenon: The Starter does not Work Even water temperature less than 80°C (176°F)) . . 1E-49
when the Ignition Switch is Turned on . . . . . . . 1E-6
Phenomenon: The Pinion Advances but
does not Mesh with the Ring gear. . . . . . . . . . . 1E-7
Phenomenon: The Pinion Meshes and the
Motor Turns, but the Engine does not Crank . . 1E-8
Phenomenon: The Pinion Meshes, but the
Engine does not Crank . . . . . . . . . . . . . . . . . . . 1E-9
Phenomenon: After the Engine Starts, the
Starter does not Stop even if the Ignition
switch is Turned off . . . . . . . . . . . . . . . . . . . . . 1E-10
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-10
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1E-16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-22
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-23
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1E-25
Maintenance Precautions . . . . . . . . . . . . . . . . 1E-25
Description of Function and Operation . . . . . . 1E-25
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 1E-26
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-27
Functional inspection: . . . . . . . . . . . . . . . . . . . 1E-28
Failure symptom list . . . . . . . . . . . . . . . . . . . . 1E-29
Phenomenon: Does not charge at all . . . . . . . 1E-30
Phenomenon: Charge is insufficient . . . . . . . . 1E-31
Phenomenon: Overcharged . . . . . . . . . . . . . . 1E-32
Phenomenon: Charged current is unstable. . . 1E-33
Phenomenon: Abnormal sound in generator . 1E-34
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-36
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1E-38
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-42
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-44
Warm up System . . . . . . . . . . . . . . . . . . . . . . . . 1E-45
Description of Function and Operation . . . . . . 1E-45
1E-2 Engine Electrical (4HK1)
Starting System
Maintenance Precautions Description of Function and Operation
When performing maintenance on the electrical Starter circuit
system, check that the ignition switch and lighting The ignition system is composed of the batteries,
switch are off, and always disconnect the negative starter, ignition switch, inhibitor switch (A/T vehicles
battery terminal before working. only) and starter relay. Each of these main components
are wired as shown in the starter circuit diagram.
4 5
P
6
N
N
ST
9
3
B
2
11
1
10
LNW21EMF000601
Legend
1. Pinion clutch 7. Inhibitor switch (A/T vehicles only)
2. Ring gear 8. Starter relay
3. Shift lever 9. Ignition switch
4. Magnetic switch 10. Batteries
5. S terminal 11. Armature
6. B terminal
Starter because the pinion is idling, it does not drive the

The starter is a magnetic shift type starter and is an armature.
outer gearing mesh method reduction starter.
The contact point of the magnetic switch closes and the
armature rotates when the ignition switch is turned ON.
At the same time, the plunger is drawn in and the pinion
is pushed to the front via the shift lever to mesh with the
ring gear, and when the ring gear rotates the engine
starts. After the engine starts, the plunger returns, the
pinion separates from the ring gear, and the armature
stops rotating when the ignition switch is turned off.
When the engine rotation increases faster than the
pinion, the pinion will be caused to turn in reverse, but

Starter motor
(S25-501C)
2 3 4
5
6
8 7
LLW81EMF000101
Legend
1. Brush 5. Clutch
2. Yoke 6. Pinion
3. Magnetic switch 7. Armature
4. Torsion spring 8. Commutator

(S25-505G)
3
4
5
6
2
1
8 7
LNW71EMF000401
Legend
1. Brush 5. Clutch
2. Yoke 6. Pinion
3. Magnetic switch 7. Armature
4. Torsion spring 8. Commutator

Failure symptom list
The starter does not work even when the ignition switch
is turned on.
The pinion advances but does not mesh with the ring
gear.
The pinion meshes and the motor turns, but the engine
does not crank.
The pinion meshes, but the engine does not crank.
After the engine starts, the starter does not stop even if
the ignition switch is turned off.

Phenomenon: The Starter does not Work Even when the Ignition Switch is Turned on

The starter does not work even when Anti-theft system is activated Check the key
the ignition switch is turned on For details on the immobilizer, refer to
"Immobilizer Control System" in Section
9I, Security and Lock
Complete battery discharge Replace the battery
Wiring circuit open circuit, improper Repair
connection
Defective contact of the ignition switch Repair or replace
contact point, or improper tightening of
the terminal
Defective contact of the starter relay or Repair or replace
defective contact of the insertion
terminals
Magnetic switch coil short circuit or Replacement
open circuit

Phenomenon: The Pinion Advances but does not Mesh with the Ring gear

The pinion advances but does not mesh Insufficient battery charge Recharge the battery
with the ring gear Wear of the pinion or ring gear teeth Replace the pinion or the ring gear
Dust adhesion on pinion shaft Repair

Phenomenon: The Pinion Meshes and the Motor Turns, but the Engine does not Crank

The pinion meshes and the motor turns, Slipping of the clutch Replace the clutch or the starter motor
but the engine does not crank Damage of the deceleration gear Replace the gear or the starter motor

Phenomenon: The Pinion Meshes, but the Engine does not Crank

The pinion meshes, but the engine Insufficient battery charge Recharge the battery
does not crank Insufficient tightening of the wiring Repair
circuit terminal
Armature or field coil short Replace the starter motor
Dirty or damaged commutator Repair or replace the starter motor
Deterioration of the brush spring or Replace the brush spring or brush
wear of the brush
Bearing lock Replace the bearing or the starter motor
Defective contact of the magnetic Replace the magnetic switch
switch contact point

Phenomenon: After the Engine Starts, the Starter does not Stop even if the Ignition switch
is Turned off

After the engine starts, the starter does Improper return of the ignition switch Replace the ignition switch
not stop even if the ignition switch is contact point
turned off Improper return of the starter relay Replace the starter relay
contact point
Magnetic switch coil short circuit Replace the magnetic switch
Model (Hitachi, Ltd.) S25-501C S25-505G

Rating
Voltage V 24 24
Output kW 4.0 4.5
Time second 30 30
Number of pinion teeth 11 11
Rotational direction (when seen from the pinion Left Left
side)
Mass (Approx.) kg (lb) 5.6 (12.3) 7.5 (16.5)
No-load characteristic
Voltage/Current V-A 23 / 120 or less 23 / 120 or less
Speed r/min 3,500 or more 3,500 or more
Load characteristic
Voltage/Current V-A 18.55 / 250 or less 14.3 / 400 or less
Torque N⋅m (kg⋅m / lb⋅ft) 14 (1.4 / 10) or more 25 (2.5 / 18) or more
Speed r/min 1,500 or more 1,000 or more
Locking characteristic
Voltage/Current V-A 10 / 1,100 or less 10 / 1,200 or less
Torque N⋅m (kg⋅m / lb⋅ft) 47 (4.8 / 35) or more 47 (4.8 / 35) or more
Starter Motor
Components
LNW21EMH000101
Legend
1. Starter ground cable
2. Starter assembly
3. Starter terminal

(S25-501C)
6
5
4
3
7
2
1
8
26
25
24
23
22
21
20 9
19
18
17
10
11
12
13
14
15
16
LNW76DLF000201
Legend
1. Plunger 14. Ball bearing
2. Dust cover 15. Armature
3. Magnetic switch 16. Ball bearing
4. Terminal cover 17. Bearing retainer
5. Gearcase 18. Pinion shaft
6. Torsion spring 19. Ball bearing
7. Dust cover 20. Clutch
8. Shift lever 21. Ball Bearing
9. Through bolt 22. Return spring
10. Rear cover 23. Stopper
11. Brush holder 24. Clip
12. O-ring 25. Ball bearing
13. Yoke 26. Bearing holder

(S25-505G)
4 5
2
1 6
7
34
33
32
31
30
29
28 8
27
26 9
25
24
23
22
21
19 20
10
12
13 11
14
15
16
17
18
LNW76DLF000301
Legend
1. Plunger 18. Ball bearing
2. Dust cover 19. Bearing retainer
3. Magnetic switch 20. Clip
4. Terminal cover 21. Pinion stopper
5. Torsion spring 22. Pinion
6. Shift lever 23. Cushion spring
7. Dust cover 24. Sleeve cover
8. Gearcase 25. Stopper washer
9. Through bolt 26. Pinion shaft
10. Rear cover 27. Ball bearing
11. Drain pipe 28. Clutch
12. Brush holder 29. Ball bearing
13. O-ring 30. Return spring
14. Yoke 31. Stopper
15. O-ring 32. Clip
16. Ball bearing 33. Ball bearing
17. Armature 34. Bearing holder

Removal • Remove the magnetic switch B terminal (1)
harness.
1. Remove the starter ground cable.
• Remove the nut attaching the starter ground
cable to remove the ground cable.
1
• Disconnect the front frame harness connector 2
LNW21ESH001401
Legend
1. B terminal
2. S terminal
LNW21ESH001001
3. Remove the starter assembly.
• Remove the 2 bolts on the top and bottom, and
remove the starter from the clutch housing.
LNW21ESH001101
LNW21ESH001001
2. Remove the harness terminal.
• Remove the magnetic switch S terminal (2)
harness.

Disassembly 3. Remove the torsion spring from the magnetic
switch.
1. Disconnect the lead wire at the magnetic switch.
RTW46DSH002801
RTW46DSH002601
4. Remove the through bolt.

2. Remove the magnetic switch bolts, then remove
the switch from the shift lever. 5. Remove the screw.
6. Remove the rear cover.
RTW46DSH002701
RTW46DSH002901

7. Remove the four brushes from the brush holders. 16. Disassemble the pinion assembly.
Brush
RTW46DSH003001 RTW46DSH003401
8. Remove the yoke along with the armature and the Inspection and Repair
brush holder from the gear case. Make the necessary adjustments, repairs, and part
9. Remove the brush holder from yoke and armature. replacement if excessive wear or damage is discovered
10. Remove the armature from yoke. during inspection.
Armature
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out mm (in)

Standard 0.05 (0.002)
Limit 0.20 (0.0079)
RTW46DSH003201
11. Remove the bearing retainer.

12. Remove the pinion assembly.
13. Remove the dust cover.
14. Remove the shift lever.
15. Remove the stopper clip.
RTW46DSH003501

2. Check the commutator mica segments for If the measured outside diameter is less than the
excessive wear. specified limit, the commutator must be replaced.
3. Measure the mica segment depth.
Mica Segment Depth mm(in)

Standard 0.5-0.8 (0.020-0.031)
Limit 0.2 (0.0079)
If the mica segment depth is less than the standard

but more than the limit, the commutator may be
reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.
1 2 HCW51ESH000901
5. Use a circuit tester to check the armature for

grounding.
4
a. Hold one probe of the circuit tester against the
commutator segment.
b. Hold the other circuit tester probe against the
armature core.
5 If the circuit tester indicates continuity, the
armature is grounded.
The armature must be replaced.
RTW56DSH000701
Legend
1. Insulator
2. 0.5 to 0.8 mm (0.020 to 0.031 in)
3. Commutator Segments
4. Correct
5. Incorrect
4. Measure the commutator outside diameter.
Commutator Outside Diameter mm(in)

Standard 36.5 (1.44)
Limit 35.5 (1.40)
RTW46DSH003601
6. Use the circuit tester to check the armature for

continuity.
a. Hold the circuit tester probes against two
commutator segments.

b. Repair Step 1 at different segments of the b. Hold the other circuit tester probe against the
armature core. field winding brush.
There should be continuity between all There should be continuity.
segments of the commutator. If there is no continuity, the yoke must be
If there is not, the armature must be replaced. replaced.
RTW46DSH003701 RTW46DSH003901
Yoke Brush and Brush Holder

1. Use a circuit tester to check the field winding 1. Use a vernier caliper to measure the brush length
ground. (four brushes).
a. Hold one circuit tester probe against the field Replace the brushes as a set if one or more of
winding end or brush. brush lengths is less than the specified limit.
b. Hold the other circuit tester probe against the
bare surface of the yoke body. Brush Length mm(in)
There should be no continuity. If there is
Standard 15.5 (0.61)
continuity, the field coil is grounded. The yoke
must be replaced. Limit 12 (0.47)
RTW46DSH003801
RTW46DSH004001
2. Use the circuit tester to check the field winding

continuity.
a. Hold one circuit tester probe against the "M"
terminal lead wire.

