01 Engine MG4HK-WE-0871 7th

TOP
(INDEX)
2008-2011MY
2008-2011MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4HK1 model)

ENGINE
(4HK1 model)
No.MG4HK-WE-0871
MG4HK-WE-0871_67372前書 2011.1.31 11:18 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
1L Power Take-Off (PTO)
2 SUSPENSION 2A1 Air Suspension Control System
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
3D Transfer Case
4 BRAKES 4A2 Brake Control System (Air Over)
4A3 Brake Control System (Full Air)
4B2 Brake (Air Over)
4B3 Brake (Full Air)
4C Anti-Lock Brake (ABS)
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
4F Speed Retarder System
4G Trailer Brake
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G Power Take-Off (PTO)
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 AND FRAME ACCESSORIES 11A Frame
MG4HK-WE-0871_67372前書 2011.1.31 11:18 AM ページ 2
MG4HK-WE-0871.book 1 ページ２０１１年５月１８日　水曜日　午後３時５６分
Engine Mechanical (4HK1) 1B-1
ENGINE
Engine Mechanical
(4HK1)
TABLE OF CONTENTS
4HK1Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-52
Maintenance Precautions . . . . . . . . . . . . . . . . . 1B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-52
Service Technology Information . . . . . . . . . . . . 1B-3 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-55
Reading the Model . . . . . . . . . . . . . . . . . . . . . . 1B-5 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1B-57
Description of Function and Operation . . . . . . . 1B-8 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-57
Functional Inspection: . . . . . . . . . . . . . . . . . . . 1B-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-58
Failure Phenomenon List . . . . . . . . . . . . . . . . 1B-18 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-59
Phenomenon: Engine does not run. . . . . . . . . 1B-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-60
Phenomenon: Engine cranks but does not Timing Gear Train. . . . . . . . . . . . . . . . . . . . . . . . 1B-62
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-62
Phenomenon: There is Much Black Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-62
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . 1B-21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-65
Phenomenon: There is Much White Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-66
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . 1B-22 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-75
Phenomenon: Engine is Experiencing Valve Stem Seal and Valve Spring . . . . . . . . . . . 1B-76
Knocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Phenomenon: Engine Rotation Problem. . . . . 1B-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Phenomenon: Charging failure . . . . . . . . . . . . 1B-25 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-77
Primary Specifications. . . . . . . . . . . . . . . . . . . 1B-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-78
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27 Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . 1B-81
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1B-29 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-37 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-82
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-37 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-84
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-38 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-87
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-39 Camshaft Position Sensor . . . . . . . . . . . . . . . . . 1B-88
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . 1B-40 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-88
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-88
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-40 Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 1B-89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-41 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-89
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-89
Oil Separator(Euro3 and Euro4 specifications) . 1B-44 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-44 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-90
Maintenance Precautions . . . . . . . . . . . . . . . . 1B-44 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-44 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-92
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-45 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-94
Oil Catch Tank(Euro2 specification only) . . . . . . 1B-47 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-47 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-48 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-100
Intake Throttle Valve(Euro4 specification only) . 1B-49 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-104
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-49 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-117
Intake Pipe(Euro2 and Euro3 specifications) . . . 1B-50 List of Tightening Torques . . . . . . . . . . . . . . . 1B-130
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-50 Crankshaft Position Sensor . . . . . . . . . . . . . . . 1B-131
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-50 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-131
Inlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-51 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-131
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-51
1B-2 Engine Mechanical (4HK1)

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-132
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-132
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-132
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-134
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-135
List of Tightening Torques . . . . . . . . . . . . . . . 1B-137
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-138
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-138
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-138
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-139
Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1B-142
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-142
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-144
Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 1B-148
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-148
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-149
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-149
Piston and Connecting Rod . . . . . . . . . . . . . . . 1B-153
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-153
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-153
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-154
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-155
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-160
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-161
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-164
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-164
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-164
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-165
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-165
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-170
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-170
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1B-174
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-174
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-174
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-175
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-176
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 Plastigage
flywheel housing.
(There is only a small gap between the oil pan and
oil pump strainer, so be careful not to damage the Type Measurable Range mm (in)
oil pan and oil pump strainer.) PG-1 (Green) 0.025 - 0.076 (0.00098-0.00299)
• When the air intake system, such as the air duct or PR-1 (Red) 0.051 - 0.152 (0.00201-0.00598)
air cleaner, has been removed, cover the air intake
to prevent foreign material from entering the PB-1 (Blue) 0.102 - 0.229 (0.00401-0.00902)
cylinder.
• To perform maintenance on the engine, always (Example) Measuring the Clearance Between the
remove the battery ground terminals. If the battery Connecting Rod Bearing and Crank Pin
ground terminals are not removed while • Clean the connecting rod and bearing, and
performing work, there is the possibility of assemble that to the connecting rod.
damaging the wire harness or electrical
• Cut the plastigage to the width of the crank pin and
components. Take adequate precautions for
lay it parallel avoiding the crank pin oil hole.
safety, such as short circuits, when inspections
require an energized state. • Align the markings on the connecting rod and on
the cap for assembly to the crank pin. Apply
• To protect and lubricate the sliding surfaces when
molybdenum disulfide to the threaded portion of
running for the first time, apply an adequate
the tightening bolts and seat surface. Alternately
amount of engine oil to the sliding surfaces.
tighten them so that the cap is at the specified
• When the valve related parts, injector, pistons, torque.
piston rings, connecting rod, connecting rod
bearing, crankshaft journal bearing, etc. have been NOTE:
removed, organize them in order for storage. Absolutely never move the connecting rod when the
• When reinstalling them, use the same part and plastigage is in use.
install it in the same position as when it was
removed.
• Whenever disassembling the gasket, oil seals and
O-rings, replace them with new ones.
• 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
plastigage to measure the flattened plastigage plastigage is in use.
(clearance).
• Gently remove the crankcase and use a scale
printed on the packaging of the plastigage to
measure the flattened plastigage (clearance).
HCW30ASH002001
HCW30ASH002201
HCW30ASH002101
(Example) Measuring the Clearance Between the

HCW30ASH002301
Crankshaft Bearing and Crankshaft 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 plastigage 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
Euro2 specification only
MFW8Z0MF000101
Legend
1. Engine number stamping (******)

MFWB1BMF001401
Legend

MFW8Z0MF000501
Legend

Description of Function and Operation
External appearance of engine
MFW8Z0MF000301

MFWB1BMF001101
MFW8Z0MF000601

MFW8Z0MF000201
MFWB1BMF001201

MFW8Z0MF000701
MFW8Z0MF000401

MFWB1BMF001301
MFW8Z0MF000801

Description of Function and Operation EGR device (Euro3 specification and Euro4
Electronic Control Engine Control specification)
This controls from injection to air intake and exhaust, The ECM applies controls based on information such
such as fuel injection amounts, injection timing, the air as water temperature, engine speed and engine load.
intake throttle, EGR (Euro3 specification and Euro4 Also, some of the exhaust gas is re-circulated to be
specification) and idling speed, using the engine control cleaned.
module (ECM). The primary components are the EGR valve, EGR
cooler, exhaust brake valve and various sensors.
Cylinder block
The cylinder block is cast iron. The pitches between Lubricating system
bores are equal, and it is a highly rigid structure with This is a full-flow bypass unitized oil filter. Oil flows
symmetry to the right and left centering on the through the oil cooler and around the sliding sections
crankshaft. Tighten the bearing cap using the plastic from the oil gallery for lubrication.
region rotational angle tightening method, with the Glow control system
ladder frame structure. The glow control system makes it easier to start the
Cylinder liner engine in low temperatures, and reduces the amount of
The cylinder liner is selected and assembled to match white smoke and noise generated immediately after
the inner diameter of the cylinder block bore and its starting the engine. When the ignition switch is turned
grade is marked on the left side surface of the cylinder. "ON", the ECM detects the temperature of the engine
coolant from a signal sent from the engine coolant
Piston temperature (ECT) sensor. This can change the glow
The pistons are autothermatic pistons cast with time to always start the engine under optimum
aluminum alloy struts, and the combustion chamber is conditions. Also, an after-glow function stabilizes the
a spherical re-entrant system. idling immediately after starting the engine. ECM
Cylinder head determines the glow time according to the engine
The cylinder head is cast iron. It has 4 valves per coolant temperature, and starts the glow relay and glow
cylinder. Tighten the head bolts using the plastic region plug (preheat) indicator light.
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 accumulates 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.

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

Intake 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.
Cylinder No. 1 2 3 4
LNW21BSH030001
Valve
In Ex In Ex In Ex In Ex
arrangement
a. Put the engine 1st cylinder at the compression
1st cylinder
top dead center.
at compression { { { {
top dead center • Rotate the crankshaft in the forward
direction. Align the crank pulley alignment
4th cylinder mark (1) and the front cover BTDC0° mark
at compression X X X X (2).
top dead center
Parts to inspect when the 1st cylinder is at

the compression top dead center
1
MFW71BSH004401
b. Insert the thickness gauge between the rocker

LNW21BSH029901
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 b. Insert a 0.4 mm (0.016 in) thickness gauge
alignment mark and the front cover BTDC0° between the rocker arm end (valve side) and
mark. cap (assembly on bridge top), and tighten the
d. Insert the thickness gauge between the rocker rocker arm adjust screw. When the movement
arm and bridge cap, and measure the of the thickness gauge becomes stiff, fasten the
clearance. adjust screw nut of the rocker arm.
e. When the measured value is not standard, Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
adjust the valve clearance.
2. Adjusting Valve Clearance
Valve clearance mm (in)

Intake 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 MFW81BSH002001
1st cylinder
at compression { { { {
top dead center c. When lightly tightening the bridge adjust screw
4th cylinder while the thickness gauge is inserted, check
at compression X X X X that the leading end of the adjust screw and the
top dead 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
BLW51BSH005701 Compression gauge adaptor:
NOTE: 5-8840-2815-0
If the bridge adjust screw adjustment is poor, the bridge Compression gauge: 5-8840-2675-0
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
the DTC after completing the measurements.
For details on how to delete the DTC, refer to the
"Diagnostic Information and Procedures" in Section 1A LNW71BSH003501
Engine Control System

7. Engage the starter to inspect the compression
pressure.
Compression pressure MPa (kg/cm2/psi) / r/min

2.75 ± 0.15
(28 ± 1.5/398± 21) / 220
2.65 ± 0.15
Standard values
(27 ± 1.5/384±21) / 185
2.55 ± 0.15
(26 ± 1.5/370±21) / 150
Limit 2.16 (22/313)
Cylinder differences 290kPa (3.0/43)
• 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 1L 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 Phenomenon 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

Phenomenon: Engine does not run
Condition Possible Cause Correction

Starter does not run The Immobilizer 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

Phenomenon: 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
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

Phenomenon: 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
Defective diesel particulate diffuser Melted or broken filter Replace
(DPD)(Euro4 spec)
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
(Euro4 specification only)
Locking of the EGR valve Repair or replace
Locking of the exhaust brake valve Repair or replace
Defective turbocharger Deformed or damaged turbine fin Replace
Unsmoothness or catching of the Replace
turbine shaft
Air leakage at the compressor outlet Repair
side

Phenomenon: 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
Defective turbocharger oil seal Replace turbocharger