2. Use a circuit tester to check the brush holder Bearing
insulation. Inspect the bearings for excessive wear and damage.
Touch one probe to the holder plate and the other Replace the bearings if necessary.
probe to the positive brush holder.
There should be no continuity.
RTW46DSH004401
RTW46DSH004101
Reassembly
Inspect the brushes for excessive wear. 1. Install the torsion spring to the hole in the magnetic
If the negative brushes have excessive wear, the switch as illustrated.
entire brush holder assembly must be replaced. 2. Insert the shift lever into the plunger hole of the
If the positive brushes have excessive wear, the magnetic switch.
entire yoke must be replaced.
Overrunning Clutch
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
RTW46DSH005601
3. Install the magnetic switch assembly in the gear

case.
4. Install the dust cover.
Dust Cover Bolt

Tightening torque 10.6 N⋅m(1.08kg⋅m/92.2 lb⋅in)
LNW61DSH002701

7. Install the brush holder with aligning the
peripheries of the yoke and the brush holder.
RTW46DSH005701
RTW46DSH004501
5. Apply a coat of grease to the reduction gear and

install the pinion assembly to the armature shaft.
8. Install the through bolts in the rear cover and
tighten them to the specified torque.
Through Bolt
Tightening torque 8.1 N⋅m(0.83 kg⋅m/69.7 lb⋅in)
LNW61DSH002801
6. Install the brushes into the brush holder with

raising the spring end of the brush spring.
NOTE:
Take care not to damage the commutator face. LNW61DSH002901
9. Connect the lead wire in the magnetic switch and

tighten the terminal nut to the specified torque.
Terminal nut
Tightening torque 8.6 N⋅m(0.88 kg⋅m/74.9 lb⋅in)

NOTE:
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the "M"
terminal.
To prevent coil burning, complete each test as quickly
as possible (within three to five seconds).
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
a. Pull-in Test
• Connect the battery negative terminal with
the solenoid switch body and the M terminal.
When current is applied to the S terminal
from the battery positive terminal, the pinion
should flutter.
RTW46DSH002601
S
Inspection After Assembly
1. Use a vernier caliper to measure the pinion shaft
thrust play.
The pinion shaft thrust play is equal to the pinion
shaft end and pinion stopper clearance.
Pinion Shaft Thrust Play (a) mm(in)

0.3 - 1.0 (0.012 - 0.039)
RTW46DSH004601
a
b. Hold-in Maintenance Test
• Disconnect the lead at the M terminal.
The pinion should continue to flutter.
MFW81ESH000201
2. Magnetic Switch
RTW46DSH005901

c. Return Test • Tighten the B terminal (1) at the specified
• Disconnect the battery positive lead at the S torque.
terminal. Tightening torque: 7.5 - 10 N⋅m
The pinion should return to its home (0.75 - 1.0 kg⋅m/65 - 87 lb⋅in)
position.
S
1
2
RTW46DSH004701 LNW21ESH001401
Legend
1. B terminal
Installation 2. S terminal
1. Install the starter assembly.
• Install the starter to the clutch housing with a
bolt, and tighten at the specified torque. 3. Install the starter ground cable.
• Install the starter ground cable.
LNW21ESH001501
LNW21ESH001001 • Connect the front frame harness connector.
2. Install the harness terminal.

• Tighten the S terminal (2) at the specified
torque.
Tightening torque: 1 - 1.5 N⋅m
(0.1 - 0.15 kg⋅m/9 - 13 lb⋅in)

a b
c
d
MFW71EMF000201
(a) 7.5 - 10 N⋅m (0.75 - 10 kg⋅m / 65 - 87 lb⋅in)

(b) 1 - 1.5 N⋅m (0.1 - 1.5 kg⋅m / 9 - 13 lb⋅in)
(c) 127 N⋅m (12.9 kg⋅m / 94 lb⋅ft)
(d) 127 N⋅m (12.9 kg⋅m / 94 lb⋅ft)
Starter Switch
Removal Inspection
1. Remove the steering cowl (1). Inspect the continuity between the ignition switch
• Remove the screws to remove the cowl. connector terminals.
2. Disconnect the ignition switch connector (2).
repair or replace it.
LNW71ESH001001
IG1 B2
ACC ST
B1 IG2
OFF ACC ON ST
B2
IG2
ST
B1
ACC
IG1
LNW71ESF000501
Installation
Installation is in the reverse order of the removal.
Charging System
When performing maintenance on the electrical The charging system is an IC integral regulator
system, check that the ignition switch and lighting charging method. The main components are connected
switch are OFF, and always disconnect the negative (-) as shown in the drawing.
battery terminal before working. The regulator is an integrated solid-state type regulator.
This is installed into the rear end cover along with the
brush holder assembly and is built-in to the generator.
Generator maintenance, such as adjusting the voltage
is unnecessary. There are 8 diodes in the rectifier
connected to the stator coil. These convert alternating
current voltage into direct current voltage. The direct
current voltage is connected to the generator output
terminal.
2
3
6 5
LNW71EMF000501
Legend
1. Ball bearing 4. Rectifier
2. Brush 5. Rotor
3. Regulator 6. Stator
Multi-function IC regulator
• Trouble diagnosis function
Trouble diagnosis is added to light the charge light
when the feed coil circuit is open and there is
excessive voltage.

Circuit Diagram
50A specifications
4
2
3
L 6
B S L
1 5
F
P 7
MIC
8
E
E
LNW71EMF001101
Legend
1. Stator 6. Charge warning light (LED)
2. Rotor 7. Heater relay
3. Charge relay 8. Regulator
4. Ignition switch 9. Generator
5. Batteries

80A specifications
B
S
4
2 3
L 6
B S L
1
5
F
P 7
MIC
8
E
E
LNW71EMF001201
Legend
1. Stator 6. Charge warning light (LED)
2. Rotor 7. Heater relay
3. Charge relay 8. Regulator
4. Ignition switch 9. Generator
5. Batteries
Specifications ACG50A ACG80A

Model (Hitachi, Ltd.) LR250-708E LR280-708B
Rated voltage V 24 24
Rated output A 50 80
Rotational direction (See from the pulley side) Right Right
Effective diameter of pulley mm (in) 65(2.56) 65(2.56)
Mass kg (lb) 6.1(13.45) 8.2(18.08)

Functional inspection:
General on-board inspection
The charging system indicates a problem in operations
using the charge warning light. If the warning light lights
up when the ignition switch is "ON" and turns off after
the engine is started, operations are normal. If the
warning light indicates an abnormality, or it is thought
that there is an insufficient battery charge or
overcharge, perform trouble diagnosis according to the
failure symptom list.

Failure symptom list
Does not charge at all
Charge is insufficient
Overcharged
Charged current is unstable
Abnormal sound in generator

Phenomenon: Does not charge at all

Does not charge at all Defective battery Replace
Open circuit, short circuit and Repair
disconnection of connecting section of
wiring or current meter
Open circuit in each coil, ground short Replace
circuit, or damaged diode of the
generator
Defective regulator Replace
Regulator terminal contact problem Repair

Phenomenon: Charge is insufficient

Charge is insufficient Defective battery Replace
Open circuit, short circuit and Repair
disconnection of connecting sections of
wiring
Loose generator drive belt Adjust belt tension
Stator coil layer short Replace
Diode failure Replace
Improper terminal contact Repair
Regulator terminal defective contact Repair

Phenomenon: Overcharged

Overcharged Defective regulator Repair

Phenomenon: Charged current is unstable

Charged current is unstable Intermittent contact of wiring, or open Repair
circuit
Loose generator drive belt Adjust belt tension
Short circuit in stator coil, or near open Repair
circuit
Improper terminal contact Repair
Regulator terminal defective contact Repair

Phenomenon: Abnormal sound in generator

Abnormal sound in generator Belt tension is loose Adjust belt tension
Defective bearing Replace the bearing
Contact of rotor core and stator core Repair
Diode failure Replace
Short circuit in stator coil, or near open Replace
circuit
Generator
Components
5
4
3 10
2
9
1
8
7
LNW76DLF000101
Legend
1. Pulley nut 6. Through bolts
2. Pulley 7. Rear cover assembly
3. Front cover assembly 8. Rectifier
4. Rotor assembly 9. Ball bearing
5. Stator assembly 10. Ball bearing
Removal
1. Remove the A/C compressor drive belt.
2. Remove the A/C compressor.

• Remove the A/C compressor harness
connector, and remove the compressor from
the A/C compressor bracket to fasten to any
1
position together with the hoses using a wire,
etc.
LNW81ESH000101
5. Remove the generator.
Disassembly
LNW71ESH001501
1. Remove the through bolts.
2. Insert a flat-blade screwdriver between the front
3. Remove the generator harness. cover and the stator. Pry the parts apart.
• Remove the B terminal cable and harness 3. Separate the front cover/rotor assembly from the
connector from the generator. rear cover/stator assembly.
4. Remove the drive belt.
a. 50A specification
• Loosen the adjust plate lock nut (2) and
through bolt (3).
• Loosen the generator adjust bolt (1) to
remove the belt.
2
LNW76DSH000801
4. Place the front cover and rotor in a vise.

5. Remove the pulley nut and the pulley.
1
3
LNW71CSH001101
b. 80A specification
• Loosen the tension pulley lock nut (3).
• Loosen the tension pulley adjust bolt (2) to
remove the belt.

6. Remove the rotor from the front cover. 10. Remove the rear cover from the stator.
11. Remove the stator assembly.

7. Remove the screw from the front cover.
8. Remove the bearing retainer and the bearing.
RTW46DSH000401
LNW71DSH000201
9. Remove the B-terminal nut and M5 nut.


12. Remove the rectifier assembly from the stator
assembly.
LNW76DSH000501
3. Measure the electrical resistance between the slip

LNW76DSH000601
rings.
If the resistance is greater than the specified limit
(open circuit), repair is required.
Inspection and Repair
Repair or replace any parts found to be excessively
Rotor coil resistance at 20°C (68°F) Ω
worn or damaged during the inspection procedure.
50A specifications 8.2
Rotor Assembly
80A specifications 10.2
1. Check for dirty or rough slip ring surfaces.
Remove dirt from the surfaces with a clean rag.
Use No.500 or No.600 sandpaper to smooth the
surfaces.
2. Measure the slip ring diameters.
Replace the slip ring if the diameter is less than the
specified limit.
Slip ring diameter mm(in)

Standard 31.7(1.248)
Limit 30.7(1.209)
LNW76DSH000301
4. Check for conductivity between the slip rings and

the rotor core.
If there is continuity, the rotor assembly must be
replaced.
Stator Coil
1. Measure the stator coil resistance.
If the resistance is less than the specified value,
the stator coil must be replaced.
Stator coil resistance at 20°C (68°F) Ω Brush height mm(in)

50A specifications 0.19 Standard 25(0.984)
80A specifications 0.07 Limit 6.5(0.260)
LNW76DSH000701
2. Measure the resistance between the stator coil and

the stator core. 3
If the resistance is less than the specified value,
the stator coil must be replaced. 4
Stator coil/core resistance: Min. 1 MΩ
LNW76DMH000101
Rectifier Assembly
Measure each of the diode resistances in both
directions (anode/cathode and cathode/anode).
2
If any of the diodes have the same resistance in both
directions, the rectifier must be replaced.
HCW31ESH004401
Brushes
Measure the brush height.
If the height is less than the specified limit, the brushes
must be replaced.
RTW46DSH001201
Tester Wire
E BAT
+ - + -
U,V, and WN U,V, and WN
+ — Conductivity + — NO conductivity
- NO conductivity — - Conductivity —
Negative side diode check Positive side diode check
Rectifier Assembly
50A specifications
L
6
SWITCH 2 8
B + OUTPUT SIGNAL
7
3 5 PULSE 5~30V
LAMP 2 LAMP 1 SWITCH 3 GENERATOR
4 -
1kHz
2
1 VOLT METER V DIRECT-CURRENT
STABILIZATION POWER SUPPLY LNW76DSF000101
80A specifications
L
E
S
7
SWITCH 2 9
B + 8 OUTPUT SIGNAL
4 6 PULSE 5~30V
LAMP 2 LAMP 1 SWITCH 3 GENERATOR
2 SWITCH 1 5 -
1kHz
3
1 VOLT METER V DIRECT-CURRENT
STABILIZATION POWER SUPPLY RTW46DSF000301
Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1 to 5.If all the items are OK, the
IC regulator is normal.