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

Phenomenon: 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

Phenomenon: 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 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- 125
stroke (4.53 - 4.92)
Total piston displacement L (in3) 5.193 (316.9)
Compression ratio 17.5
2
Compression pressure MPa (kg/cm /psi) 2.75 (28/398)/220
/r/min
Idling speed r/min 650(Smoother) 575(M/T)
Valve clearance Intake 0.4 (0.016) (while cool)
mm (in) Exhaust 0.4 (0.016) (while cool)
Ignition method Compressed ignition
Injection order 1-3-4-2
Injection period (top dead center) deg 0
Lubrication device
Lubricating method Force feed method
Oil pump type Gear type
Lubricant capacity [reference values] L (Imp⋅gal) Except 4WD 13.0 (2.86)
4WD 12.5 (2.75)
Oil filter type Full-flow filter (cartridge type)
Oil cooler type Built-in type, water cooled
Item 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 (Imp⋅gal) 18.5(4.07)
(Including radiator)
Fuel device
Injection pump type Electronic control common rail type
Charging device
Generator type Alternating current type
Output V-A 24 - 50, 24 - 60, 24 - 90
Regulator type IC
Starter device
Starter type Reduction type
Output V-kW 24 - 4.5
Preheat device model Glow plugs (QOS 2)
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 5-8840-2222-0
Crankshaft stopper Sealing cup installer
5884022300 5884022220
5-8840-2621-0 5-8840-0266-0
Valve spring replacer Angle gauge
5884026210
5-8840-2808-0 5-8840-2826-0
Pivot Injector remover
5884028080 5884028260
5-8840-2625-0 5-8840-2623-0
Valve stem seal installer Nozzle sleeve remover
Illustration Tool Number/ Description Illustration Tool Number/ Description
5-8840-2627-0 8-9439-6818-0
Oil seal installer Crankshaft gear puller
5884026270 8943968180
5-8840-2626-0 8-9439-6819-0
Bridge guide setting tool Crankshaft gear installer
5884026260
5-8840-2624-0 1-8522-1097-0
Nozzle sleeve setting tool Oil filter wrench
5884026240 1852210970
5-8840-9018-0 5-8840-2930-0
Piston setting tool Valve guide installer
5884090180 5884029300
5-8840-2360-0
Slinger puller
5-8840-2703-0
Oil seal installer kit
5884027030
Engine Assembly
Removal
CAUTION: 4. Disconnect the starter ground cable.
• Always apply chock blocks to the vehicle wheels. • Disconnect the front frame harness connector
near the transmission control box and remove
• Select an engine hoist that is able to withstand the
each of the clips fastening the harness.
weight of the engine.
• Remove the 2 bolts (upper and lower) attaching
• Never get under the engine while it is hoisted.
the starter, and remove the starter from the
• Never put your hands where they can get easily clutch housing.
caught.
• Fasten with a wire, etc. to a position where it
1. Disconnect the battery cable negative terminal (1). will not interfere with the removal of the
transmission.
1 5. Remove the transmission.

• Refer to "Transmission ASM" in Section 5B
Automatic Transmission (Smoother (MZX)).
Refer to "Transmission ASM" in Section 5B
Automatic Transmission (Smoother (MZW)).
Refer to "Transmission ASM" in Section 5C
Manual Transmission (MLD).
Manual Transmission (MZX).
Manual Transmission (MZW).
Manual Transmission (MZZ).
6. Remove the engine harness.

LNW71BSH008101 • Remove the ECM.
• Remove the 2 main harness connectors from
2. Drain the coolant. the ECM.
• Remove the engine ground cable.
7. Remove the intake duct (2) and the air charge pipe
(1) located between the intake duct and the
intercooler.
• Remove the boost sensor connector.
1 2
MFW71CSH000201
Legend
1. Radiator drain plug
3. Remove the oil level gauge.

• Remove the rubber hose clip of the oil level MFW71JSH001201
gauge guide tube and the rubber hose.
8. Disconnect the air charge pipe located between

the intercooler and turbocharger.
9. Disconnect the radiator upper hose.

• Remove the upper hose at the engine side.
10. Disconnect the coolant reserve tank hose.

• Disconnect the coolant reserve tank hose (1) at
the radiator side.
LNW21BSH027501
12. Disconnect the fuel return hose.
13. Disconnect the fuel feed hose.

• Remove from the supply pump side and put a
plug and tie closed pointing upward so that fuel
is not spilled.
14. Disconnect the radiator lower hose (1) at the

MFW71CSH000501 engine side.
• For Smoother, disconnect the oil hose.
MFW71CSH001801
4
MFW71CSH001501
Legend 15. Remove the fan guide and hang it on the fan
1. Radiator stay assembly.
2. Intercooler
3. Radiator 16. Remove the radiator.
4. Oil hose • Remove the radiator by removing the mounting
nuts and bolts on the left and right sides of the
radiator, and the radiator stay.
11. Disconnect the heater hose.
• Remove the fan guide that has been hanged on
• Remove the 2 heater hoses at the engine side.
the fan assembly.

MFW71BSH005901
MFW71BSH010801
Legend
17. Remove the front exhaust pipe.
1. Engine rear hanger for PTO specifications
• Remove the front exhaust pipe from the 2. Oil separator bracket bolt
exhaust adapter and the exhaust brake.
18. Remove the power steering oil pump. 23. Remove the engine mount.
• Remove the power steering oil pump from the • Before removing the engine from the engine
engine side together with the bracket. Fasten to mount, use a hoist to suspend the engine.
appropriate position with a wire along with the • Remove the installation nut on the engine foot
hoses. side of the engine mount.
19. Remove the A/C compressor. 24. Install or remove the engine assembly.
• Remove the A/C compressor drive belt. • Slowly operate the hoist to raise the engine
• Remove the compressor from the A/C above the surface of the chassis frame.
compressor bracket. Fasten to appropriate
position with wire along with the hoses.
20. Disconnect the air pipe flexible joint section of the

air compressor.
• Remove the hose at the air compressor side.
21. Remove the AC generator harness.

• Remove the B terminal cable and harness
connector from the generator.
22. Remove the oil separator together with the oil

separator bracket (Euro3 specification and Euro4
specification), and install the engine rear hanger
for PTO specifications. However, the one with
flywheel PTO is excluded (Euro4 specification
only). MFW71BSH006801
Tightening torque: 104 N⋅m (10.6 kg⋅m/76.7 lb⋅ft) • Turn the engine 90° and move it from the
chassis frame top surface to remove the engine
assembly.
MFW71BSH006901 MFW71BSH006801
Installation 2. Install the engine mount.

• Install the engine to the engine mount and
1. Install the engine ASM.
tighten the nut at the specified torque.
• Install the hoist wire to the engine hanger and
hoist to lift the engine. Tightening torque: 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
• Operate the hoist to move the engine to the 3. Remove the engine rear hanger (Euro4
installation position. specification only) for PTO specifications and
install the oil separator together with the bracket
(Euro3 specification and Euro4 specification).
4. Connect the charge air pipe of the air compressor.
5. Install the AC generator harness.
• Install the harness connector (1 pole) and B
terminal cable to the generator.
6. Install the A/C compressor.
• Install the A/C compressor as shown in the
diagram, and tighten at the specified torque.
MFW71BSH006901
• Turn the engine over 90° and slowly lower the

engine to the installation position.
• At this time, operate the hoist so that the
transmission side is low, while pulling to the
rear of the engine.
CAUTION:
Never get under the engine while it is hoisted.
MFW51ESH000301

• Install the drive belt and adjust its tension using
the adjustment bolt of the tension pulley.
a
• Refer to "Drive Belt" in Section 1C Engine 1
Cooling for details on the belt tension
adjustment.
2
Belt tension adjustment value
Frequency
Amount of
of
Belt types flex
vibrations
mm (in)
(Hz)
Generator 5-7
New belt 197 - 221
drive belt (0.20-0.28)
a ; 50, 60A
Reused 7-9
specifications 168 - 182
belt (0.28-0.35)
b 1
Generator 5-7
New belt 190 - 212
drive belt (0.20-0.28)
b ; 90A
Reused 7-9 2
specification 163 - 175
belt (0.28-0.35)
16 - 21
New belt 68 - 82
(0.63-0.83)
A/C drive belt
Reused 21 - 24
59 - 67
belt (0.83-0.94)
NOTE: LNW71EMH000201
• A V-ribbed belt is used for the generator drive belt, Legend

which requires a more accurate tension adjustment
(a) 50,60A specifications
than conventional V belt. Therefore, use a sonic
(b) 90A specification
tension meter to check that the measured frequency
of vibrations is within the adjustment value. Perform
adjustment if the value is improper. Improper
7. Power steering oil pump
tension causes the belt life to shorten or the belt to
squeak. • Install the power steering oil pump and tighten it
at its specified torque.
• After the adjustment, securely tighten each bolt.
• After adjusting the belt tension, tighten the lock

Power steering oil pump mounting bolt (1)
nut of the tension pulley.
Tightening torque 50 N⋅m (5.1 kg⋅m/37 lb⋅ft)

• Place the fan guide on the fan ASM.
• Install the left and right bracket sections of the
radiator to the frame side bracket as shown in
the drawing.
Tightening torque:
Upper side nut 41.4 N⋅m (4.2 kg⋅m/31 lb⋅ft)
Lower side nut 85.1 N⋅m (8.7 kg⋅m/63 lb⋅ft)
1
MFW71BSH003301
8. Front exhaust pipe

• Install the front exhaust pipe (1) and tighten it at
the specified torque.
Exhaust adaptor side MFW71BSH005901
Tightening torque 67 N⋅m (6.8 kg⋅m/49 lb⋅ft) 10. Install the fan guide.
11. Connect the radiator lower hose (1).

Exhaust brake side Tightening torque: 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
Side of the engine (clamp)

MFW71CSH001801
12. Connect the coolant reserve tank hose.

13. Connect the radiator upper hose.
1 • For Smoother, connect the oil hose.
MFW71GSH004201 Tightening torque: 5 N⋅m (0.5 kg⋅m/43 lb⋅in)

9. Install the radiator.
2
1 1
MFW71CSH000401 MFW71JSH000801
18. Install the inlet manifold duct.

14. Connect the fuel feed hose. 19. Install the engine harness.
15. Connect the fuel return hose. • Install the engine ground cable.
16. Connect the heater hose. • Install the 2 main harness connectors to the
• Attach the hose so that the mark is facing ECM.
upward. • Install the ECM.
20. Install the transmission ASM.
21. Install the starter motor.
LNW21BSH027501
• Install the starter to the clutch housing with a
bolt, and tighten at the specified torque.
17. Install the air intake duct assembly (1) and rubber
hose.
• Install the bolt and clip band and tighten them at
the specified torques.
• Connect the connector of the boost sensor (2).
Refer to "Boost Pressure Sensor" in this
section.
Bolt
Clip
Tightening torque: 7 N⋅m (0.7 kg⋅m/61 lb⋅in)

Insertion target:guide tube bracket
2
5 4 3
LNW21BSH011601
MFWB1BSH007701
22. Connect the front frame harness connector.
Legend
23. Install the guide tube of the oil level gauge and the
1. Bracket
oil level gauge.
2. Guide tube
• Install the rubber hose to the second spool or 3. Clip
the bracket of guide tube, and fix with the clip. 4. First spool
Insertion target:spool(second) 5. Rubber hose
24. Refill the coolant.

25. Connect the battery cable negative terminal.
1
2
3
5 4
MFWB1BSH007801
Legend
1. Second spool
2. Guide tube
3. Clip
4. First spool
5. Rubber hose
Engine Mount
Components
1 2
2
1
3
MFW71BMF003501
Legend
1. Engine mount 3. Lock plate
2. Engine foot
Removal
1. Remove the oil separator together with the oil
separator bracket (Euro3 specification and Euro4
specification), and install the engine rear hanger
for PTO specifications. However, the one with
flywheel PTO is excluded (Euro4 specification
only).