Circuit components
1 DC regulated power supply 0 - 30 volts variable with output of 1 ampere or more
2 Lamps (2) 24 volts, 1.8 watts
3 Switches (3) —
4 DC voltmeter 0 to 60 volts, 0.5 grade
5 Pulse generator (Oscillator) 5 to 30 volt output at a frequency of 1KHz
Judgment criteria
Switch Switch Switch Voltmeter Lamp condition

NO. Remarks
1 2 3 reading Lamp 1 Lamp 2
On
1 ON OFF OFF 24V ON Initial excitation check
(dim)
On or
2 ON ON OFF 24V OFF Full excitation check
flashing
Off or Lamp 1 off or dimly lit when the voltmeter
3 ON ON OFF 32V OFF
on (dim) shows less than 24 or 32 volts
On or
4 ON ON OFF 24V ON Stator and brush separation check
flashing
5 ON ON ON 36V On ON Excess voltage check
Reassembly
Follow the disassembly steps in reverse order to
reassemble the generator.
Pay close attention to the items below.
• Be very careful not to reverse battery polarity.
Reversed battery polarity will destroy the rectifier
diodes.
• Do not ground the generator B-terminal.
Heat and fire damage to the harness will result.
• If using a fast charge procedure, be sure to
disconnect the battery positive cable.
If you do not, the rectifier diodes will be exposed to
high positive voltage that will destroy them.
• Be very careful to reassemble the parts to their
original positions.
Particular care must be taken with insulated parts.
• Carefully clean all insulated parts so that they are RTW46DSH002101
completely free of oil and/or grease.

• Be sure that B-terminal twist-type stoppers (round
terminal) are securely inserted before tightening
the nuts.
Final Assembly
1. Pulley and rotor assembly.
• Install the pulley and rotor assembly
a. Carefully clamp the rotor assembly in a vise.
b. Tighten the pulley nut.

c. The rear ball bearing is pressed into the wheel c. Insert the pin from the outside of the rear cover.
eccentric groove. Press the brushes into the holder.
The bearing ring projects from the groove. Complete the assembly procedure.
During installation, rotate the bearing to the
point of minimum bearing ring projection.
Pin
RTW46DSH005301
3. Use a bench press to install the rear cover

LNW81ESH000201
assembly to the front cover assembly.
Legend
1. Ring
2. Projection part 0.65 mm(0.0256 in) blow
3. Eccentric groove
2. Rear cover and stator assembly.

a. Use a pair of long-nose pliers to connect the
stator coil leads and the rectifier leads.
b. Finish the work as quickly as possible to
prevent the rectifier from heat transferred by the
soldering.
RTW56DSH000201
4. Through bolts.
• Place a guide bar through the holes in the front
cover and rear cover flange for proper
alignment.
Install the through bolts.
Tightening torque: 4 N⋅m (0.4 kg⋅m / 35 lb⋅in)
Installation
RTW46DSH000401 1. Install the generator.
a. 50A specifications
• Install the generator to the bracket and
adjust plate and temporarily tighten.
NOTE:
• Tighten the generator after adjusting the drive belt.

b. 80A specifications
• Tighten the generator at the specified
torque.
Tightening torque
Upper side (1) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Lower side (4) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
2 LNW71ESH001501
6. Install the A/C compressor harness connector.

4
7. Install the A/C compressor drive belt.
• Install the drive belt and adjust belt tension.
For details on the adjustment, refer to "Drive
Belt" in Section 1C, Engine Coolant (4HK1).
3
LNW81ESH000101
2. Install the drive belt.

• Install the fan belt and adjust belt tension.
For details on the adjustment, refer to "Drive
Belt" in Section 1C, Engine Coolant (4HK1).
3. Tighten the temporarily tightened portions of the
generator at the specified torques. (50A
specifications)
Tightening torque
Lock nut 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Trough bolt 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
4. Install the generator harness.

• Install the harness connector (1 pole) and B
terminal cable to the generator.
5. Install the A/C compressor, and tighten at the
specified torque.
NOTE:
Tighten the 2 backside mounting bolts of the
compressor first and tighten the 2 front side bolts.

a a
b c
c
LNW81ESF000101
(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
Warm up System
• To reduce the white smoke, improve warming up
and the heating, a warming system is
implemented.
• This warming system composed of an intake
throttle valve, EGR valve and exhaust brake valve
closes each throttle valve according to the engine
coolant status. This increases the load on the
engine with exhaust pressure and bypasses the
heat energy generated by the engine to the coolant
via the cylinder block to improve warming and
heating.
• This controls the intake throttle, exhaust brake and
injector, increases fuel, raises the exhaust
temperature and raises the engine coolant
temperature to promote improvement in the
warming and heating. Also, by operating the
exhaust brake valve, residual combustion gas in
the cylinders increases raising the combustion
chamber and exhaust temperatures, which
suppresses the generation of un-consumed gas,
which is the cause of white smoke, thereby
reducing it.
• The control unit that controls the quick warm-up
system (QWS) is the ECM. For details on these,
refer to "Diagnostic Information and Procedures" in
Section 1A, Engine Control System (4HK1).

Exhaust brake valve
Operation
• Check for the sound of the valve hitting the stopper
when the exhaust brake is operated while the
vehicle is idling. Check to make sure that the valve 1
returns smoothly when put back to OFF.
Individual 2
• When actuated at 66.7 - 93.3 kPa(0.680 - 0.951 3

kg/cm2/9.670 - 13.52 psi) with the vacuum pump in
the power chamber, the exhaust brake valve
should open and close smoothly. 5
4
LNW21GSH001501
Exhaust brake magnetic valve

Inspection
Inspect continuity between the ports by connecting the
terminal number (1) of the magnetic valve connector to
the battery (+) terminal, and the terminal number (2) to
the (-) terminal.
LNW21GSH000401
2 1
• When actuated at negative pressure 86.7 - 93.3
kPa(0.884 - 0.951 kg/cm2/12.57 - 13.52 psi) with
the vacuum pump on the power chamber (1), the
gaps (3), and (4) of the valve (5) and the body
should be averaged. If the gap is beyond the
standard value, adjust it using the adjust bolt (2).
Average gap mm (in) Min. gap mm (in)

0.1 - 0.25 (0.0039 - 0.0098) 0.1 (0.0039)
LNW21FSH000201

Warm-up switch
Inspection
Inspect the continuity between the ignition connector
terminals.
repair or replace it.
1
2
2 1
4 3
LNW71ESH000901

Warming is not promoted with the warm-up switch at
ON (when idling; water temperature less than
80°C(176°F))

Phenomenon: Warming is not Promoted with the Warm-up Switch at ON (when idling; wa-
ter temperature less than 80°C (176°F))

Warming is not promoted with the Exhaust throttle valve does not open Inspect whether the normal negative
warm-up switch at ON (when idling; fully pressure is being applied to the
water temperature less than 80°C magnetic valve and whether the normal
(176°F)) voltage is being applied to the terminal.
Inspect the circuit if NG. Replace the
magnetic valve if voltage and negative
pressure are normal
Inspect the action of the throttle valve
shaft and repair when there is an
abnormality
The intake throttle valve does not work Inspect for a normal signal being
applied to the DC motor terminals.
Inspect the circuit if NG. Replace the
DC motor if signal is normal
Inspect the action of the throttle valve
shaft and repair when there is an
abnormality
MEMO
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Emission Control (4HK1) 1F-1
ENGINE
Emission Control
(4HK1)
TABLE OF CONTENTS
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1F-2
Description of Function and Operation . . . . . . . 1F-2
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . 1F-4
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-5
List of Tightening Torques . . . . . . . . . . . . . . . . . 1F-7
1F-2 Emission Control (4HK1)
EGR System
When assembling the EGR system, temporarily tighten The EGR system recirculates a part of the exhaust gas
once, then firmly tighten in order not to apply to the intake manifold, and by mixing in inert gas to the
unnecessary stress on the components. intake air, the combustion temperature is lowered and
the generation of NOx is suppressed.
The control method of this EGR employs an electronic
control method that ensures both drivability and low
emissions. This activates the DC (direct current) motor
using a control current from the engine control module
(ECM) to control the EGR valve.
For details on the EGR system trouble diagnosis, refer
to "Engine Control System" in Section 1A, Engine
Control System (4HK1).
3 4
6
7
10
LNWA1FLF000101
Legend
1. ECM 6. Intake throttle valve
2. EGR valve 7. MAF sensor
3. Engine coolant outlet 8. Intake throttle position sensor
4. Engine coolant inlet 9. Engine speed
5. EGR cooler 10. Engine load

EGR Valve and EGR Cooler

Components
2
1
6 5
LNWA1HLF000501
Legend
1. EGR cooler duct 5. Exhaust EGR cooler duct
2. EGR valve 6. EGR cooler Assembly; 1st
3. EGR cooler exhaust bracket 7. Rear EGR cooler bracket
4. Front EGR cooler bracket 8. EGR cooler Assembly; 2nd
Removal NOTE:
After removing the EGR cooler duct, seal it so that
foreign material does not get in.
2. Disconnect the EGR valve connector.
3. Remove the water rubber hose. 6. Remove the EGR cooler Assembly; 1st.
4. Remove the EGR cooler heater protector. 7. Remove the EGR cooler duct.
5. Remove the exhaust EGR cooler duct.
NOTE:
After removing the EGR cooler duct, seal it so that
foreign material does not get in.

8. Remove the EGR cooler Assembly; 2nd.
9. Remove the EGR valve.
NOTE:
After removing the EGR valve, seal it so that foreign
material does not get in.
Inspection
Inspection of gas leaks
• Check for gas leaks in each part of the EGR gas
line.
If any problem is found in the inspection results,
repair it or replace the part.
Inspection of the EGR valve

• Clean if there is carbon buildup.
LNWA1HSH000801
• For details on the EGR valve electro-magnetic
system, refer to "Engine Control System" in
Section 1A, Engine Control System (4HK1).
3. Install the EGR cooler duct to the EGR valve and
cylinder head.
Installation • Insert the gasket and temporarily install the
NOTE: EGR cooler duct.
• If the procedures or methods for assembling parts 4. Install the EGR cooler Assembly; 2nd.
for the EGR cooler are mistaken, it can lead to • Fit gaskets into both ends of the EGR cooler
cracks to pipe or gas leaks. Always follow the Assembly and temporarily install it.
procedures. 5. Install the exhaust EGR cooler duct to the cylinder
After temporarily installing, securely tighten it. head and exhaust manifold.
• Even when disassembling only one EGR-related • Insert the gasket and temporarily install the
part, loosen all of the EGR-related parts, replace exhaust EGR cooler duct.
gaskets with new ones, temporarily tighten the 6. Install the EGR cooler Assembly; 1st.
parts in the following tightening order, then
securely tighten the parts. • Fit gaskets into both ends of the EGR cooler
assembly and temporarily install it.
1. Tighten the front EGR cooler bracket and rear
EGR cooler bracket at the specified torque. (1)
NOTE:
• After inserting each bolt, temporarily tighten bolts
Tightening torque (2) to (7) at the torque of 4 N⋅m (0.4 kg⋅m / 35 lb⋅in)
M8 24 N⋅m(2.4 kg⋅m/17 lb⋅ft) using a tool (follow the tightening order shown in
the diagram).
M12 104 N⋅m(10.6 kg⋅m/77 lb⋅ft)
• Temporarily tighten bolts (8) to (14) to a point
immediately before they are seated.
2. Install the EGR valve to the inlet cover.
• Tighten at the specified torque in the order of (2) to
• Insert the gasket and temporarily install the (14).
EGR valve.
7. Tighten the EGR valve and inlet cover at the

specified torque. (2)
8. Tighten the EGR cooler duct, the EGR cooler

assembly and the exhaust EGR cooler duct at the
specified torque in the order of the numbers shown
in the diagram.

a. EGR valve and EGR cooler duct bolt (3) f. Exhaust EGR cooler duct and exhaust manifold
bolts (8) to (11)
b. EGR cooler duct and cylinder head bolts (4)
g. Exhaust EGR cooler duct and EGR cooler
Tightening torque: 104 N⋅m (10.6 kg⋅m/77 lb⋅ft) assembly; 1st bolt (12)
c. EGR cooler assembly; 1st and rear EGR cooler
bracket bolts (5)
h. EGR cooler exhaust bracket and front EGR
Tightening torque: 40 N⋅m (4.1 kg⋅m/30 lb⋅ft) cooler bracket bolt (13)
d. EGR cooler duct and EGR cooler assembly; Tightening torque: 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
2nd bolts (6)
i. Exhaust EGR cooler duct and EGR cooler
Tightening torque: 28 N⋅m (2.9 kg⋅m/21 lb⋅ft) exhaust bracket bolt (14)
e. EGR cooler assembly; 1st and EGR cooler
assembly; 2nd bolts (7)
7 6
5
1
12
14
13
14
9 8,11
10 4
LNWA1HLF000301
9. Install the EGR cooler heat protector and tighten it


11. Connect the EGR valve connector.
10. IConnect the water pipe and rubber hose. 12. Replenish the coolant.
• Install the clip to the specified position.
c
b
o
n
g
j
m i
LNWA1HLF000401
(n) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(a) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft) (o) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(e) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(h) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(i) 35 N⋅m (3.6 kg⋅m / 26 lb⋅ft)
(j) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(k) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(l) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
(m) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MEMO
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Engine Exhaust (4HK1) 1G-1
ENGINE
Engine Exhaust
(4HK1)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1G-2
Description of Function and Operation . . . . . . . 1G-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1G-3
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1G-4
Phenomenon: Vibrations and Rattling
Sounds from the Exhaust System. . . . . . . . . . . 1G-5
Phenomenon: Clogging of the Exhaust System 1G-6
Phenomenon: Exhaust Gas Leak, Noise . . . . . 1G-7
Phenomenon: Exhaust Gas is Mostly Black in
Large Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Exhaust Gas is Mostly White in Large Quantity 1G-9
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-10
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-11
List of Tightening Torques . . . . . . . . . . . . . . . . 1G-12
Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
Functional inspection: . . . . . . . . . . . . . . . . . . . 1G-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-15
List of Tightening Torques . . . . . . . . . . . . . . . . 1G-16
Exhaust Brake Solenoid Valve . . . . . . . . . . . . . . 1G-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
1G-2 Engine Exhaust (4HK1)
Exhaust System
Vibrations and looseness of the exhaust system are The exhaust brake includes a valve inside the exhaust
caused by mis-positioning when assembling. pipe, and closing this valve increases resistance in the
Temporarily install all bolts and nuts until all exhaust stroke, to raise the effect of the engine brake.
components are positioned. After positioning is Also, by adjusting the exhaust pressure, quick warm-up
completed, tighten them from the engine side to the system (QWS) is executed.
rear side. The main components are: a front exhaust pipe,
exhaust brake, silencer and tail pipe.
This diagram shows a vehicle with a wheel base of 3,800 mm(149.6 in)
1 2 3 4 6
5
LNWA1GSF000101
Legend
1. Front exhaust pipe A 4. Silencer
2. Exhaust brake ASM 5. Extension pipe
3. Front exhaust pipe B 6. Tail pipe

• When inspecting or repairing the exhaust system,
check that there is an adequate gap between the
floor and body.
• Damage caused by heat from the body panel or
vibrations can cause exhaust gas to enter the
cabin. Be careful.
• Inspect for loose or damaged connections and
exhaust gas leaks.
• Inspect the clamp and rubber for degradation,
cracks or damage.
• If the pipes or silencer are damaged or dented,
repair or replace them.
• Inspect for dents or damage, or holes and
fractures caused by corrosion, and abnormal noise
when driving the vehicle.

• Vibrations and Rattling Sounds from the Exhaust
System
• Clogging of the Exhaust System
• Exhaust Gas Leak, Noise
• Exhaust Gas is Mostly Black in Large Quantity
• Exhaust Gas is Mostly White in Large Quantity

Phenomenon: Vibrations and Rattling Sounds from the Exhaust System

Vibrations and rattling sounds from the Loose components, or improper Retighten after aligning the connections
exhaust system installation Inspect the hanger, installed brackets
and clamps for damage

Phenomenon: Clogging of the Exhaust System

Clogging of the exhaust system The exhaust brake is ON Inspect and repair the control system.
Refer to "Diagnostic Information and
Procedures" in Section 1A, Engine
Control System (4HK1)
Also, inspect the exhaust brake shaft
for strain. Replace if there is a problem
Clogging of the exhaust pipe Repair or replace the exhaust pipe
Clogging of the silencer (oxidation Repair or replace the silencer (oxidation
catalyst) catalyst)

Phenomenon: Exhaust Gas Leak, Noise

Exhaust gas leak, noise Improper installation or connection Retighten after aligning the connections
Exhaust pipe or silencer damage, Replace the damaged parts
burning
Defective exhaust system components Replace the unnecessary parts
(clamps, pipe, silencer)
Internal damage on silencer Replace the damaged parts

Phenomenon: Exhaust Gas is Mostly Black in Large Quantity

Silencer (catalyst) failure Melted or broken catalyst Replacement
Clogging of the catalyst Repair or replacement

Exhaust Gas is Mostly White in Large Quantity

Silencer (catalyst) failure Accumulation of the exhaust gas Repair or replacement
content and clogging of the catalyst
Exhaust Pipe
Components
This diagram shows a vehicle with a wheel base of 3,800 mm(149.6 in)
LNWA1GLF000101
Legend
1. Front exhaust pipe A 4. Silencer
2. Exhaust brake assembly 5. Extension pipe
3. Front exhaust pipe B 6. Tail pipe
Removal 6. Remove the front exhaust pipe A.

1. Remove the tail pipe. • Remove the clamp, and remove the front
exhaust pipe.
• Remove the clamps and tail pipe.
2. Remove the extension pipe.
3. Remove the silencer. Inspection
4. Remove the front exhaust pipe B . 1. Externally inspect the exhaust pipe components.
5. Remove the exhaust brake assembly. • Damage caused by heat from the body panel or
• Remove the vacuum hose and the exhaust vibrations can cause exhaust gas to enter the
brake assembly. cabin. Be careful.

• Inspect for loose or damaged connections and
exhaust gas leaks.
• Inspect the clamp and rubber for degradation,
cracks or damage.
• Inspect the pipe or silencer for dents, or cracks
caused by corrosion. If damaged, repair or replace
them.
Installation
NOTE:
• Do not reuse the removed gasket and nut.
• Visually check that there is no foreign material in
the exhaust pipe.
1. Temporarily tighten the front exhaust pipe A,

exhaust brake assembly, and front exhaust pipe B.
NOTE:
Uniformly tighten the front exhaust pipe so that there is
no exhaust gas leak.
2. Install the exhaust brake vacuum hose.

3. Temporarily tighten the silencer.
4. Temporarily install the extension pipe.
5. Temporarily install the tail pipe.
After temporary installation, securely tighten it.
6. Turbocharger from the front exhaust pipe A.

7. Transmission right side bracket from the clamp of
the front exhaust pipe A.
8. Exhaust brake
9. Silencer from the front exhaust pipe B.
10. Silencer
11. Front side of extension pipe.
12. Tail pipe
13. Tighten the clamp after tightening the pipe joint.
Start the engine after tightening the parts and check for
exhaust leaks from the part joints and for vibrations.

k
e
b c
a
h
i
LNWA1GLF000201
(a) 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)

(b) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(e) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(f) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(g) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(h) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(i) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(j) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(k) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
Exhaust Brake
Components
3 6 5
7 8
2
9
10
11
13
12
11
LNWA1GMF000101
Legend
1. Exhaust brake assembly 8. Bearing
2. Bolt 9. Nut
3. Cover 10. Pin
4. Power chamber 11. Gasket
5. Gasket 12. Exhaust brake valve
6. Clevis joint 13. Nut
7. Split pin

Operation Inspection Individual inspections
• Check for the sound of the valve hitting the stopper • When negative pressure is actuated from the
when the exhaust brake is operated while the vacuum pump to the power chamber at 66.7 - 93.3
vehicle is idling. kPa(0.680 - 0.951 kg/cm2 / 9.670 - 13.523 psi), the
exhaust brake valve should open and close
smoothly.
Removal
1. Remove the vacuum hose and clip from the
exhaust brake assembly.
brake assembly.
• Remove the front exhaust pipe A and
turbocharger installation nut.
• Remove the front exhaust pipe A and exhaust
brake assembly installation nut.
The exhaust brake assembly will also be
removed together.
• Remove the transmission right side exhaust
pipe bracket mounting bolts.
LNW21GSH000401
Reassembly
1. Install the power chamber.
LNWA1GSH000101
Disassembly
1. Remove the split pin.
2. Remove the lock nut.
3. Remove the clevis joint.
4. Remove the power chamber.
Inspection
Inspect the following parts for damage and LNW41GSH001101
degradation. 2. Install the lock nut.

• Exhaust brake valve 3. After installing the clevis joint, tighten the lock nut
• Exhaust brake shaft at the specified torque.
• Butterfly valve Tightening torque: 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
• Bushing
• Power chamber
LNW21GSH002201
4. Install the split pin.
Installation
1. Install and temporarily tighten the front exhaust
pipe A and exhaust brake assembly.
LNWA1GSH000101
2. Tighten the mounting bolt and nut at the specified

torque.
Tightening torque: N⋅m (kg⋅m / lb⋅ft)

Turbocharger side nut 67 (6.8 / 49)
Exhaust pipe clamp bolt 41 (4.2/ 30)
Exhaust brake side nut 27 (2.8 / 20)
3. Install the vacuum hose and clip.


g
b
f
e
LNWA1GMF000201
(a) 14 N⋅m (1.4 kg⋅m / 122 lb⋅in)

(b) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
(c) 6 N⋅m (0. 6 kg⋅m / 52 lb⋅in)
(d) 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
(e) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(f) 27 N⋅m( 2.8 kg⋅m / 20 lb⋅ft)
(g) 50 N⋅m( 5.1 kg⋅m / 37 lb⋅ft)
Exhaust Brake Solenoid Valve

Removal Inspection
1. Remove the rubber hoses (1). 1. Perform a continuity test between terminals (1)
and (2), and confirm that continuity exists.
3 4 2 1
LNW71FSH002901
LNW86FSH000101
2. Remove the exhaust brake solenoid valve.
2. Confirm that air exits from (5) when blowing your
breath from (4). At this time, confirm that air does
not exit from (3).
3. Confirm that an operation sound is made when
providing power supply voltage to the connector.
4. While providing power supply voltage to the
connector, confirm that air exits from (3) when
blowing your breath from (4).
At this time, confirm that air does not exit from (5).
Installation
1. Install the exhaust brake solenoid valve.
LNW71FSH003001
LNW71FSH003001

2. Install the rubber hoses (1).
LNW71FSH002901
Engine Lubrication (4HK1) 1H-1
ENGINE
Engine Lubrication
(4HK1)
TABLE OF CONTENTS
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . 1H-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1H-2
Description of Function and Operation . . . . . . . 1H-2
Functional inspection: . . . . . . . . . . . . . . . . . . . . 1H-3
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
List of Tightening Torques . . . . . . . . . . . . . . . . . 1H-5
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
List of Tightening Torques . . . . . . . . . . . . . . . . . 1H-7
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
List of Tightening Torques . . . . . . . . . . . . . . . . 1H-16
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-17
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-21
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . 1H-26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-26
1H-2 Engine Lubrication (4HK1)
Lubrication System
• Use a scraper to completely scrape off old liquid A full-flow bypass integrated filter element, water-
gasket from the locations where it is used. After cooling oil cooler, and piston coolant oil jet are adopted
cleaning using a rag, etc., to completely remove for the lubrication system.
any oil, moisture and filth, apply the specified liquid
gasket.
Apply the proper amount to avoid an excess or
lack in application. If an excessive amount is
applied, the oil gallery and oil jet head can clog,
which leads to seizures. If an insufficient amount is
applied, it causes the oil and water leaks.
Overlap the beginning and ending of the
application.
Lubricating system diagram
Oil pressure switch