Euro4 specification only Installation
1. Install engine mount, and tighten at the specified
torque.
Chassis frame side bolt

1 Engine foot side nuts
2. Remove the engine rear hanger for PTO

2 specifications (Euro4 specification only) and install
the oil separator (Euro3 specification and Euro4
specification) together with the bracket.
• Start the engine to verify whether there are any
abnormalities in the engine mount.
MFW71BSH010801
Legend
1. Engine rear hanger for PTO specifications
2. Oil separator bracket bolt
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.
• Slightly raise the engine ASM to remove the
engine mount.
MFW71BSH006801

List of Tightening Torques
c
b
d
f
MFW81BMF002701
(a) 103 N⋅m (10.5 kg⋅m/76 lb⋅ft)

(b) 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
(c) 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
(d) 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
(e) 103 N⋅m (10.5 kg⋅m/76 lb⋅ft)
(f) 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
Cylinder Head Cover

Components
MFW81BLF003401
Legend
1. Cylinder head cover 5. Lower case
2. Gasket 6. Gasket
3. Noise cover (with noise cover type) 7. Rubber plug
4. Harness bracket (with harness bracket type)
Removal
1. Remove the EGR cooler (Euro3 specification and
Euro4 specification).
Refer to “EGR Cooler” in Section 1F, Emission
Control.
2. Remove the harness the bracket (2) (with harness
bracket type).
3. Remove the noise cover (1) (with noise cover
type).

4. Remove the cylinder head cover (3).
2
1
2 1
2
2
2
LNW81BSH005101
MFW71BSH007201
2. Install the gasket to the lower case (1).
5. Disconnect the injector harness connector (2). 3. Install the lower case (1).
6. Remove the lower case (1) and gasket.
4. Connect the injector harness connector (2).
1
NOTE:
Push in until the locking claw is completely raised.
LNW21BSH057001
Legend
1. Lower case
2. Injector harness connector 2
7. Remove the rubber plugs.

LNW21BSH057001
• Clean the liquid gasket remaining on the
cylinder head.
5. Install the gasket to the cylinder head cover.
6. Install the cylinder head cover, and tighten in the
Installation order shown in the diagram.
1. Install the rubber plugs (1).
• Apply liquid gasket (TB-1207B) to the area
indicated in the diagram (2) with a width of 3 - 4
mm (0.12 - 0.16 in), and install it to the cylinder
head.
5 1 3 7
6 2 4 8
LNW21BSH030101
7. Install the noise cover (1) (with noise cover type).

8. Install the harness the bracket (2) (with harness
bracket type).
2
1
MFW71BSH007201
Legend
1. Noise cover (with noise cover type)
2. Harness bracket (with harness bracket type
3. Cylinder head cover
9. Install the EGR cooler (Euro3 specification and

Refer to “EGR Cooler” in Section 1F, Emission
Control.

a c
MFWB1BMF001001
(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)
Oil Separator(Euro3 and Euro4 specifications)

Components With flywheel PTO (Euro4 specification only)
•
Without flywheel PTO (Euro3 specification and

1
Euro4 specification)
•
2
1
2
3
MFW71BSH007401
Legend
1. Oil separator
4
2. Rubber hose (blow-by gas OUT)
3. Rubber hose (blow-by gas IN)
4. Oil drain hose
Maintenance Precautions
MFW71BMH000201 Replace the element of the oil separator (1) once a
year. Remove the cap (by turning it with your hand) at
Legend
the top of the separator and replace the element and O-
1. Oil separator
ring.
4. Oil drain hose Removal
1. Disconnect the rubber hose (2) that is located

between the oil separator and the intake duct.
between the oil separator and the flywheel
housing.
3. Disconnect the oil drain hose (4).

4. Remove the oil separator mounting bolt and 3. Disconnect the oil drain hose (4).
remove the oil separator (1) from the bracket.
1
1
2
4
3
MFW71BSH007401
4 4. Remove the mounting bolt (1) of the bracket and

remove the oil separator together with the bracket.
MFW71BMH000201
NOTE:
Replace the oil separator element once a year.
Replace the O-ring at the same time.
1
With flywheel PTO (Euro4 specification only)

between the oil separator (1) and the intake duct.
MFW71BSH007501
between the oil separator and the flywheel
NOTE:
housing.
Replace the oil separator element once a year.
Replace the O-ring at the same time.
Installation
1. Install the oil separator to the bracket.
• After applying the liquid gasket, install it within 5
minutes.
2. Insert the oil drain hose (4) into the plug of the
flywheel housing and fix it with a clip.

3. Insert the rubber hose (3) between the oil
separator (1) and the flywheel housing and fix it
with a clip.
separator and the intake duct and fix it with a clip.
2
1
MFW71BSH007501
3 Legend
1. Mounting bolt
4 2. Insert the oil drain hose (4) into the plug of the
flywheel housing and fix it with a clip.
separator (1) and the flywheel housing and fix it
with a clip.
separator and the intake duct and fix it with a clip.
1
MFW71BMH000201
2
With flywheel PTO (Euro4 specification only)
1. Install the oil separator with the bracket assembled
to the flywheel housing.
MFW71BSH007401
Oil Catch Tank(Euro2 specification only)

Components
3
7
5 6
MFW81BLF004101
Legend
1. Oil catch tank 5. Adaptor
2. PCV hose (blow-by gas OUT) 6. Oil drain hose
3. PCV hose (blow-by gas IN) 7. Bracket
4. Bracket
Removal • Disconnect the oil drain hose (6) from the oil
catch tank (1).
1. Disconnect the PCV hoses.
3. Remove the mounting bolt of the bracket (7) and
• Disconnect the PCV hose (3) from the flywheel
oil catch tank (1) together with the bracket.
housing and oil catch tank.
• Disconnect the PCV hose (2) from the oil catch
tank (1) and bracket (4).
2. Disconnect the oil drain hose.
• Remove the adapter (5).

4. Remove the oil catch tank from the bracket.
1
1
2
2
7 3
7 3
56
56
4
4
MFW81BSH007701
MFW81BSH007701
Legend
Legend 1. Oil catch tank
1. Oil catch tank 2. PCV hose
2. PCV hose 3. PCV hose
3. PCV hose 4. Bracket
4. Bracket 5. Adapter
5. Adapter 6. Oil drain hose
6. Oil drain hose 7. Bracket
7. Bracket
Installation
1. Install the oil catch tank (1) with the bracket (7)
assembled to the EGR cooler bracket.
2. Insert the oil drain hose (6) into the adaptor of the
flywheel housing and fix it with a clamp.
3. Insert the PCV hose (3) between the oil catch tank
and the flywheel housing and fix it with a clamp.
4. Insert the PCV hose (2) into the oil catch tank,
fasten it with the clamp and affix its bottom end to
the bracket (4).
Intake Throttle Valve(Euro4 specification only)

Removal
1. Remove the air duct. 1 2
2. Disconnect the injection pipe clip (2).
3. Disconnect the intake throttle valve harness
connector (8).
8
4. Remove the intake throttle valve (1).
7
• The installation rubber comes off easily, so be 6
careful not to lose it. 3
1 2
4
8
7 5
6
3 MFW81BSH002401
Legend
1. Intake throttle valve
2. Injection pipe clip
4 3. Gasket
4. Mounting rubber
5. Bolt
6. Nut
5 7. Mounting rubber
MFW81BSH002401 8. Connector
Legend
2. Connect the intake throttle valve harness
1. Intake throttle valve
connector (8).
3. Gasket 3. Connect the injection pipe clip (2).
4. Mounting rubber 4. Install the air duct.
5. Bolt • Install the clip band, and tighten at the specified
6. Nut torque. Use a new clip.
7. Mounting rubber
8. Connector
Clip band tightening torque
ABA W4 Stainless 6.4 N⋅m (0.65 kg⋅m/56 lb⋅in)
Installation clamp
1. Install the intake throttle valve (1). NORMA W1 Steel 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
• Install the gasket (3) and intake throttle valve, clamp
and tighten at the specified torque.
Tightening torque: 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Intake Pipe(Euro2 and Euro3 specifications)

Removal
1. Remove the air duct.
2. Disconnect the injection pipe clip.
3. Remove the intake pipe (5).
2 5
1
4
3
1 5
MFW81BSH007801
4 Legend
1. Inlet cover
2. Gasket
3. Bolt
MFW81BSH007801
4. Nut
Legend 5. Intake pipe
1. Inlet cover
2. Gasket 2. Connect the injection pipe clip.
3. Bolt 3. Install the air duct.
4. Nut
• Install the clip band, and tighten at the specified
5. Intake pipe
torque. Use a new clip.
Installation Clip band tightening torque

1. Install the intake pipe. ABA W4 Stainless 6.4 N⋅m (0.65 kg⋅m/56 lb⋅in)
clamp
• Install the gasket (2) and intake pipe (5), and
tighten at the specified torque. NORMA W1 Steel 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
clamp
Inlet Cover
Components
Euro2 specification and Euro3 specification
2
3
MFW81BMF002901
Legend
1. Inlet cover 3. Intake pipe
2. Gasket

4
LNW71BMF001301
Legend
1. Inlet cover 3. Throttle valve ASM
2. Throttle valve gasket 4. Mounting rubber
Removal • Carefully remove the fluid gasket.

1. Remove the common rail.
Refer to "Common Rail" in Section 1D Engine
Fuel.
2. Remove the intake pipe (Euro2 specification and
3. Remove the throttle valve ASM (Euro4
specification only).
• The installation rubber comes off easily, so be
careful not to lose it.
• Refer to "Intake Throttle Valve" in the section.
4. Remove the inlet cover.
• There is 1 bolt on the throttle valve ASM
installation section (arrow) in the inlet cover. Be
careful not to forget to remove it.
MFW51BSH002601
Installation
1. Install the inlet cover.

• Apply liquid gasket (TB1207C) to about dia.2.5 2. Install the intake pipe (Euro2 specification and
- dia.5.5 mm (dia.0.098 - dia.0.22 in) width Euro3 specification).
along the inlet cover groove (1). Assemble it • Install the gasket and intake pipe, and tighten at
within 5 minutes after applying the liquid the specified torque.
gasket.
NOTE:
• Be careful not to forget tightening the bolt indicated
by the arrow.
• Tighten the stud along with the common rail.
1
2
1 5
MFW81BSH007801
Legend
1. Inlet cover
2. Gasket
MFW81BSH008201
3. Bolt
4. Nut
5. Intake pipe
• Tighten in the order of the numbers in the 3. Install the throttle valve ASM (3) (Euro4
diagram. specification only).
• Tighten the stud bolts (6) and (9) together with • Install the gasket (5) and throttle valve ASM,
the common rail. and tighten at the specified torque.
• Securely mount the mounting rubber.
Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb⋅ft) • Refer to "Intake Throttle Valve" in this section.
5
10 4 1 11
8 3 2 7
6 9
MFW71BSH004801
3
2
1
4
8 5
7 6
MFW71BSH004901
Legend
1. Nut
2. Mounting rubber
3. Throttle valve ASM
4. Inlet cover
5. Gasket
6. Mounting rubber
7. Bolt
8. Bolt
4. Install the common rail.

Refer to "Common Rail" in Section 1D, Engine
Fuel.

c
a
b
MFW81BMF003101
(a) 22 N⋅m (2.2 kg⋅m/16 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)

c
a
b
MFW71BMF003601
(a) 22 N⋅m (2.2 kg⋅m/16 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)
Exhaust Manifold
Components
2 3
5
6
MFW81JLF000401
Legend
1. Turbocharger feed oil pipe 5. Exhaust adapter ASM
2. Turbocharger ASM 6. Turbocharger drain oil pipe
3. Water pipe ASM (return) 7. Water pipe ASM (feed)
4. Exhaust manifold

2 3
7 6 5
MFW71BLF000701
Legend
1. Turbocharger feed oil pipe 5. Exhaust adapter ASM
2. Turbocharger ASM 6. Turbocharger drain oil pipe
3. Water pipe ASM (return) 7. Water pipe ASM (feed)
4. Exhaust manifold
Removal
1. Remove the turbocharger ASM.
Refer to "Turbocharger Assembly" in Section 1J
Induction.
2. Remove the A/C compressor bracket.
• Remove the compressor from the bracket
without disconnecting the A/C compressor
hose.

• Remove the compressor bracket from the • Remove 2 nuts and 6 bolts to remove the
cylinder head. exhaust manifold.
2
3
MFW51ESH000301 MFW51BSH000301
Legend
1. Cylinder head
2. Gasket
3. Exhaust manifold
4. Distance tube
Inspection
1. Inspecting the exhaust manifold
• Inspect the flatness of the installation surface of
the manifold and cylinder head.
Flatness of the manifold installation mm (in)

Standard values 0.3 (0.012) or less
1 2 3
Repair limit 0.5 (0.020)
MFW71BSH004501
Legend NOTE:
1. Bracket fixing bolt Replace if the flatness is beyond the repair limit.
2. A/C compressor bracket
3. Front engine hanger
3. Remove the exhaust manifold.


NOTE:
Since it will expand or contract due to the heat of the
manifold, do not over-tighten.
Nuts (7), (8) and bolts (1), (2), (3), (4), (5), (6)
5 3 4 6
1 2
7 8
LNW71BSH009001
• Visually check the exhaust manifold for cracks.

2. For turbocharger ASM inspection, refer to
"Turbocharger Assembly" in Section 1J Induction.
LNW71BSH008901
2. Install the A/C compressor bracket.

Installation
• Install the A/C compressor bracket to the
1. Sandwich the gasket and install the exhaust cylinder head, and tighten at the specified
manifold. torque.
2
3
MFW51BSH000301
Legend 1 2 3
1. Cylinder head MFW71BSH004501
2. Gasket
Legend
3. Exhaust manifold
1. Bracket fixing bolt
4. Distance tube
• Attach the 2 nuts and 6 bolts, and tighten in the
order shown in the diagram.
• Install the A/C compressor to the bracket, and
tighten at the specified torque.
MFW51ESH000301
3. Install the turbocharger ASM.

Induction.
Timing Gear Train

Components
1 2
4
11 10
5
16
6
9
22
12
21 7
8
17
20
18
13
15
19
14
MFW81BLF003901
Legend
1. Power steering pump 12. Oil return plug
2. Idle gear B shaft 13. Flexible plate (Smoother vehicle)
3. Idle gear A 14. Flywheel
4. Idle gear B 15. Crankshaft position sensor
5. Power steering pump idle gear 16. Stiffener (RH)
6. Power steering pump idle gear cover 17. Rubber spacer
7. Pilot bearing 18. Stiffener (LH)
8. Flywheel (M/T vehicle) 19. Oil pan
9. Rear oil seal 20. Air compressor
10. Flywheel housing 21. Supply pump bracket
11. Slinger 22. Supply pump
Removal 2. Remove the rocker arm shaft ASM.

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

3. Remove the camshaft ASM.
Refer to "Camshaft ASM" in this section.
4. Remove the cylinder head ASM.
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
air compressor (4).
• Remove the coupling (3) and O-ring. 5
6
4 7
MFW41BSH033101
Legend
2 3
1 1. Supply pump
2. Key
3. O-ring
4. Supply pump bracket
5. Nut
6. Coupling
7. Flange bolt
MFW41BSH033201 8. Remove the air compressor (1).

Legend • Remove the nut and the bolt to remove the air
1. Supply pump (Including bracket) compressor (1).
2. O-ring 9. Remove the gear (3) from the air compressor (1).
3. Coupling
4. Air compressor
1
7. Remove the supply pump bracket (4).

• Tighten the 2 bolts in the coupling (6) screw
holes for turning prevention, and remove the
nut. 2
• Remove the 2 tightened bolts in the coupling
(6) screw holes via the gear puller to remove 3
the coupling (6).
4
MFW41BSH021201
Legend
1. Air compressor
2. Key
3. Gear
4. Nut
5. O-ring

10. Remove the crankshaft position sensor (2) from
the flywheel housing (1).
Refer to "Crankshaft Position Sensor" in this
section.
1 4
6 7
1
3 2
2
8 5
MFW81BSH000501
12. Remove the rear oil seal and slinger.

Refer to "Crankshaft Rear Oil Seal" in this section.
MFW71BSH004201
13. Remove the stiffener and spacer rubber.
• Remove the right side stiffener (1) and the left
11. Remove the flywheel.
side stiffener (3), and then remove the spacer
• Install the crankshaft stopper to the flywheel rubber (2).
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
2
1 3
MFW81BSH006701
14. Remove the oil pan.

15. Remove the power steering pump.
16. Remove the power steering pump idle gear cover.
LNW21BSH007701
• Slowly loosen the bolts in the order shown in

the diagram to remove the crankshaft stopper.
Then remove the flywheel.

17. Remove the power steering pump idle gear. 21. Remove the idle gear B shaft.
MFW81BSH007301 LNW81BSH004901
18. Remove the flywheel housing. Inspection

• Do not forget to remove the bolt indicated by
1. Measurement of idle gear backlash
the arrow in the diagram.
• 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.)
• Replace the idle gear if the measured value
exceeds the limit.
Timing gear backlash mm (in)

Standard values 0.10 - 0.17 (0.0039 - 0.0067)
Limit 0.30 (0.012)
• 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 Limit
0.150 - 0.225
Idle gear A 0.3 (0.012)
(0.0059-0.0089)
0.080 - 0.155
Idle gear B 0.2 (0.0079)
(0.0031-0.0061)
0.090 - 0.154
Idle gear C 0.2 (0.0079)
(0.0035-0.0061)
LNW21BSH003501
• Measure idle gear play in the axis direction 4. Clearance between the idle gear and the idle gear
before removing idle gear B. shaft
• Measure the inner diameter of the idle gear
bush to calculate the clearance between the
idle gear and the idle gear shaft.
• Replace the idle gear or shaft if the measured
value exceeds the limit.
Clearance between the idle

gear and shaft mm (in)
0.020 - 0.062
Standard values
(0.0008 - 0.0024)
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)
29.959 -29.980
Standard values
(1.1795-1.1803)
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
center.
• Align the crankshaft gear (6) and idle gear A (9)
• After installing, apply engine oil to the shaft. alignment marks and install to the cylinder
block.
• It is oil application, and the application range
does things more than 17 mm (0.67 in) to bolt
from the bolt tip.
• It is oil application to the washer both sides.
• Tighten the mounting bolt at the specified
torque.
LNW81BSH004601
2. Install the idle gear (1) B.

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

2
1
9 3
0 L 0
6 5
7
LNW71BMF004401
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 pump gear 9. Idle gear A
5. Power steering pump idle gear
4. Install the flywheel housing.

• Especially, clean the excessive liquid gasket
that comes out when the crankcase is installed.
• As shown in the diagram, uniformly apply liquid
gasket (TB1207B) to the inside of the bolt hole
(excluding the bolt hole at the arrow).
Bead width 3.5 mm (0.14 in)

Bead height 2.0 - 4.0 mm (0.08 - 0.16 in)
LNW21BSH033201

• Position the cylinder block knock pin to install • Tighten the one marked (3) and (4) from the
the flywheel housing. cylinder block side.
Flywheel housing tightening torque

N⋅m (kg⋅m/ lb⋅ft)
(1),(2)=96 (9.8/71) (3)=38 (3.9/28) (4)=48 (4.9/35)
1
1
2
4
MFWA1BMF000801
5. Install the power steering 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.
LNW21BSH053701
LNW21BSH004301
1
MFW71BSH003301
8. Install the oil pan.

6. Install the power steering pump idle gear cover to • Apply a bead of liquid gasket (TB1207C) to 3
the flywheel housing. mm (0.12 in) in the joints of the cylinder block,
• Install the O-ring to the cover, and tighten the front cover and flywheel housing.
bolts at the specified torque. • After applying the liquid gasket, install the oil
pan within 5 minutes.
LNW21BSH004601
MFW81BSH000801
7. Install the power steering pump.

• Install the power steering pump and tighten it at
its specified torque.
Power steering pump mounting bolts (1)

• 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 ASM (1) on the oil pan,
and tighten with the bolts and nuts. 1 2
2
4
3
1
LNW21BSH013801
9. Install the stiffener (1), (3) and space rubber (2).

• The length of the M12 bolts differs.
Stiffener bolt Tightening torque N⋅m (kg⋅m/lb⋅ft)

M10 bolt 59 (6.0/43)
2
M12 bolt 76 (7.7/56)
3
1
LNW21BMH000101
Legend
1. Rubber ASM
2. Oil pan
3. Gasket
• After tightening the oil pan at (1), (2, (3), and

(4), tighten the others. (No particular order is 2
required.) 1 3
MFW81BSH006701
10. Install the crankshaft position sensor (2) to the

flywheel housing (1).
section.
2 2
11. Install the rear slinger and oil seal. Legend

Refer to "Crankshaft Rear Oil Seal" in this section. 1. Air compressor
12. Install the flywheel. 2. Key
3. Gear
• Align to the crankshaft knock pin, install the
4. Nut
flywheel, and tighten at the specified torque in
5. O-ring
the order shown in the diagram.
14. Rotate the crankshaft in the forward direction to
align the 1st cylinder piston to the compression top
Tightening torque N⋅m (kg⋅m/lb⋅ft)
dead center (BTDC 0°).
1st time 78 (8.0 /58)
2nd time angle method 60° → 60° - 90°
2
1 4
6 7
3 2
8 5
MFW71BSH004401
15. Remove the oil return plug (viewing hole).

16. Install the air compressor to the cylinder block.
MFW81BSH000501
• Install the O-ring to the air compressor.
13. Install the gear (3) to the compressor (1). • Align the air compressor side cast line (1) and
• Install the key (2) to the shaft of the compressor gear slit (2).
(1). • Use the cylinder block stud bolt as a guide to
• Insert the gear (3) into the shaft and tighten the assemble to the air compressor.
nut (4) at the specified torque. • Look through the viewing hole in the flywheel
Tightening torque: 137 N⋅m (14.0 kg⋅m/101 lb⋅ft) housing to check that the gear slit (2) is near
the center of the hole.