39 (0.4/6) Fuse
98 (1.0/14) Oil pressure Engine control Battery

Safety valve indicator lamp switch
(Filter installed)
Full flow filter Oil cooler Oil gallery
By pass valve 441 (4.5/64)

200 (2.0/28) Relief valve
Valve train Crankshaft Check valve Vacuum (Front cover
bearing 196 (2.0/28) pump installed)
800 (8.2/116)
Relief valve
Oil pump (Oil pump Turbo Gear train Con-rod Oil jet
internal charger bearing
organs)
Oil strainer
Oil pan
kPa(kg/cm2/psi)
LNWA1HLF000101

Engine oil used 2. Install the oil pressure gauge.
• Besco Engine Oil or equivalent
5
NOTE:
Always use this engine oil for this engine.
Inspecting the engine oil amount

• Park the vehicle on a level area. Inspect prior to
starting the engine or following more than 30
minutes after stopping the engine.
• Oil amount inspection method
- Remove the oil level gauge and wipe off any
adhering oil.
1
- Insert it all the way in again, and pull out slowly.
If the oil is between the MIN and MAX
inspection markings, the level is acceptable.
- If the oil is insufficient, refill it to the MAX refill
marking.
Engine oil replacement period for except Europe

market: Every 20,000 km (12,428 mile) or once every
year.
4 3 2
LNW46AMH000201
Legend
1. Oil filter cartridge
2. Adaptor
3. Connector
4. Hose
5. Pressure gauge
1 2 3. Adequately warm up the engine.

4. Measure and confirm that the oil pressure is 294
kPa(3.0 kg/cm2/42.66 psi) or higher at 1,700 r/min.
5. Stop the engine.
LNW61HSH000401 6. Remove the oil pressure gauge.
Legend 7. Install the pressure switch.
1. Upper limit 8. Start the engine and check that there is no oil leak.
2. Lower limit
NOTE:
Inspect whether the engine oil is excessively dirty or
Inspecting the oil pressure contains water. If the engine oil is excessively dirty or
1. Inspect the engine oil level. If the engine oil is contains water, investigate the causes, take the
insufficient, refill it. appropriate measures and change the oil.
Inspecting for engine oil leaks

• Inspect for leaks from the oil seals, cylinder head
cover, oil pan, etc.
Oil Filter Cartridge

Components
1
LNW21HSF000101
Legend
1. Oil filter cartridge
Removal Installation
1. Place a pan under the oil filter cartridge. 1. Install the oil filter cartridge.
2. Use the oil filter wrench to remove the oil filter • Apply grease (Besco L2 or L3) or engine oil to
cartridge. the cartridge seal and use the oil filter wrench to
install.
Special Tool • Tighten the cartridge at the specified torque.
Oil filter wrench: 1-8522-1097-0
NOTE: OR
When attaching and removing the cartridge, be careful After touching the oil seal, further tighten one and 1/4
not to sandwich the CRP sensor harness. turns.
Special Tool
Oil filter wrench: 1-8522-1097-0
LNW21HSH000601

LNW71HSF000401
(a) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)

Oil Filter Assembly

Components
2
5
1
6
LNWA1EMF000301
Legend
1. Oil pressure switch 4. Nut
2. O-ring 5. Oil filter cartridge
3. Oil filter body 6. Bolt
1. Place a pan under the oil filter assembly. 1. Install the O-rings (1) and (2) to the oil filter body.
2. Remove the oil pressure switch.
3. Remove the oil filter body. 1
4. Remove the O-ring.
MFW51HSH000201

3. Install the oil pressure switch to the oil filter body.
2. Install the oil filter body to the cylinder block and • Apply liquid gasket (Loctite No. 262) to 2 or 3
tighten it at the specified torque. threads from the leading end of the threaded
portion of the oil pressure switch, and install it
Tightening torque: 48 N⋅m (4.9 kg⋅m / 34 lb⋅ft) to the position shown in the diagram.
LNW21HSH000301
LNW21HSH000401
LNWA1EMF000401
(b) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)

(a) 48 N⋅m (4.9 kg⋅m / 34 lb⋅ft) (c) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
Oil Cooler
Components
2 3
8 7 6 5 4
LNW91HLF000801
Legend
1. Bypass hose 5. Common rail
2. EGR cooler water pipe (IN) 6. Cylinder block cover
3. EGR cooler water pipe (OUT) 7. Water inlet pipe
4. Supply pump 8. Oil cooler assembly
Removal
1. Remove the common rail.
Fuel (4HK1).
2. Remove the supply pump.
(4HK1).
3. Remove the A/C drive belt.
4. Remove the idle pulley bracket.

• Remove the A/C drive belt and the bracket 7. Remove the cylinder block cover.
mounting bolt to remove the bracket with the
tensioner and idle pulley. 1 2
LNW91HSH000401
Legend
LNW41BSH003401
1. Oil cooler
2. Cylinder block cover
8. Remove the oil cooler assembly.
6. Remove the clip of the head side for the water
• Twist in the removed oil cooler mounting bolt
bypass hose and remove using the water inlet pipe
into the replacer hole (1) shown in the diagram
and the assembly.
and remove the oil cooler.
2
1
1
4 LNW81HSH000701
LNW71GSH001201
Legend
1. Bypass hose
2. EGR cooler water pipe (OUT) 9. Remove the oil cooler gasket.
3. EGR cooler water pipe (IN)
4. Water inlet pipe
Disassembly
1. Remove engine mounting bolts.
2. Remove the element (1).

3. Remove the O-rings (2). NOTE:
The liquid gasket should not adhere to the oil cooler
gasket.
1 2
• After applying the liquid gasket, install within 5
minutes.
• Refer to the diagram for the tolerance range for
miss-positioning the liquid gasket.
1
2 3
LNW71GSH001301
Reassembly 5 6
1. Install the O-rings (2) to the oil cooler case. 4
2. Install the element (1).
3. Tighten the element mounting bolt at the specified LNW81HSH000201
torque.
Legend
Tightening torque: 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) 1. Oil cooler gasket
2. Liquid gasket
3. Oil cooler gasket
4. 0.1 - 2.0 mm (0.0039 - 0.0787 in)
1 2 5. 2 - 4 mm (0.079 - 1.56 in)
6. 1 mm (0.039 in)
2. Install the cylinder block cover.

LNW71GSH001301
Installation
1. Install the oil cooler gaskets (1) and (3).
• Apply liquid gasket (TB1207B) along the
groove in the flange surface.
• Install the oil cooler gasket to the oil path
entrance / exit areas.

• Refer to the diagram for the tolerance range for
1 2 miss-positioning the liquid gasket.
3 4
LNW91HSH000401
2
Legend
LNW81HSH000301
1. Oil cooler
2. Cylinder block cover Legend
1. liquid gasket
2. 0.5 - 2.0 mm (0.020 - 0.079 in)
3. 2 - 5 mm (0.079 - 0.197 in)
3. Install the oil cooler assembly. 4. 1 mm (0.039 in)
• Align to the cylinder block stud (13), install the
oil cooler, and tighten it at the specified torque
in the order shown in the drawing.
• Install to the position shown in the drawing and
Tightening torque: 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) tighten together with the oil cooler.
• (1) indicates the nut.
NOTE:
The installation of the water inlet pipe is directly after
11 8 4 1 5 9 12 the installation of the oil cooler (because liquid gasket
is used with the tightening).
13
14
7 3 2 6 10 15
LNW21HSH006301
4. Install the water inlet pipe.

• Position to the groove (1) of the water inlet pipe
flange surface, and apply liquid gasket
(TB1207B) in a width of approx. 2 to 5
mm(0.079 to 0.197 in)

9. Install the common rail.
Fuel (4HK1).
LNW21HSH005201
Legend
1. Nut
2. Bolt

6. Install the idle pulley bracket and tighten it at the
specified torque.
LNW41BSH003401
7. Install and adjust the A/C drive belt.

Refer to "Drive Belt" in Section 1C, Engine Cooling
(4HK1).
8. Install the supply pump.
(4HK1).
Oil Pan
Components
4 5
LNW71HLF000301
Legend
1. Oil level switch 5. Gasket
2. Oil pan gasket 6. Drain plug
3. Oil pan 7. Clip
4. Oil pan rubber
Removal 2. Remove the oil level switch connector.

1. Drain the engine oil. 3. Remove the stiffener(LH/RH).
• After draining the oil, tighten the drain plug at 4. Remove the rubber spacer.
the specified torque. 5. Remove the oil pan.
6. Remove the oil level switch from the oil pan.
NOTE:
Do not forget to tighten the drain plug.

Installation • Use the flywheel housing, the front cover and
the crank case stud as a guide to assemble the
1. Install the oil level switch to the oil pan.
oil pan gasket (3) and install the oil pan (2).
Tightening torque: 9 N⋅m (0.9 kg⋅m / 78 lb⋅in) Next, tighten the oil pan rubber assembly (1)
with the mounting bolt and nut to fasten.
• Apply a bead of liquid gasket (TB1207B) in the
width of 3 mm to the joints (arrows at four
locations) of the cylinder block, front cover and
3
flywheel housing.
• After applying the liquid gasket, install the oil
pan within 5 minutes.
2
3 2
LNW21BSH004601
LNW21BMH000101
Legend
1. Oil pan rubber
2. Oil pan
3. Oil pan gasket
• After tightening the (1), (2), (3), and (4) locations in

the drawing, tighten the others. (No particular
order is required.)
2 1 4 5 2
1
4
3
3 3
Legend
NOTE: 1. Stiffener (RH)
Recheck the tightening of the oil pan drain plug. 2. Stiffener (LH)
3. Bolt
3. Install the rubber spacer.
4. Bolt A
5. Bolt B
5. Install the oil level switch connector.

6. Fill the engine oil.
3
1 2 3
LNW91BSH006701
Legend
1. Rubber spacer
2. Stiffener (RH)
3. Bolt
4. Stiffener (LH)
4. Install the stiffener (RH/LH).
Tightening torque
Bolt (3) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
Bolt A(4) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
Bolt B(5) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

c
c
LNW71HMF000401
(a) 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)

(b) 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
(c) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
Oil Pump
Components
4
3
1
LNW81HMF000101
Legend
1. Oil pump assembly 5. Driven gear and shaft
2. Spring 6. Oil pump body
3. Ball 7. Slinger
4. Split pin
Removal • Remove the pressure plate from the flywheel.

1. Drain the engine oil.
3. Remove the transmission assembly. 1 5
For details on Smoother vehicles, refer to
"Smoother Transmission assembly" in Section 5B,
Automatic Transmission.
For details on M/T vehicles, refer to "Transmission 7
assembly" in Section 5C, Manual Transmission. 3
9
4. Remove the cylinder head assembly. 10
Refer to "Cylinder Head" in Section 1B, Engine 4
Mechanical (4HK1). 8
5. Clutch pressure plate
• Insert the clutch aligner in the spline of the
clutch disk.
6 2
• Remove the pressure plate mounting bolts in
the order numbered in the drawing.
LNW21BSH002501
6. Clutch disk 13. Remove the stiffener (LH/RH).

• Remove the clutch disk from the flywheel along
with the clutch aligner (1).
1 4 5 2
3 3
LNW91BSH006601
Legend
LNW21BSH002601 1. Stiffener (RH)
Legend 2. Stiffener (LH)
1. Clutch aligner 3. M12 bolt
4. M10 bolt
5. M12 bolt
7. Remove the supply pump assembly.
(4HK1).
14. Remove the rubber spacer.
Refer to "Flywheel" in Section 1B, Engine
Mechanical (4HK1).
9. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal" in Section 1B,
Engine Mechanical (4HK1).
10. Remove the power steering oil pump.
11. Remove the power steering oil pump idle gear
cover.
12. Remove the power steering oil pump idle gear.
4
3
1 2 3
LNW91BSH006701
Legend
1. Rubber spacer
2. Stiffener (RH)
3. M12 bolt
4. Stiffener (LH)

LNW81BSH003601 16. Remove the flywheel housing.

• Do not forget to remove the bolt shown in the 18. Remove the oil pump assembly.
drawing.
LNW81HSH000401
LNW21BSH053601
Disassembly
17. Remove the idle gear A.
1. Remove the driven gear and shaft.
2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Inspection
1. Measure the gap between the gear and the inner
wall of the oil pump body.
• Use a thickness gauge to measure the gap
between the gear and the oil pump body.
• If the gap between the gear and the inner wall
of the body exceeds the limit, replace the gear
assembly or driven gear assembly.
Gap between gear and the inner wall of mm

LNW81HSH000501 the body (in)
Standard 0.125 - 0.221
values (0.00492 - 0.00870)
0.30
Limit
(0.012)
Gap between the driven gear shaft and the mm

bushing (in)
0.04 - 0.07
Standard values
(0.0016 - 0.0028)
0.20
Limit
(0.0079)
LNW21HSH001901
2. Measure the gap between the drive gear shaft and

bushing.
• Use a micrometer to measure the outer
diameter of the driven gear shaft.
Outer diameter of the drive gear shaft mm (in)

15.989 - 16.000
Standard values
(0.62949 - 0.62992) LNW81HSH000601
15.900
Limit
(0.625983)
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin (1) and bend as shown at (1).
LNW21HSH002101
• Use a dial indicator to measure the inner

diameter of the oil pump body and cylinder
block bushing. LNW21HSH006201
• If the gap between the drive gear shaft and the Legend
bushing exceeds the limit, replace the driven 1. Split pin
gear assembly.

4. Apply engine oil to the driven gear and shaft, and • Rotate the crankshaft in the forward direction to
install them to the oil pump body. align the first cylinder piston to the top dead
center.
LNW21HSH002401
LNW81BSH005301
Installation
1. Install the oil pump assembly. • Align the crankshaft gear and idle gear A
• Apply liquid gasket (TB1207B) as shown in the alignment marks and install to the cylinder
drawing, and install it to the cylinder block block.
within 5 minutes. After that, tighten it at the
specified torque.
CAUTION:
Apply liquid gasket so that it does not get in the hole at
the arrow in the drawing, to the gear, and inside the oil
pump body.
LNW81BSH005401

seat surface of the bolt, and to both sides of the
washer.
Before assembling, be sure to confirm that the
threaded portion and seat surface of the bolt
and both sides of the washer are completely
covered in engine oil.
LNW21HSH002501
• Tighten the mounting bolt at the specified
torque.
2. Install the idle gear A.
• Fit the idle gear shaft into the position shown in Tightening torque: 157 N⋅m (16.0 kg⋅m / 116 lb⋅ft)
the drawing and apply engine oil to the shaft.

3. Install the flywheel housing.
• Clean the cylinder block back side. Particularly, • Position with the cylinder block knock pin to
clean the liquid gasket that projects out when install the flywheel housing.
the crank case is installed.
• As shown in the drawing, uniformly apply liquid
gasket (TB1207B) to the inside of the bolt hole Flywheel housing tightening torque
(excluding the bolt hole at the arrow). Bolt (1) 96 N⋅m (9.8 kg⋅m / 71 lb⋅ft)
• After applying the liquid gasket, install within 5 Bolt (2) 96 N⋅m (9.8 kg⋅m / 71 lb⋅ft)
minutes.
Bolt (3) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
• Tighten (3) from the cylinder block side.
LNWA1BSH000401
1
1
LNW91BMF001901

Refer to "Oil Pan" in this Section.

5. Install the rubber spacer between flywheel housing
and stiffener.
1 4 5 2
3 3
3
1 2 3 LNW91BSH006601
Legend
LNW91BSH006701
1. Stiffener (RH)
Legend 2. Stiffener (LH)
1. Rubber spacer 3. M12 bolt
2. Stiffener (RH) 4. M10 bolt
3. M12 bolt 5. M12 bolt
4. Stiffener (LH)
7. Install the power steering oil pump idle gear.

6. Install the stiffener (LH/RH). • Apply engine oil to the gear assembly sections
of the idle gear shaft.
• Assemble the idle gear and shaft, install as
Tightening torque
shown in the drawing, install to the flywheel
M12 bolt (3) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft) housing and tighten it at the specified torque.
M10 bolt (4) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
M15 bolt (5) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
LNW21BSH004301
1
MFW51BSH002701
LNW21BSH053601
Legend
1. Power steering oil pump mounting bolt
8. Install the power steering oil pump idle gear cover.
• Install the O-ring to the cover, install it to the
flywheel housing and tighten the mounting bolt 12. Install the supply pump assembly.
at the specified torque. Refer to "Supply Pump" in Section 1D, Engine Fuel
Tightening torque: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft) (4HK1).
13. Install the clutch disk.
14. Install the clutch pressure plate.
• Insert the clutch aligner (1) in the spline of the
clutch disk.
• Install the clutch disk to the flywheel.
• Align the pressure plate installation hole to the
knock pin in the flywheel and install the
pressure plate to the flywheel.
1
LNW81BSH003701
9. Install the crankshaft rear seal.

Refer to "Crankshaft Rear Oil Seal" in Section 1B,
Engine Mechanical (4HK1).
Refer to "Flywheel" in Section 1B, Engine
Mechanical (4HK1).
LNW21BSH002601
11. Install the power steering oil pump and tighten it at
Legend
its specified torque.
1. Clutch aligner
Power steering oil pump mounting bolts

Tightening torque 43 N⋅m (4.4 kg⋅m / 32 lb⋅ft)

• Tighten the pressure plate in the order shown in
the drawing at the specified torque.
1 5
7
3
9
10
4
8
6 2
LNW21BSH002501

For details on Smoother vehicles, refer to
"Smoother Transmission assembly" in Section 5B,
Automatic Transmission.
For details on M/T vehicles, refer to "Transmission
assembly" in Section 5C, Manual Transmission.
16. Install the cylinder head assembly.
Refer to "Cylinder Head" in Section 1B, Engine
Mechanical (4HK1).
17. Refill the coolant.
18. Fill the engine oil.
Oil Pressure Switch

Inspection 3. Disconnect the oil pressure switch connector, and
inspect that the oil pressure warning light lights
Inspect the continuity between the switch terminal and
when the harness side connector is connected to
body ground without a load applied.
the ground.
Replace with a normal part if there is no continuity in
the inspection.
If it does not light, inspect the circuit between the
meter and the oil pressure switch. Repair any open
circuit.
LNW21HSH003301
Inspection of the circuit LNW21HSH003401

1. Turn the ignition switch ON.
2. Disconnect the oil pressure switch connector, and
inspect that the oil pressure warning light turns off
at the time of the disconnection.
• If it does not turn off, inspect the circuit between
the meter and the oil pressure switch. Repair
any open circuit.
LNW71HSH002101
Engine Speed Control System (4HK1) 1I-1
ENGINE
Engine Speed Control System
(4HK1)
TABLE OF CONTENTS
Accelerator Pedal Sensor . . . . . . . . . . . . . . . . . . . 1I-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Idle Up Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-4
1I-2 Engine Speed Control System (4HK1)
Accelerator Pedal Sensor

Components
1
2
LNW41ILF000101
Legend
1. Nut 4. Accelerator pedal
2. Accelerator pedal position (APP) sensor 5. Bolt
3. Control link and bracket Assembly
1. Remove the control link and bracket assembly 1. Connect APP sensor harness connector.
installation nut. 2. Install the accelerator pedal installation bolt.
2. Remove the accelerator pedal installation bolts. 3. Install the control link and bracket assembly.
3. Disconnect the APP sensor harness connector. 4. Confirm there is a gap (a) when the pedal is fully
depressed.
NOTE:
When removing the harness connector, remove the Gap length (a) (Reference value):
battery ground. 0 - 2 mm (0 - 0.079 in)
Engine Speed Control System (4HK1) 1I-3

• When adjusting, loosen the nut (2), then screw
the bolt (1) to adjust the gap, finally lock the nut
(2).
a
2
LNWA1ISH000101
NOTE:
After adjustment, do not remove stopper bolt (1).
1I-4 Engine Speed Control System (4HK1)
Idle Up Sensor
Removal
1. Disconnect the idle up sensor harness connector.
2. Remove the knob (3).
3. Remove the nut (2).
4. Remove the idle up sensor (1).
LNW81ISH000101
Installation
1. Install the idle up sensor (1).
2. Install the nut (2) and tighten at the specified
torque.
Tightening torque: 0.9 N⋅m (0.09 kg⋅m / 8 lb⋅in)
3. Install the knob (3).
4. Connect the idle up sensor harness connector.
Induction (4HK1) 1J-1
ENGINE
Induction
(4HK1)
TABLE OF CONTENTS
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Turbocharger Assembly . . . . . . . . . . . . . . . . . . . . .1J-4
Maintenance Precautions . . . . . . . . . . . . . . . . . .1J-4
Failure Symptom List . . . . . . . . . . . . . . . . . . . . .1J-5
Phenomenon: When Output has Dropped
Although the Engine Appears Normal. . . . . . . . .1J-6
Phenomenon: When Output has Dropped
Although the Turbocharger Generally
Appears normal. . . . . . . . . . . . . . . . . . . . . . . . . .1J-7
Phenomenon: When There are Abnormal
Vibrations in the Turbocharger . . . . . . . . . . . . . .1J-8
Phenomenon: When Oil is Leaking From the
Exhaust or Intake and Exhaust is White . . . . . . .1J-9
Phenomenon: When noise is Generated from
the Turbocharger. . . . . . . . . . . . . . . . . . . . . . . .1J-10
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-13
List of Tightening Torques . . . . . . . . . . . . . . . . .1J-15
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-16
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-16
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-18
Ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-19
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-20
MAF/IAT Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . .1J-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-22
VNT Control Module. . . . . . . . . . . . . . . . . . . . . . .1J-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-23
Air Cleaner Indicator (MID Vehicles) . . . . . . . . . .1J-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-24
1J-2 Induction (4HK1)
Air Cleaner Element

Removal • Blow air at pressures of 690 kPa(7 kg/cm2/99.54
psi) or below from the inside to remove the dust,
1. Remove the 3 clips to remove the air cleaner
while turning the element.
cover.
LNW21JSH000201
LNW71JSH001901
(When blackened by oil burnt smoke such as soot)

2. Remove the air cleaner element from the body.
• Dissolve a mild detergent in water and soak for
approximately 30 minutes. Thoroughly rinse with
Inspection water and allow to dry naturally (for 2 to 3 days).
Do not use compressed air or fire to dry.
• Inspect the element for damage and for clogging
caused by filth. NOTE:
When the element is dirty or when the dust clog There is no problem in dissolving mild detergent in
indicator light is lit, clean the element. Replace it if water for cleaning, but if the part is excessively dirty,
it is damaged. replace it.
• Change the air cleaner element after cleaning 6
times, or in accordance with the maintenance
schedule.
Cleaning
(When dry dust from dust sand is adhering)
HCW31BSH057501
Installation
1. Install the air cleaner element.

2. Carefully align the air cleaner cover claw and notch
on the body, and securely fasten the clips at 3
places.
LNW71JSH001901
Turbocharger Assembly
• The turbocharger has an extremely precise finish
and rotates at high speeds, and therefore, it cannot
be disassembled. Replace the turbocharger
assembly, if even small abnormalities such as bent
fins or bent housing or scratches are found.
• Take measures to prevent foreign material from
entering the turbine housing, compressor housing,
the oil filler and outlet while performing the
maintenance work.
• After maintenance of the turbocharger, pour in 3 to
5 cc(0.00066 to 0.0011 lmp⋅gal)of clean engine oil
into the fuel filler before installing the oil pipe.
• If you grip the actuator rod to lift the turbocharger, it
will deform, causing improper operation. Always
hold the turbocharger main unit without gripping
the rod.