NOTE: • Tighten the air compressor at the specified
If the slit is miss positioned, redo this. torque.
NOTE:
Tighten in diagonal order.
2
3
1
M10 nut 40 (4.1/30)
M12 nut 73 (7.4/54)
M12 bolt 73 (7.4/54)
17. Assemble the units of the supply pump (1) and

supply pump bracket (4).
• Insert an O-ring (3) into the supply pump (1)
and assemble to the supply pump bracket (4).
6 • Tighten the bolts (7) in diagonal order.
4
5 Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
MFW41BSH022601
• Insert the key (2) into the supply pump shaft
Legend and install the coupling (6).
1. Casting burr • Tighten the 2 bolts in the coupling (6) screw
2. Slit holes (M10, P=1.25) to fasten and tighten the
3. Slit location before insertion nuts (5) at the specified torque.
4. Slit location after insertion
5. Eye hole Tightening torque: 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
6. Air compressor
• After assembling the air compressor (2), the

assembly is correct if a line joining the center of
the claw, as shown in the drawing, is angled
approximately 15° to the level surface of the 4
engine, when looking from the engine front 1
3
side. 2
2
1
5
6
MFW41BSH033101
3
Legend
1. Supply pump
2. Key
3. O-ring
4
5. Nut
MFW41BSH021101 6. Coupling
7. Flange bolt
Legend
1. Cylinder block
18. Install the supply pump (1) to the air compressor.
2. Air compressor
3. Approximately 15° • Fit in the coupling (3) with the damper to the air
4. Claw compressor (4).

NOTE: • Thinly apply engine oil to the O-ring (2) for
Check that the coupling (3) rubber dampers are assembly.
assembled facing alternately.
• Insert the O-ring (2) to the supply pump BRKT

and assemble the supply pump to the air
compressor. 1
2
NOTE:
There is no need to align the supply pump (1) pawl.
• Tighten the bolts in diagonal order at the

specified torque.
MFW71FSH000101
20. Install the clutch disk and clutch pressure plate.

21. Install the cylinder head ASM.
3 22. Install the camshaft ASM.
2 Refer to "Camshaft ASM" in this section.
1
23. Install the rocker arm shaft ASM.
24. Install the cylinder head cover.
MFW81BSH011601
Legend
1. Supply pump (Including bracket)
2. O-ring
3. Coupling
19. Attach the oil return plug (1) to the viewing hole,
and tighten it at the specified torque.

b
c
d
e
s
l
r m
g
q h
n
p
j i
MFW81BLF004001
(s) M10; 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)

(a) 50 N⋅m (5.1 kg⋅m/37 lb⋅ft) M12; 73 N⋅m (7.4 kg⋅m/54 lb⋅ft)
(b) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
(c) 31 N⋅m (3.2 kg⋅m/24 lb⋅ft)
(d) 110 N⋅m (11.2 kg⋅m/81.0 lb⋅ft)
(e) 157 N⋅m (16.0 kg⋅m/116 lb⋅ft)
(f) 134 N⋅m (13.7 kg⋅m/99 lb⋅ft)
(g) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(h) 78 N⋅m (8.0 kg⋅m/58 lb⋅ft) → 60° → 60° - 90°
(i) 78 N⋅m (8.0 kg⋅m58 lb⋅ft) → 60° → 60° - 90°
(j) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(k) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(l) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(m) 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
(n) 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
(o) 11 N⋅m (1.1 kg⋅m/95 lb⋅in)
(p) 73 N⋅m (7.4 kg⋅m/54 lb⋅ft)
(q) 52 N⋅m (5.3 kg⋅m/39 lb⋅ft)
(r) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
Valve Stem Seal and Valve Spring

Components
10
9
8
MFWB1BLF001401
Legend
1. Camshaft bearing cap 6. Valve stem oil seal
2. Camshaft bearing 7. Valve spring
3. Camshaft ASM 8. Spring upper seat
4. Rocker arm shaft ASM 9. Split collar
5. Spring lower seat 10. Bridge
Removal 4. Remove the camshaft ASM.

Refer to "Camshaft Assembly".
1. Remove the cylinder head.
Refer to "Cylinder Head" in this section. 5. Remove the bridge cap (1).
2. Remove the injector. 6. Remove the bridge (2).
Refer to "Injector" in Section 1D Engine Fuel.
NOTE:
3. Remove the rocker arm ASM. Be very careful not to drop the bridge cap (1) into the
Refer to "Rocker Arm Shaft Assembly". cylinder head rear-side gear case or front side oil return
hole.

NOTE: 9. Remove the valve spring.
Store the removed bridge (2) and bridge cap (1) so that Organize the removed valve springs in the order of
they can be returned to their original positions. the cylinder number.
10. Remove the valve stem oil seal.
• Remove the oil seal using pliers.
NOTE:
1 Do not reuse the removed oil seal.
LNW21BSH031301
Legend
1. Bridge cap
2. Bridge
LNW21BSH056801
7. Remove the split collar.
11. Remove the spring lower seat.
• Compress the valve spring and remove the split
collar using a replacer.
Inspection
Special Tool Inspect the valve springs
Valve spring replacer: 5-8840-2621-0 NOTE:
Pivot: 5-8840-2808-0 Visually inspect the valve spring for damage or excess
wear. Replace if necessary.
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 (2.36) 70.3 (2.77)
Limit 58.7(2.31) 68.9 (2.71)
LNW21BSH031401
8. Remove the spring upper seat.

• Remove the special tool and remove the upper
seat.
Valve spring tension N (kg/lb)

Inlet Exhaust
Installation
47.0 (1.85) 47.0 (1.85)
height mm (in)
Standard values 333 (34.0/75.0) 490 (50.0/110)
Limit 315 (32.1/71.0) 463 (47.3/104)
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 mm (in)
Limit 3.4 (0.13) LNW21BSH056701
Installation
1. Install the spring lower seat.
2. 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:
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
loose.
Special Tool
LNW21BSH017101
Valve stem seal installer: 5-8840-2625-0
3. Tension
• Using a spring tester, compress the spring to
the installation height. Measure the
compressed spring tension. If the measured
tension is lower than the limit, replace the
spring.

• Using a replacer, compress the valve spring to
install the split collar.
Special Tool
Valve spring replacer: 5-8840-2621-0
Pivot: 5-8840-2808-0
LNW21BSH031901
3. 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).
LNW21BSH031401
Paint mark
Inlet Blue 6. Apply engine oil to the bridge (2) for assembly.
Exhaust Red
NOTE:
Move it up and down to confirm that it moves smoothly.
7. Apply engine oil to the bridge cap (1) for assembly.
NOTE:
Be very careful not to drop the bridge cap into the
cylinder head rear-side gear case or front side oil return
hole.
LNW21BSH016701
Legend
1. Spring pitch
2. Paint mark
4. Install the spring upper seat.

5. Install the split collar.
MFW61BSH000401
Legend
1. Bridge cap
2. Bridge
8. Install the camshaft assembly.

Refer to "Crank shaft assembly" in this section.
9. Install the rocker arm shaft assembly.
Refer to "Rocker Arm Shaft assembly" in this
section.
10. Install the injector.
Refer to "Injector" in this section.
11. 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 ASM.
• Remove the rocker arm shaft ASM 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
LNW21BSH002001
Legend
1. Camshaft bracket
NOTE: 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 runout.

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

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

Limit 0.3 (0.012)
LNW21BSH019101
4. Inspect the clearance 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 clearance with the shaft outer diameter.
• Replace the rocker arm and shaft if the
LNW21BSH056601
Clearance between the rocker arm and

3. Inspect the rocker arm shaft for wear. rocker arm shaft mm (in)
• Use a micrometer to measure the rocker arm
sliding portion at 8 places. 0.010 - 0.056
Standard 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)

21.979 - 22.000
Standard values
(0.8653 - 0.8661)
Limit 21.85 (0.86023)
LNW21BSH019201
5. Inspect the clearance between the rocker arm

roller and rocker arm pin.

a. Pass a cord through the clearance 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 clearance between the roller and the
rocker arm pin. Replace the rocker arm if the
clearance exceeds the limit.
Clearance between the roller and

rocker arm pin mm (in)
0.068 - 0.100
Standard values
(0.0027- 0.0039) LNW21BSH033101
Limit 0.2 (0.0079)

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 ASM to arms.
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 ASM 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).
NOTE:
hole.
LNW21BSH030201
• Apply engine oil to the threaded portions of the

nut and bolt.

• Temporarily tighten the rocker arm ASM
tightening bolts (2), and (3). Gradually tighten
the whole rocker arm ASM to become level, in
the order of nut (1) of the rocker arm side.

Bolt (3) 56 (5.7/41)
Nut (1), bolts (2), (4) 27 (2.8/20)
1
2
3
1
2
4
LNW21BSH059201
Legend
1. Nut
2. Bolt
3. Bolt
4. Bolt
2. Adjust valve clearance.

Refer to "Functional inspection" in this section.

LNW71BMF002201
(a) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)

(b) 56 N⋅m (5.7 kg⋅m/41 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(d) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Camshaft Position Sensor

Removal
1. Disconnect the camshaft position sensor
connector.
2. Remove the camshaft position sensor.
LNW71BSH007301
Installation
1. Install the camshaft position sensor and tighten at
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.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
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
clearance 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)
0.05 - 0.170
Standard values
(0.0020 - 0.0067)
Limit 0.25 (0.0098)
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 values 52.8 (2.08) 54.5 (2.15)
Limit 51.8 (2.04) 53.5 (2.11)
LNW21BSH020501
5. Inspect the camshaft for runout.

• Place the camshaft in the V-block and use a
dial indicator to measure runout.
• Use a dial indicator to measure the camshaft
central portion runout. Replace the camshaft if
the runout exceeds the limit.
Camshaft runout mm (in)

Limit 0.05 (0.0020)
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)

39.950 - 39.975
Standard values
(1.5728 - 1.5738)
Limit 39.850 (1.5689)
Disproportionate wear of the camshaft
journal mm (in)
Limit 0.05 (0.0020)
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)

0.025 - 0.087
Standard values
(0.001 - 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. 1
2. Install the camshaft gear.
• Put the side of the camshaft gear center boss
that is projected to the camshaft side, and align 2
it to the knock pin. Then install the camshaft
gear.
NOTE:
When tightening the gear, be careful not to damage the
cam and journal.
MFW71BSH004401
2. Install the camshaft bearing lower.

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

• Assemble the camshaft ASM so that the " B "
marks on the camshaft gear end and top
surface of the cylinder head are aligned.
LNW21BSH030901
LNW71BSH010601
NOTE: 7. Install the cylinder head cover.
After tightening, check again that the " B " marks are Refer to "Cylinder Head Cover" in this section.
aligned.
4. Attach 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
• Apply engine oil to the threaded portion and

tighten the bearing cap at the specified torque.

LNW71BLF003301
(a) 27 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
17 5
6
7
3
8
9
10
11
16
12
15
13
14
MFW81BLF000301
Legend
1. Bridge cap 10. Idle gear C cover
2. Bridge 11. Idle gear C
3. Bridge guide 12. Glow plug (or dummy glow plug)
4. Split collar 13. Intake and exhaust valve
5. Spring upper seat 14. Cylinder head
6. Valve spring 15. A/C compressor bracket
7. Valve stem oil seal 16. Thermostat
8. Spring lower seat 17. Water outlet pipe
9. Valve guide
Removal 4. Remove the air intake duct.