• When Output has Dropped Although the Engine
Appears Normal
• When Output has Dropped Although the
Turbocharger Generally Appears Normal
• When There are Abnormal Vibrations in the
Turbocharger
• When Oil is Leaking from the Exhaust or Intake
When the Exhaust Turns White
• When noise is Generated from the Turbocharger

Phenomenon: When Output has Dropped Although the Engine Appears Normal

When output has dropped although the The turbine fins or compressor fins are Replace the turbocharger assembly
engine appears normal deformed or damaged
The fin and housing are touching Replace the turbocharger assembly
There is a large amount of carbon Clean or replace the turbocharger
deposit adhering to the turbine exhaust assembly
and are in contact with the turbine fins
The turbine shaft is manually turned Replace the turbocharger assembly
and it catches on something or the
rotation is heavy
There is a large amount of clearance in Measure it and replace it if it exceeds
the shaft direction or rotation direction the standard value
of the turbine shaft

Phenomenon: When Output has Dropped Although the Turbocharger Generally Appears
normal

When output has dropped although the Gas leaks of each exhaust sections Repair or replacement
turbocharger generally appears normal Excessive exhaust resistance caused Repair or replacement
(The fuel system and other mechanical by deformed exhaust muffler, or carbon
parts are normal) clogging
Dirty air cleaner element Cleaning or replacement
Clogging of intercooler cooler section Cleaning
Locking of the exhaust brake valve Repair or replacement
Defective boost sensor Replacement
Cause due to the vehicle side, such as Repair
dragging of the brakes

Phenomenon: When There are Abnormal Vibrations in the Turbocharger

When there are abnormal vibrations in The cause is bearing damage and Replace the turbocharger assembly
the turbocharger contact of the rotating section with the
surrounding sections
The cause is degraded oil, or entry of
foreign material in the fuel hose,
clogging of the oil filter, or bearing
failure caused by repeated sudden
starting and stopping
When there is no problem in the Replace the turbocharger assembly
lubricating oil system, but there is
damage from the rotating section and
the surrounding sections in contact, it is
suspected that the rotating section has
become unbalanced or the shaft is
bent. This is the cause of either bearing
wear or damage to the turbine wheel or
compressor wheel by flying debris

Phenomenon: When Oil is Leaking From the Exhaust or Intake and Exhaust is White

When oil is leaking from the exhaust or Clogging, collapsing or deformation of Repair or replacement
intake. the oil return pipe
Exhaust is white (normal engine) There is a large clearance of the turbine Measure the clearance and replace it if
shaft it exceeds the standard value
Degraded engine oil Replace the engine oil

Phenomenon: When noise is Generated from the Turbocharger

When noise is generated from the Air leaks from the coupling of the rubber Repair
turbocharger hose on the compressor expulsion side
or gas leaks from the exhaust
Contact of the turbine fin with the Replace the turbocharger assembly
housing
Internal damage from foreign material Replace the turbocharger assembly
Wear or seizure of the turbine shaft Replace the turbocharger assembly
bearing

Components
3
1
4 5
8 6
11 9
13
10 7
12
LNW81JLF000401
Legend
1. Oil feed pipe 8. Turbocharger assembly
2. Water return pipe 9. Oil return pipe
3. Exhaust adaptor gasket 10. Turbocharger gasket
4. Exhaust adaptor 11. Turbocharger actuator
5. Exhaust adaptor heat protector 12. Exhaust manifold
6. Turbocharger heat protector 13. Exhaust manifold gasket
7. Water feed pipe
Removal • Remove the front exhaust pipe A and exhaust

brake assembly installation nut.
The exhaust brake assembly will also be
2. Remove the front exhaust pipe A and exhaust removed together.
brake assembly.
• Remove the transmission right side exhaust
• Remove the front exhaust pipe A and pipe bracket mounting bolts.
turbocharger installation nut.

11. Remove the turbocharger assembly and gasket.
• Remove the turbocharger installation nut.
• Remove the bolt from the exhaust adaptor
bracket.
• Remove with the exhaust adaptor installed to
the turbocharger.
Inspection
Visual and aural inspection
Remove the turbine housing outlet adaptor, and
compressor housing inlet rubber hose to visually
inspect the turbocharger.
It is not possible to disassemble and adjust the
turbocharger.
• Inspect for abnormal sounds coming from the
LNWA1GSH000101 turbocharger while it is running.
• Inspect if the compressor cover and turbine
housing and fins are in contact with each other, or
3. Remove the air duct from the turbocharger. if there is drag damage or cracking.
• Disconnect the PCV hose (2) from the air duct. • Inspect for oil leaking to the inside surface of the
• Loosen the air duct tightening clamp (5) at the housing.
turbocharger inlet. • Inspect for large amounts of carbon deposit
4. Remove the air intake hose(4). adhering to the turbine exhaust and whether they
are not in contact with the fins.
clamp (3). • Manually turn the turbine shaft to inspect for
contact or catching.
5. Disconnect the connector (6) from the
turbocharger actuator. • Move the shaft to inspect for any large amount of
clearance in the shaft and rotating directions.
Play in the shaft direction of the wheel shaft

4 • Use a dial indicator to measure the play of the
3 shaft direction of the wheel shaft.
• Apply approximately 12 N(1.2 kg/2.6 lb) of force
2 alternately on the compressor wheel ends.
Play mm(in)
1 0.03 - 0.10
Standard values
(0.00118 - 0.00394)
5 0.13
6 Limit
(0.00512)
LNW81JSH000801
6. Remove the turbocharger top surface oil feed pipe

eyebolt.
7. Remove the water return pipe eyebolt from the
turbocharger.
8. Remove the water feed pipe eyebolt from the
turbocharger.
9. Remove the water feed pipe.
10. Remove the oil return pipe.

• Install the gasket and turbocharger assembly,
and tighten the nut at the specified torque.
2. Insert the O-rings to both ends of the oil return pipe
and tighten the bolts at its specified torque.
Tightening torque
Turbocharger side 9 N⋅m (0.9 kg⋅m/78 lb⋅in)
Cylinder block side 21 N⋅m (2.1kg⋅m/15 lb⋅ft)
3. Install the water feed pipe.

• Install the water feed pipe cylinder block side
eyebolt and tighten it at the specified torque.
• Install the turbocharger side eyebolt and tighten
LNW21BSH022201 it at the specified torque.
Gap between turbine shaft and bearing

Tightening torque
• Use a dial indicator to measure the gap between
the wheel shaft and bearing. Cylinder block side 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Turbocharger side 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Gap mm(in)
4. Install the water return pipe.
0.08 - 0.11
Standard values • Tighten the water return pipe eyebolt at its
(0.00315 - 0.00433
specified torque.
0.14
Limit Tightening torque: 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(0.00551)
• Connect the rubber hose that connects the
water return pipe and thermostat housing.
5. Install the oil feed pipe.
• Install the eyebolt to the turbocharger top
surface oil feed pipe and tighten it at the
1 specified torque.
6. Install the exhaust adaptor to the turbocharger and
tighten it at the specified torque.
• Tighten the exhaust adaptor and exhaust
2 manifold with bolts.
7. Install the heat protector and tighten it with bolts.
LNW21BSH022301 Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Legend
1. Oil outlet
2. Oil inlet 8. Install the intake hose(4).
NOTE:
Installation misalignment, and tighten the clamp to the specified
1. Install the turbocharger assembly. torque.

• Install the intake hose to the turbocharger
intake duct, and hose clamp (3) to the specified
torque.
NOTE:
torque.
• Tighten the turbocharge inlet air duct tightening

clamp (5) at its specified torque.
• Connect the PCV hose (2) to the air duct. LNWA1GSH000101
Tightening torque 12. Refill the coolant.

Bolts (1) 9 N⋅m (0.9 kg⋅m/78 lb⋅in)
10. Connect the connector (6) to the turbocharger

actuator.
4
3
5
6
LNW81JSH000801

assembly and tighten it at the specified torque.
Tightening torque
Turbocharger side nut 67 N⋅m (6.8 kg⋅m/49 lb⋅ft)
Exhaust pipe bracket
41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
bolt
Exhaust brake side
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
nut

i
b
j
c
l
g
e m
f
d
n
p
r
q
t
v s
u
LNW81JLF000501
(s) 21 N⋅m (2.1 kg⋅m / 15 lb⋅ft)

(a) 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in) (t) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
(b) 7.5 N⋅m (0.76 kg⋅m / 66 lb⋅in) (u) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)
(c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in) (v) 34 N⋅m (3.5 kg⋅m / 25 lb⋅ft)
(d) 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(e) 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(h) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(i) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(j) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(k) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(l) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(m) 32 N⋅m (3.3 kg⋅m / 24 lb⋅ft)
(n) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(o) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(p) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(q) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(r) 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
Intercooler
Components
LNW91JLF000601
Legend
1. Intercooler 2. Radiator assembly
Inspection
1. If the intercooler fins are deformed, this can lead to
Removal a drop in heat dissipation and reduce engine
performance. Repair the fins.
1. Disconnect the air duct from the intercooler.
When repairing, be careful not to damage the base
2. Remove the intercooler from the radiator
of the fins.
assembly.
2. Inspect the inside of the intercooler for filth. If it is
significantly dirty, clean it.
a. Cleaning the radiator core and intercooler core.

1. Cooling efficiency is compromised when
there is dirt or dust plugging air passages in
the radiator core and intercooler core. 4
This can also cause corrosion of these 3
cores. Periodically wash the radiator core
with tap water.
CAUTION:
• Make sure to turn the engine off and remove the key
from the starter switch before cleaning cores.
• The engine, exhaust pipe and radiator will be hot
immediately after the vehicle is driven.
Be careful around these parts to prevent burns.
Clean the engine when it is cold.
CAUTION:
• Do not clean the radiator(1), intercooler(2) and their
surrounding areas using water that is supplied 5
under high pressure. Doing so may cause damage. LNW91CSH001601
• When cleaning the radiator core(3) and intercooler

core(4), do not crush or damage the fins(5).
• The fins are very fragile so be careful not to bend Cleaning
them out of shape. Washing the intercooler core
If they become deformed, their cooling efficiency will CAUTION:
be impaired. Do not perform high-pressure washing onto the
radiator, intercooler and surrounding parts when they
are still installed on the vehicle.
1. Seal the hose connecting section with a cap or

fabric tape.
2. Sufficiently wet the front and back surfaces of the
intercooler.
• Adhering matter which easily comes off with a
splash of tap water should be washed off
sufficiently in advance.
NOTE:
Do not use a high-pressure washer or brush.
1
3. Prepare a mild detergent.
2
• Use a type which contains approx. 8% of
surface acting agent.
LNW91CSH001501 NOTE:
Do not use anything other than a mild detergent. Use of
any product other than a mild detergent may cause
corrosion.
4. Spray the mild detergent onto both sides of the

fins, and leave them as is for 10 minutes.
5. Rinse off the mild detergent using a high-pressure
washer.
• Start washing from the engine side of the
intercooler.
NOTE:
• Apply the high-pressure water in a direction
perpendicular to the fins.

• Do not bring the high-pressure water too close to
the fins.
• Be careful not to deform the fins.
6. After washing is finished, inspect the fins to

confirm that the dirt is removed sufficiently.
• If washing is not sufficient, wash them again.
NOTE:
If some dirt is still left, fine black particles attached on
the fins can be seen.
7. Rinse off the detergent constituents on the fins and

resin parts using the tap water.
8. Remove the seal on the hose connecting section.
9. Clean and dry the hose connecting section
sufficiently.
Installation
1. Install the intercooler to the radiator.
Tightening torque
Upper side bolts 15 N⋅m (1.5 kg⋅m / 11 lb⋅ft)
Lower side nuts 15 N⋅m (1.5 kg⋅m / 11 lb⋅ft)
2. Install the air duct to the intercooler.

Ventilator
Components
4
1 3
2
LNW81JSF000101
Legend
1. Bracket 3. Ventilator pipe
2. Ventilator 4. PCV hose

Models for Frigid Zone
3
2
1
1
LNWA1FLF000401
Legend
1. Cover 4. Cover
2. Ventilator pipe 5. Ventilator
3. PCV hose 6. Bracket
Removal 2. Install the ventilator pipe along with the PCV hose
and tighten it at the specified torque.
1. Remove the ventilator bracket along with the
rubber hose. Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
2. Remove the ventilator pipe along with the PCV
3. Install the bracket along with the rubber hose and
hose.
tighten them at the specified torque.
3. Remove the ventilator from the flywheel housing.
Installation
1. Install the ventilator.
• Insert the ventilator into the flywheel housing
pipe.
MAF/IAT Sensor
Removal
1. Turn the ignition switch OFF. Condition Resistance
2. Disconnect the harness connector. temperature characteristic
°C(°F)
3. Remove the Mass Air Flow(MAF) / Intake Air
Temperature(IAT) sensor. -20(-4) 12.5 - 16.9 kΩ
25(77) 1.8 - 2.2 kΩ
60(140) 500 - 608 Ω
Mass Air Flow sensor

Inspect for filth or damage.
CAUTION:
There should be no solvents or lubricants adhering to
the detecting section of the sensor.
Installation
1. Install the Mass Air Flow(MAF) / Intake Air
Temperature(IAT) sensor.
Tightening torque: 1.5N⋅m (0.15 kg⋅m/13 lb⋅in)
LNW71JSH001801
2. Connect the harness connector.
Inspection
3 2
4
1
5
MFW4ADSH000601
Legend
1. MAF sensor power supply
2. MAF sensor GND
3. MAF sensor signal
4. IAT sensor signal
5. IAT sensor GND
Intake Air Temperature Sensor

Measure the resistance between the terminals 4←→5.
Boost Pressure Sensor

Removal
1. Disconnect the boost pressure sensor connector.
2. Remove the boost pressure sensor.
LNW81BSH002901
Legend
1. Air intake hose
2. Boost pressure sensor
Installation
1. Install the boost pressure sensor.
2. Connectl the boost pressure sensor connector.
VNT Control Module

Removal
1. Disconnect the VNT control module connector.
LNW81JSH000101
Legend
1. Front bumper
2. VNT control module
2. Remove the VNT control module and bracket.

3. Remove the VNT control module.
Installation
1. Install the VNT control module in bracket.
Tightening torque: 6.5 N⋅m(0.65 kg⋅m/56 lb⋅in)
2. Install the VNT control module and bracket.
3. Connect the VNT control module connector.
Air Cleaner Indicator (MID Vehicles)

Removal
1. Disconnect the indicator assembly connector.
2. Remove the indicator assembly.
• The indicator assembly can be removed by 2
turning it counterclockwise by hand with the
boot attached.
1
1
LNW81JSH001301
Legend
1. Air cleaner indicator
2. Vacuum pump
LNW81JSH000901 Installation
Legend 1. Install the indicator assembly.
1. Indicator assembly • Apply Vaseline or equivalent to the groove
2. Boot inside the boot.
• Install the indicator assembly by turning it
clockwise.
Inspection • Make sure that the drain pipe of the boot is
• Confirm that there is no conductivity between the falling downward.
connector terminals without applying the negative 0.98 - 1.96 N⋅m
pressure of the vacuum pump to the air cleaner Tightening torque:
(0.10 - 0.19 kg⋅m/0.7 - 1.4 lb⋅in)
indicator.
• Gradually apply the negative pressure to the air
cleaner indicator with the vacuum pump and
measure the working pressure when the
conductivity first appears between the connector
terminals.
Working pressure: MPa(kg⋅cm2 / psi)

9.90 - 8.04(0.10 - 0.08 / 1.44 - 1.17)
LNW81JSH000901
Legend
1. Indicator assembly
2. Drain pipe
2. Connect the indicator assembly connector.

MEMO
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Pre-Heating System (4HK1) 1K-1
ENGINE
Pre-Heating System
(4HK1)
TABLE OF CONTENTS
Pre-Heater System. . . . . . . . . . . . . . . . . . . . . . . . 1K-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1K-2
Description of Function and Operation . . . . . . . 1K-2
Functional inspection: . . . . . . . . . . . . . . . . . . . . 1K-3
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1K-6
Phenomenon: The Glow Indicator Light
Does not Light . . . . . . . . . . . . . . . . . . . . . . . . . . 1K-7
Phenomenon: Preheating does not Operate. . . 1K-8
Phenomenon: The Preheating Time is too
Long or too Short . . . . . . . . . . . . . . . . . . . . . . . 1K-9
Primary Specifications. . . . . . . . . . . . . . . . . . . . 1K-9
1K-2 Pre-Heating System (4HK1)
Pre-Heater System
Be careful because the glow plug can be damaged if it
is over-tightened.

Glow control system
The glow control system makes it easier to start the
engine in low temperatures, and reduces the amount of
white smoke and noise generated immediately after
starting the engine. When the ignition switch is turned
ON, the ECM detects the temperature of the engine
coolant from a signal sent from the engine coolant
temperature (ECT) sensor. This can change the glow
time to always start the engine under optimum
conditions. Also, an after-glow function stabilizes the
idling immediately after starting the engine. ECM
determines the glow time according to the engine
coolant temperature, and starts the glow relay and glow
plug (preheat) indicator light.
For details on the glow control system, refer to the
"Engine Control System" in Section 1A, Engine Control
System (4HK1).

Preheat system inspection and repair • If the measurement reveals that the resistance
1. Inspecting the system value is not at the standard value, replace the
glow relay.
• Disconnect the engine coolant temperature
sensor connector.
Glow relay resistance value is approximately
100Ω
3
2
2 3
4 5
5 4
LNW21KSH001101
• Connect a voltmeter between the glow plug and LNW21KSH000301

engine ground.
• Turn the ignition switch ON (the engine is
stopped) position, and inspect the following. • Location of glow relay installation;
- The glow indicator lights for 3.5 seconds. Outdoor relay box
- The voltage indicates the power voltage for
approximately 18 seconds.
• If the inspection reveals an abnormality, inspect
the glow relay, engine coolant temperature
sensor and glow plug. If they are normal,
inspect the engine control system.
LNW71KSH000301
HCW31KSH000201
2. Glow relay inspection

• Using a circuit tester, measure the resistance
value of the glow relay (between 4 and 5).

3. Engine coolant temperature sensor inspection
ECM engine coolant temperature sensor is a
thermistor type whose characteristic is that the
electrical resistance decreases as the temperature
rises.
1 2
1 2
MFW71KSH000201
Resistance value at a certain temperature (appro-

3 ximate value)
MFW71CSH000601
Engine coolant
Legend Resistance value
temperature
20°C(68°F) 2.45 kΩ
3. ECM thermistor 50°C(122°F) 0.81 kΩ
80°C(176°F) 0.32 kΩ
• Place the temperature sensor portion of the

engine coolant temperature sensor into water,
and inspect whether the resistance value
changes as in the graph while changing the
water temperature.
• Exanple of how to measure the thermistor Thermistor characteristic
characteristics. 30
20
10
7.0
)
5.0
Resistance value(k
3.0
2.0
1.0
0.7
0.5
0.3
0.2
0.1
-20/-4 0/32 20/68 40/104 60/140 80/176 100/212 120/248
Engine coolant temperature( )
LNW91CMH000201

• Replace it if any abnormality is found during the
inspection.
4. Glow plug inspection

• Use a circuit tester to measure the resistance
value of the glow plug.
• If the measurement reveals that the resistance
value is not at the standard value, replace the
glow plug.
Glow plug resistance value is approximately 6Ω

(Room temperature).
NOTE:
Use a set of 4 glow plugs from the same manufacturer.
Do not use glow plugs that have been dropped.
MFW61KSH000401

• The Glow Indicator Light Does not Light
• The Preheating Does not Operate
• The Preheating Time is too Long or too Short

Phenomenon: The Glow Indicator Light Does not Light

The glow indicator light does not light Slow-blow fuse has blown Replace the slow-blow fuse
Fuse has blown Replace the fuse
Burnt-out indicator bulb Replace the indicator bulb
Engine control system failure Refer to "Diagnostic Information and

Phenomenon: Preheating does not Operate

The preheating does not operate Slow-blow fuse has blown Replace the slow-blow fuse
Improper or defective glow relay Re-attach the glow relay or replace it.
connector contact

Phenomenon: The Preheating Time is too Long or too Short

The preheating time is too long or too Thermo-sensor problem, open circuit or Replace the thermo-sensor; repair the
short short circuit in the circuit circuit
Faulty glow plug Replace the glow plug, or tighten it
Item Model
Preheat device model Glow plug •QOS
Glow plug rated voltage and current (V-A) 23 - 3.5
MEMO
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LG4HK-WE-1001_4306024_奥付 2012.12.17 9:36 AM ページ 1
Published: Dec., 2012 All rights reserved.

Fifth Edition
WORKSHOP MANUAL
ENGINE
(4HK1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LG4HK-WE-1001_4306024_奥付 2012.12.17 9:36 AM ページ 2
2010-2012MY
2010-2012MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4HK1 model)

ENGINE
(4HK1 model)
No.LG4HK-WE-1001

Workshop Manual: (4HK1 Model)

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WORKSHOP MANUAL ENGINE (4HK1 model)

Engine Mechanical (4HK1) 1B-1

1B-2 Engine Mechanical (4HK1)

Engine Mechanical (4HK1) 1B-3

1B-4 Engine Mechanical (4HK1)

(Example) Measuring the Gap Between the Crank

Engine Mechanical (4HK1) 1B-5

1B-6 Engine Mechanical (4HK1)

Description of Function and Operation Cylinder liner

Cylinder block Piston

Engine Mechanical (4HK1) 1B-7

1B-8 Engine Mechanical (4HK1)

Valve clearance mm(in)

• When the 1st cylinder is at the compression top

Parts to inspect when the 1st cylinder is at

b. Insert the thickness gauge between the rocker

Engine Mechanical (4HK1) 1B-9

Valve clearance mm(in) Tightening torque: 22 N⋅m(2.2 kg⋅m/16 lb⋅ft)

• When the 1st cylinder is at the compression top

a. Completely loosen each adjust screw of the

1B-10 Engine Mechanical (4HK1)

4. Install the battery negative terminal.

Compression pressure inspection

Engine Mechanical (4HK1) 1B-11

• Sequentially measure each cylinder.

8. Remove the compression gauge.

Determining the overhaul period

Increasing the fuel consumption rate

Abnormal noises in engine

1B-12 Engine Mechanical (4HK1)

Engine Mechanical (4HK1) 1B-13

Condition Possible Cause Correction

1B-14 Engine Mechanical (4HK1)

Condition Possible Cause Correction

Engine Mechanical (4HK1) 1B-15

Condition Possible Cause Correction

1B-16 Engine Mechanical (4HK1)

Condition Possible Cause Correction

Engine Mechanical (4HK1) 1B-17

Condition Possible Cause Correction

1B-18 Engine Mechanical (4HK1)

Condition Possible Cause Correction

Engine Mechanical (4HK1) 1B-19

Condition Possible Cause Correction

Item Engine model 4HK1-TC

1B-20 Engine Mechanical (4HK1)

Item Engine model 4HK1-TC

Engine Mechanical (4HK1) 1B-21

1B-22 Engine Mechanical (4HK1)

Illustration Tool Number/ Description Illustration Tool Number/ Description

Engine Mechanical (4HK1) 1B-23

Illustration Tool Number/ Description

1B-24 Engine Mechanical (4HK1)

1. Disconnect the battery cable negative terminal (1).

6. Remove the transmission.

2. Drain the engine coolant.

5. Remove the front exhaust pipe A and exhaust

Engine Mechanical (4HK1) 1B-25

Legend 15. Remove the fuel return hose.

1B-26 Engine Mechanical (4HK1)

18. Remove the fan guide and place it on the fan

• Turn the engine 90° and move it from the