1. Drain the coolant.
2. Remove the engine harness.
3. Remove the front exhaust pipe.

5. Remove the air charge pipe on the left and right of 8. Remove the water rubber hoses (2, 4), EGR cooler
the engine. duct (1), EGR cooler (3) and EGR valve (5) (Euro4
1 2 • Refer to "EGR Valve and EGR Cooler" in
Section 1F Emission Control.
4
3 5
MFW71JSH001201
Legend
1. Air charge pipe
2. Air intake duct
MFW71FSH000201
6. Disconnect the radiator upper hose.
7. Remove the water rubber hoses (1, 4), EGR cooler Legend
pipe (2), EGR cooler (3) and EGR valve (5) (Euro3 1. EGR cooler duct
specification only). 2. Feed water rubber hose
3. EGR cooler
• Refer to "EGR Valve and EGR Cooler" in
4. Return water rubber hose
5. EGR valve
9. Remove the oil separator together with the bracket
4 (Euro3 specification and Euro4 specification).
3
1
5
2 2
1
3
MFW81BSH011301
Legend
1. Feed water rubber hose 5 4
MFW71BSH003501
2. EGR cooler pipe
3. EGR cooler Legend
4. Return water rubber hose 1. Oil separator
5. EGR valve 2. Rubber hose (blow-by gas OUT)
3. Oil separator bracket
5. Oil drain hose

10. Remove the oil catch tank from the bracket (Euro2 12. Remove the water pipe assemblies (3, 7) and the
specification only). oil pipes (1, 6).
Euro2 specification only Euro4 specification only
1 2
2 3
5
1
4
3
4
7 6 5
Legend Legend
1. Oil catch tank 1. Turbo feed oil pipe
2. PCV hose 2. Turbocharger
3. PCV hose 3. Water pipe assembly (return)
4. Adaptor 4. Exhaust manifold
5. Oil drain hose 5. Exhaust adaptor assembly
6. Turbocharger return oil pipe
11. Remove the water pipe assemblies (3, 7) and the 7. Water pipe assembly (feed)
oil pipes (1, 6).
Euro2 specification and Euro3specification 13. Remove the A/C compressor drive belt.
• Loosen the tension pulley nut (1) and adjust
2 3 bolt (2), and remove the drive belt.
1
4
1
6 5
7
MFW81BSH011101
Legend
1. Turbo feed oil pipe MFW81BSH007601
2. Turbocharger
Legend
3. Water pipe assembly (return)
1. Tension pulley nut
4. Exhaust manifold
2. Adjust bolt
5. Exhaust adaptor assembly
6. Turbocharger return oil pipe
14. Remove the A/C compressor bracket.
7. Water pipe assembly (feed)

• Remove the A/C compressor harness 18. Remove the nozzle leak-off pipe (4).
connector, and remove the compressor from
the A/C compressor bracket to fasten to
appropriate position together with the hoses
using a wire, etc. Remove the A/C compressor
bracket from the cylinder head. 1
2 4
LNW71DSH003501
Legend
1. Harness bracket
2. Connector
3. Terminal nut
MFW51ESH000301
4. Leak-off pipe
19. Disconnect the leak-off hose.

20. Disconnect the leak-off pipe (2).
1 2
1 2 3
MFW71BSH004501
Legend
1. Bracket mounting bolt
2. A/C compressor bracket MFW71BSH003601
3. Front engine hanger Legend

1. Injection pipe (C/R)
15. Remove the cylinder head cover. 2. Leak-off pipe
Refer to "Cylinder Head Cover".
16. Loosen the injector terminal nut (3) and remove 21. Disconnect the water bypass hose (1) from the
the terminal. cylinder head side.
17. Loosen the injector harness bracket bolts, remove • Remove the engine coolant temperature sensor
the inside connector (2), and remove the harness connector.
bracket (1).
NOTE:
The injector ID code identifies each injector.
Do not remove the injector ID codes from the injectors.

29. Remove the injection pipe clip (2), and remove the
injection pipe (1).
2
1
MFW71BSH003701
Legend
1. Water bypass hose 2
2. Engine coolant temperature sensor
22. Remove the cam position sensor connector and

sensor.
25. Store the removed bridge and bridge cap so that MFW81BMH000401
they can be returned to their original positions. Legend

26. Remove the bridge. 1. Injection pipe
NOTE:
Store the removed bridge and bridge cap so that they 30. Remove the common rail.
can be returned to their original positions. • Remove the common rail pressure sensor
connector.
27. Remove the glow plug connector. (with glow plug)
31. Remove the injector bracket.
28. Remove the glow plug. (or dummy glow plug)
32. 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
NOTE:
• The injector ID code identifies the injectors. Do not
confuse between other injector ID code plates.
• When the injector ASM is replaced, use the scan
tool to register the ID code to the ECU.
For details on writing, refer to "Repair Instructions"
in Section 1A Engine Control System.
LNW21BSH055301 • 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.

• Evenly loosen the cylinder head bolts in the
order shown in the diagram.
NOTE:
(1) and (2) are tightened to the flywheel housing by
1 M10 bolts, so do not overlook them.
• Remove the cylinder head gasket.

2
NOTE:
Do not reuse the removed cylinder head gasket.
3 7 15 18 10
3 11 19 14 6 2
1
4 12 20 13 5
8 16 17 9
LNW46CMH000301
Legend LNW21BSH030401
1. Sliding hammer
2. Injector remover
3. Injector ASM Disassembly
1. Remove the exhaust adaptor (2) and turbocharger
NOTE: (1).
Store the removed injector with the cylinder number on Euro2 specification and Euro3 specification
it.
Take sufficient care not to hit the injection hole.
MFW81BSH008401
MFW71BSH005301
33. Remove the cylinder head ASM.


Euro4 specification only • Carefully remove the fluid gasket.
MFW71BSH003901
MFW51BSH002601
2. Remove the exhaust manifold. 6. Remove the A/C compressor bracket.

7. Remove the EGR cooler bracket (Euro3
specification and Euro4 specification).
8. Remove the water outlet pipe.
9. Remove the thermostat.
2
3
MFW51BSH000301
Legend
1. Cylinder head
2. Gasket
3. Exhaust manifold
LNW21BSH056501
4. Distance tube
10. Remove the idle gear C cover.
3. Remove the intake pipe (Euro2 specification and
• Be careful not to lose the gasket.
Refer to "Intake Pipe" in this section.
4. Remove the throttle valve ASM (Euro4
• Be careful not to lose the gasket.
Refer to "Intake Throttle Valve" in this section.
5. Remove the inlet cover.
• There is 1 bolt on the throttle valve ASM
installation section (arrow) in the inlet cover. Be
careful not to forget to remove it.

• As shown in the drawing, lightly tap the sealing • Remove the upper seat and valve springs.
cup outer perimeter with the leading end of the Organize the removed valve springs in the
screwdriver, turn the sealing cup over and pull it order of the cylinder number.
out using pliers.
LNW21BSH031401
LNW21BSH054701
15. Remove the inlet valve and exhaust valve.

11. Remove the idle gear C (1). • Organize the removed valves according to the
cylinders using tags, etc.
LNW21BSH055601
Legend LNW21BSH016801
1. Idle gear C
2. Idle gear shaft
16. Remove the valve stem oil seal.
12. Remove the split collar.

13. Remove the spring upper seat.
14. 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 oil seal using pliers. • Do not reuse the removed injector sleeve.
• Carefully remove any drill powder in the cylinder
head screws.
LNW21BSH056801
17. Remove the spring lower seat. 1
LNW21BSH056301
18. Remove the valve guide.
• Use the valve guide replacer to tap out the
valve guide from the lower side of the cylinder 20. Remove the bridge guide.
head. • Electrically weld (1) the nut to the top of the
bridge guide, attach the sliding hammer to
Special Tool
remove the bridge guide.
Valve guide replacer: 5-8840-2628-0
LNW21BSH058201
LNW21BSH055701
21. Remove the oil seal.

19. Attach the injector sleeve remover to the bottom
surface of the head and tap to pull out the injector
sleeve (1).
Special Tool
Injector sleeve remover: 5-8840-2623-0
NOTE:
• Be careful not to damage the bottom surface of the
head.

• Attach a metal plate from the inside of the head
to tap and remove.
LNW21BSH017301
LNW21BSH056401
• Use a dial indicator to measure the

clearance between the valve guide and
Inspection valve stem within a range of 10 mm (0.39 in)
1. Inspect the valve guide. from the valve guide.
• Replace the valve and valve guide together
NOTE: as an assembly if the measured value
If there are scratches or abnormal wear on the inner exceeds the limit.
diameter of the valve stem or valve guide, replace it
together with the valve guide.
Clearance between the valve guide and
a. Measure the valve guide clearance. valve stem mm (in)
• Measure the diameter of the valve stem Standard values Limit
using the micrometer.
If the diameter of the valve stem is smaller 0.039 - 0.071 0.20
Inlet valve
than the limit, replace the valve and valve (0.0015 - 0.0028) (0.0079)
guide together. 0.064 - 0.096 0.25
Exhaust valve
(0.0025 - 0.0038) (0.0098)
Outer diameter of the valve stem mm (in)
Standard values Limit
7.946 - 7.961
Inlet valve 7.88 (0.3102)
(0.3128 - 0.3134)
7.921 - 7.936
(0.3118 - 0.3124)
1
BLW51BSH005801
2. Inspect the bridge cap for wear.


• 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 (0.004)
LNW21BSH017801
Valve seat
• Remove the carbon and water deposit on the
bottom surface of the cylinder head.
Install the valve to the cylinder head.
Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the
cylinder head lower surface.
Replace the valve and insert if it exceeds the
LNW21BSH019401 limit.
3. Inspect the valve. Valve depression mm (in)

Valve thickness
• Measure the thickness of the valve.
0.73 - 1.10
• Replace the valve and valve guide together as Inlet 2.3 (0.091)
(0.0287-0.0433)
an assembly if the measured value exceeds the
limit. 1.16 - 1.54
Exhaust 2.8 (0.110)
(0.0457-0.0606)
Valve thickness mm (in)
• Measure the valve contact width of the valve
Standard values Limit seat. Repair or replace when there are
Inlet valve 1.71 (0.0673) 1.3 (0.051) scratches on the seat contact surface, or it is
rough, or if the contact surface wear exceeds
Exhaust valve 1.75 (0.0689) 1.3 (0.051) the limit.
Valve seat contact width mm (in)

Inlet valve 2.7 (0.1063) 3.2 (0.13)
Exhaust valve 2.7 (0.1063) 3.0 (0.12)

• Use a seat cutter to minimize the scratches and
other uneven parts, and return the touching
width to the standard value.
Inlet valve
1
3
2
MFW51BSH003501
Legend
1. Contact length width
2. Valve depression LNW76BSH005501
3. Contact surface angle
Legend
1. 119°45’
Valve seat surface
Exhaust valve
• Measure the contact surface of the valve seat.
If the valve seat contact surface is improper,
1
repair or replace together as an assembly with
the valve, valve guide and valve seat.
Contact surface angle

Inlet 30°
Exhaust 45°
LNW76BSH005401
Legend
1. 89°45’
NOTE:
Get rid of only the scratches and uneven portions, but
be careful not to over-cut.
Use an adjustable valve cutter pilot.
The valve cutter pilot should not be allowed to scrape
inside the valve guide.
LNW21BSH018101
Repair of the seat surface

• Remove the carbon from the valve seat insert
top surface.

• 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.

• Insert the valve into the valve guide. LNW21BSH056001
• Add compound to the valve seat surface and
Legend
gently tap the valve while turning it to check that
1. Arc welding
it is touching evenly around the entire
2. Valve seat insert
circumference.
3. Screw driver
NOTE:
After fitting, remove all applied compound. Installation of the valve seat insert
• Be careful when placing the dolly block (1)
(smaller outer diameter than the valve seat
insert) over the valve seat insert (2).
• Use the press (3) to gradually apply pressure to
the dolly block and push in the valve seat insert.
NOTE:
Do not apply excessive pressure with the press.
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.
LNW21BSH031801
Replacement of the valve seat insert

Removal of the valve seat insert
• Arc weld the entire inner circumference (1) of
the valve seat insert (2).
• Cool the valve seat insert for 2 to 3 minutes.
Cooling makes it easier to remove the valve
seat insert due to contraction.

• Inspect for cracks between the valve seat
and exhaust port of the cylinder head.
Replace the cylinder head if there is
damage or cracks. Perform a color check as
3 necessary.
LNW21BSH018601
Legend
1. Dolly block
2. Valve seat insert
3. Press
LNW21BSH032401
c. Flatness of the cylinder head bottom surface

4. Inspect the cylinder head ASM. • As shown in the diagram, measure the 4
• Completely remove the varnish-like matter and sides and diagonal line with a simple
soot on the metal surfaces. Use a metal brush straight ruler and thickness gauge. Replace
for the gasket installation surfaces. Be careful if the limit is exceeded.
not to scratch the seal surface.
• If the cylinder head seal surface is leaking, Deformation on the bottom surface of
corroded or blown out, and the gasket is the cylinder head mm (in)
defective, check the following possible causes.
- Incorrect installation Standard values 0.05 (0.0020) or less
- Improper cylinder head tightening Limit 0.20 (0.0079)
- 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 5. Inspect the bridge.
straight ruler and thickness gauge. Replace
• There should be no strain in the bridge (1) and
if the limit is exceeded.
bridge guide (2).
• Measure the clearance between the bridge (1)
Strain on the installation surface of the and bridge guide (2).
manifold and cover mm (in)
Standard values 0.05 (0.0020) or less Clearance mm (in)
Limit 0.20 (0.0079) 0.020 - 0.056
Assembly Standard
(0.00079 - 0.0022)
Limit for use 0.1 (0.0039)
LNW21BSH032601
e. Flatness of the exhaust manifold

• Measure flatness using a simple straight LNW21BSH059101
ruler and thickness gauge. Replace the
exhaust manifold if it exceeds the limit.
Reassembly
Deformation of the exhaust manifold mm (in) 1. Install the oil seal.
Standard values 0.3 (0.012) or less • Install to the injection pipe insertion surface.
• Uniformly tap the seal so that it is not slanted.
Limit 0.5 (0.020)
NOTE:
Be careful not to damage the lip section.
Special Tool
Oil seal installer: 5-8840-2627-0
LNW71BSH009001
a
LNW21BSH056401 MFW81BSH001401
Legend
1. a :37.5 mm (1.48in)
2. b :122.5 mm (4.823in)
1 2
3 3. Install the injector sleeve.
• Install the O-rings (1), (2) to the injector sleeve
and apply engine oil.
• Apply Loctite to the tapered section (3) of the
injector sleeve.
Loctite No. LT290
• Apply engine oil (4) to the injector sleeve
contact surface of the cylinder head.
NOTE:
Check the combination of the O-rings.
Upper O-ring: With white paint
MFW81BSH006201 Lower O-ring: Without paint
Legend
1. Cylinder head
2. Oil seal
3. 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 (1.48 in) from the top
surface of the head.)
Special Tool
Bridge guide setting tool: 5-8840-2626-0
2
1
2
6
5 3
MFW61BMH000101 LNW21BMH001001
Legend Legend
1. O-ring (white paint) 1. Punch bar
2. O-ring 2. Ball
3. Loctite application area 3. Guide sleeve
4. Engine oil application area 4. Injector sleeve
5. Injector clamp
• Install the injector sleeve (4) to the cylinder 6. Injector clamp bolt
head, and insert the guide sleeve (3) included
in the injector setting tool (5-8840-2624-0).
• Insert with the guide sleeve (3) so that the 4. Install the valve guide.
injector sleeve securely attach to the bottom • Hammer in the valve guide from the upper
surface of the cylinder head. surface of the cylinder head, using the valve
• Fasten the guide sleeve (3) with the injector guide replacer and valve guide installer.
clamp (5) and injector clamp bolt (6).
• Insert a ball (2) (bearing steel ball 9.525 mm Special Tool
(0.3750in)) into the guide sleeve (3) and attach
Valve guide replacer: 5-8840-2628-0
a punch bar (1), then hammer the ball (2)
through. Valve guide installer: 5-8840-2930-0
NOTE:
• Allow the cylinder head to float so that the ball
comes out from the bottom surface.
Special Tool
Injector sleeve setting tool: 5-8840-2624-0

NOTE:
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
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 mm - 17.9 mm
(0.673 in - 0.705 in).
NOTE: LNW21BSH031901
When replacing the valve guide, replace as a set with
the valve.
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.
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
LNW21BSH018801
valve stem seal setting tool.
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 Blue
Exhaust Red
1 LNW21BSH031401
11. Install the thermostat.

• Install the thermostat (1) to the position shown
2 in the diagram.
LNW21BSH016701
Legend
1. Spring pitch
2. Paint mark
1
9. Install the spring upper seat.
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
1
stem with a rubber hammer to stabilize the split
collar.
Special Tool
LNW21BSH021901
Pivot: 5-8840-2808-0 Legend
1. Thermostat
NOTE:
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.
1 2 3
LNW21BSH022001 MFW71BSH004501
Legend
13. Install the EGR cooler bracket and tighten the bolt 1. Bracket mounting bolt
at the specified torque. 2. A/C compressor bracket
Tightening torque N⋅m (kg⋅m/ lb⋅ft) 15. Install the inlet cover.
M12 104 N⋅m (10.6 kg⋅m/77 lb⋅ft) • Apply liquid gasket (TB1207C) to about dia.2.5
– dia.5.5 mm (dia.0.098 – dia.0.22 in) width
M8 26 N⋅m (2.7 kg⋅m/20 lb⋅ft) along the inlet cover groove (1). Assemble it
within 5 minutes after applying the liquid
gasket.
14. Install the A/C compressor bracket.
Install the A/C compressor bracket and tighten the NOTE:
bolt at the specified torque. Be careful not to forget tightening the bolt indicated by
the arrow.

1
MFW81BSH008201
• Tighten in the order of the numbers in the

diagram.

• Tighten the stud bolts (6) and (9) together with 17. Install the intake pipe (Euro2 specification and
the common rail. Euro3 specification).
• Install the gasket (2) and intake pipe, and
Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb⋅ft) tighten at the specified torque.
5
10 4 1 11
2
3
8 3 2 7
6 9 5
1
4
MFW71BSH004801
MFW81BSH007801
16. Install the throttle valve ASM and gasket, and Legend
tighten at the specified torque (Euro4 specification 1. Inlet cover
only). 2. Gasket
Refer to "Intake Throttle Valve" in this section. 3. Bolt
4. Nut
Tightening torque: 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft) 5. Intake pipe
18. Install the exhaust gasket.

19. Install the exhaust manifold.
3
2
1
4
8 5
7 6
MFW71BSH004901
Legend
1. Nut
2. Throttle rubber mounting
3. Intake throttle ASM
4. Inlet cover
5. Gasket
6. Throttle rubber mounting
7. Bolt
8. Bolt

• Install the distance tube (1), disc spring (2) and Euro4 specification only
nut (3) in that order to the stud on the cylinder
head.
5 3 4 6
1 2 1 2
3
7 8
LNW71BSH008901
MFW81BSH000601
20. Install the turbocharger (1) and exhaust adaptor
Legend (3) (Euro2 specification and Euro3 specification).
1. Distance tube • Install the turbocharger assembly (1) to the
2. Disc spring exhaust manifold (5) through the gasket (4),
3. Nut and tighten the nut at the specified torque.

• Tighten the exhaust manifold at the specified
torque in the order of numbers in diagram. • Install the turbocharger (1) to the exhaust
adaptor (3) through the gasket (2), and tighten
Nuts (7), (8) and bolts (1), (2), (3), (4), (5), (6)
Tightening torque: 34 N⋅m (3.5 kg⋅m/25 lb⋅ft) Tightening torque: 33 N⋅m (3.4 kg⋅m/25 lb⋅ft)
NOTE:
Since it will expand or contract due to the heat of the
manifold, do not over-tighten.
3
2
1
5
5 3 4 6
1 2 4
7 8
MFW81BSH008501
21. Install the turbocharger (1) and exhaust adaptor

(3) (Euro4 specification only).
MFW81BSH011001

• Install the turbocharger assembly (1) to the • The measuring positions of the piston head and
exhaust manifold (5) through the gasket (6), reference points on the cylinder block side are
and tighten the nut at the specified torque. shown in the diagram below.

• Install the turbocharger (1) to the exhaust
adaptor (3) through the gasket (2), and tighten
• Tighten the mounting bolt (4) at the exhaust
manifold side of the adaptor (3).
2
3
4 LNW21BSH068001
Measurement
Piston head :Points (2) and (3)
points
Reference
6 Cylinder block top surface :Point (1)
Points
NOTE:
5 In the table below, there are 3 selections for the piston
protrusion amount on the head gasket, so be careful.
• Calculate the average value (Ti) for the

MFW71BSH004001 protrusion amount of piston for each cylinder.
• Find the maximum value (Timax) of the
average value (Ti) for each cylinder.
Installation
1. Install the cylinder head gasket.
• 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 Timax.
a
c
3
b
d
1
LNW21BSH002401
Legend
MFW81BSH001501
1. Grade identification hole
Legend
1. Cylinder block top surface • Apply liquid gasket.
2. Piston head • As shown in the diagram, apply liquid gasket
3. Piston head (TB-1207C) to about 3 mm (0.12 in) width to the
4. a :50 deg aligning surface (mating surface) (1) of the
5. b :20 deg cylinder block and flywheel housing.
6. c :70mm (2.76in)
• After applying the liquid gasket, install the
7. d :100mm (3.94in)
cylinder head within 5 minutes.
Protrusion amount of 1
Gasket
Identification the piston (Timax)
Grade
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.
Head tightening torque N⋅m (kg⋅m/lb⋅ft)

1st time 98 (10.0/72)
M14
2nd time 147 (15.0/108)
(1 - 18)
3rd time 30° - 60°
M10
38 (3.9/28)
(19,20)
Use a stud bolt for (16).
Special Tool
Angle gauge: 5-8840-0266-0
LNW21BSH015601
2. Install the cylinder head ASM.

• Gently install the cylinder head while aligning 14 6 3 11
18 10 2 7 15
with the cylinder block dowel. 19
NOTE:
20
When installing, be careful not to damage the head
gasket. 17 9 1 8 16
13 5 4 12
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.
NOTE:
MFWB1BSH009301 hole.
• 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.

• Apply engine oil on the idle gear C shaft and
the inner diameter of the idle gear.
Apply molybdenum disulfide grease to the
1 thread and seating surface of the bolt.
Install the idle gear C so that the side with gear
groove is on the side of the rear surface of the
engine.
2 • Tighten the idle gear C with the designated
torque.
• Do not use impact wrench and like.
1 2
MFW81BSH002301
Legend
1. Bridge cap
2. Bridge
5. Insert the gasket into the injector (2) and install to 4

3
the cylinder head.
6. Apply engine oil to the threaded portion and seat
surface of the injector clamp bolt (3), and
temporarily tighten.
LNW61BSH003901
Legend
2 3
1. Idle gear C
4 2. Idle gear C shaft
3. Washer
1 4. Bolt
8. Install the idle gear C (Euro4 specification only).

a. Assembly of the idle gear C.
5
NOTE:
6 When disassembling the idle gear C, assemble it while
paying attention to the following points because it is
difficult to position the idle gear C shaft.
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 (Euro2 specification and


1. Position the marked line on the crank pulley 4. Apply engine oil to the
(2) and the alignment mark on the front both surfaces of the thrust collar, and
cover (1) and set to compression top dead molybdenum disulfide to the threaded
center of the 1st cylinder. portion of the bolt and seat surface.
Assemble the bolt which is installed to the
thrust collar.
However, the bolt should be tightened at a
torque of 40 N⋅m (4.1 kg⋅m/30 lb⋅ft), and
loosen by 30° – 90° after tightening.
1 (Confirm that the idle gear C moves.)
1
2 3
MFW71BSH004401 4
5
2. With the idle gear B assembled, insert the
idle gear C from above the cylinder head. 6
• Apply engine oil to the inner
circumference of the idle gear C bush
and the thrust bearing surface.
3. Apply engine oil to the outer circumference
of the shaft and pass from the cylinder head
rear surface hole to the gear center hole.
BLW71BMH000501
Legend
1. Insertion Direction
2. Shaft
3. Thrust Collar
4. Bolt
5. Idle Gear C
6. Bush
b. Installation of the camshaft ASM.

1. Set the cam bearing lower to the cylinder
head. Apply engine oil to the bearing inner
circumference.

2. Assemble the camshaft with the gear
installed to mesh with the idle gear C
installed to the cylinder head.
At this time, when the marked line on the 1
crank pulley and alignment mark on the front
cover are positioned compression top dead
center of the first cylinder, install so that the
alignment mark B on the camshaft gear
matches the top surface of the cylinder
head.
LNW81BSH005601
c. Tightening the idle gear C.

1. Manually rotate the camshaft gear in the left
direction (when looking from the engine
rear) (2), gently mesh the idle gear C to the
direction of the arrow (1) in the diagram, and
set the idle gear C shaft position.
NOTE:
Be careful as backlash can excessively build up if too
LNW71BSH010601
much force is applied when rotating the camshaft gear.
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).
2
Apply engine oil to the threaded portion and seat 1

surface 1
Tightening torque N⋅m (kg⋅m / lb⋅ft)
Cap bolts 27 (2.8 / 20)
Cap nuts 27 (2.8 / 20) 2
NOTE:
Do not assemble the rocker arm. 3
BLW71BSH009801
Legend
(1) Lightly engage the idle gear C.
(2) Rotate the camshaft gear counterclockwise.
1. Camshaft gear
2. Idle gear C
3. Idle gear B

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

and seat surface
Idle gear C bolt 71 (7.2 / 52) a
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.
MFW81BSH000901
10. Installation of the camshaft ASM (Euro2

Between the idle gear C and camshaft gear mm (in) specification and Euro3 specification).
0.015 - 0.146 (0.00059 - 0.00575) Refer to "Camshaft ASM" in this section.
a. Set the cam bearing lower to the cylinder head.
If the camshaft gear does not move with Apply engine oil to the bearing inner
rattling when manually moving it, there is the circumference.
possibility that that the backlash has b. Assemble the camshaft with the gear installed
excessively built up. Check the backlash to mesh with the idle gear C installed to the
and readjust. cylinder head.
At this time, when the marked line on the crank
NOTE:
pulley and alignment mark on the front cover
If the backlash cannot be adjusted, assemble with the
are positioned compression top dead center of
service idle gear C shaft (8-97186-398-1).
the first cylinder, install so that the alignment
4. Remove the cam cap and camshaft. mark B on the camshaft gear matches the top
surface of the cylinder head.
5. Use a flat-blade screwdriver (large size),
etc., to check the backlash of the idle gear C
while holding down the idle gear B.
Between the idle gear C and idle gear B mm (in)

0.015 - 0.217 (0.00059 - 0.00854)
6. Repeat Step b. 1 to 4.
7. Remove the camshaft cap end once, and
assemble with the rocker arm assembly.
9. Install the idle gear C cover.

• Apply liquid gasket (Loctite 262) to the outer
circumference of the idle gear C cover, and
then use the sealing cup setting tool to tap in to
the dimensions (a :1.5 - 2.5mm (0.059 -
LNW71BSH010601
0.098in)) shown in the diagram.
c. Set the cam bearing upper to the camshaft cap,
Special Tool and apply engine oil to the bearing inner
circumference.
Sealing cup installer: 5-8840-2222-0

d. Assemble the #2, #3, #4 and #5 caps (1).
1
Apply engine oil to the threaded portion and seat
surface
Cap bolts 27 (2.8 / 20)
Cap nuts 27 (2.8 / 20)
2
NOTE:
Do not assemble the rocker arm.
1
MFW81DSH000801
14. Tighten the injector clamp (1) (temporarily

tightened earlier) at the specified torque.
15. Tighten the injection pipe (2) at the specified
torque.
Tightening torque N⋅m ( kg⋅m/ lb⋅ft )

LNW81BSH005601 Injector side 30 (3.1/22)
11. Install the rocker arm shaft ASM. common rail side 25 (2.5/18)

1
• Install the common rail pressure sensor
connector.
13. Install the injection pipe (1).
• Thinly apply engine oil to the outer
circumference of the injector side sleeve
nut and install it.
• 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

MFW81DSH000901
Legend
2. Injection sleeve nut
16. Install the glow plug. (or dummy glow plug)

Tightening torque: 20 N⋅m (2.0 kg⋅m/14 lb⋅ft))

NOTE:
Do not over-tighten. There is the possibility of damage
by tightening beyond the standard.
2
17. Install the glow plug connector and tighten at the
specified torque. (with glow plug)
1
Tightening torque: 1.0 N⋅m (0.10 kg⋅m/9 lb⋅in)
18. Install the camshaft position sensor and tighten at

• After the installation of the camshaft
position sensor, the connector is
connected.
Refer to "Camshaft Position Sensor" in this
section.
Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in) MFW71BSH003701
Legend
1. Water bypass hose
20. Install the leak-off pipe (2).
1 2
MFW71BSH004101
19. Install the water bypass hose (1).

• Install the engine coolant temperature
sensor (2) connector to the thermostat housing.
MFW71BSH003601
21. Install the leak-off hose.

• Install the leak-off hose to the leak-off pipe and
fasten with the clips.
22. Fit the new gasket onto the nozzle leak-off pipe,
and install leak-off pipe.

MFW81BSH001701 LNW71DSH003601
Legend
23. Install the injector harness connector from the 1. Injector
inside, and tighten the harness bracket at the 2. Harness
specified torque. 3. Terminal nut
Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) 25. Install the cylinder head cover.
26. Attach the radiator upper hose.
27. Install the A/C compressor.
• Install the A/C compressor to the A/C
compressor bracket, and tighten at the
specified torque.
• Install the A/C compressor harness connector.
LNW21DSH007201
24. Install the terminal nuts (3) to the injector (1).

NOTE:
• Alternately tighten the terminal nuts so that not only
1 side is tightened because this is an integrated 1 2 3
part. MFW71BSH004501
• As the terminal stud can be damaged if the nut is Legend

over-tightened, never over-tighten the nut. 1. Bracket mounting bolt

2 3
1
4
7 6 5
MFW51ESH000301
MFW71BSH003401
Legend
28. Install the A/C compressor drive belt and adjust the
1. Turbocharger feed oil pipe
belt tension.
2. Turbocharger
• Refer to "Drive Belt" in Section 1C Engine 3. Water pipe (return)
Cooling. 4. Exhaust manifold
5. Exhaust manifold adaptor ASM
29. Install the water pipe (3,7) and oil pipe (1,6) to the 6. Turbocharger return oil pipe
turbocharger (2). 7. Water pipe (feed)
Induction. 30. Install the oil catch tank (1) with the bracket (7)
Euro2 specification and Euro3 specification assembled to the EGR cooler bracket (Euro2
2 3
1 1
7 3
4
56
4
6 5
7
MFW81BSH011101
Legend MFW81BSH007701
1. Turbocharger feed oil pipe Legend
2. Turbocharger 1. Oil catch tank
3. Water pipe (return) 2. PCV hose
4. Exhaust manifold 3. PCV hose
5. Exhaust manifold adaptor ASM 4. Bracket
6. Turbocharger return oil pipe 5. Adapter
7. Water pipe (feed) 6. Oil drain hose
7. Bracket

31. Install the oil separator (1) together with the • Install the EGR cooler following the procedures.
bracket (3) (Euro3 specification and Euro4 Refer to "EGR Valve and EGR Cooler" in
specification). Section 1F Emission Control.
Tightening torque
4
Bracket 104 N⋅m (10.6 kg⋅m/77 lb⋅ft) 3
Oil separator 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) 5
• Install the rubber hoses (2), (4) and oil drain

2
hose (5) and fix them with the clips.
1
1
3
MFW81BSH011301
Legend
1. Water rubber hose (feed)
2. EGR cooler pipe
3. EGR cooler
4. Water rubber hose (return)
5. EGR valve
5 4
MFW71BSH003501 33. Install the EGR cooler (3), EGR duct (1), EGR
Legend valve (5) and the water rubber hose (2,4) (Euro4
1. Oil separator specification only).
3. Oil separator bracket
5. Oil drain hose
32. Install the EGR cooler (3), EGR cooler pipe (2),
EGR valve (5) and the water rubber hose (1,4)
(Euro3 specification only).

• Install the EGR cooler following the procedures.
Refer to "EGR Valve and EGR Cooler" in
1 2
4
3 5
MFW71JSH001201
Legend
1. Charge air pipe
MFW71FSH000201
2. Air intake duct
Legend
1. EGR cooler duct 38. Install the front exhaust pipe tighten it at the
2. Water rubber hose (feed) specified torque.
3. EGR cooler
4. Water rubber hose (return) Tightening torque
5. EGR valve Exhaust manifold: 67 N⋅m (6.8 kg⋅m/49 lb⋅ft)
34. Install the oil level gauge and guide tube.

39. Install the engine harness.
35. Install the radiator upper hose.
36. Install the charge air pipe on the left and right of
the engine to the intercooler.
37. Install the air duct to the turbocharger.

• Tighten the turbocharger inlet air duct
tightening clip (5) at its specified torque. Use a
new clip.

a
e
g
f
MFW71BMF000901
(a) 59 N⋅m (6.0 kg⋅m/43 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/52 lb⋅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 (1).
2. Remove the crankshaft position sensor (2).
• This is sensitive to shocks so do not throw or
drop.
MFW81ESH000501
Installation
1. Install the crankshaft position sensor (2) and
tighten at the specified torque.
2. Connect the crankshaft position sensor harness
connector (1).
MFW81ESH000501
Flywheel
Components
MFW71BMF001001
Legend
1. Flywheel housing 4. Pilot bearing
2. Flywheel ASM 5. Crankshaft position (CKP) sensor
3. Washer
Removal
1. Remove the starter.
• Disconnect the starter ground cable.

• Disconnect the front frame harness connector • Refer to "Crankshaft Position Sensor" in this
near the transmission control box and remove section.
MFW71BSH004201
LNW21BSH011501
3. Remove the transmission ASM.

clutch housing.
• Fasten with a wire etc. to a position where it will Refer to "Transmission ASM" in Section 5C
not interfere with the removal of the Manual Transmission (MLD).
transmission. Refer to "Transmission ASM" in Section 5C
4. Remove the clutch pressure plate.
• Insert the clutch aligner in the spline of the
clutch disk.
• Remove the pressure plate mounting bolts in a
diagonal line order.
• Remove the pressure plate from the flywheel.
5. Remove the clutch disk.

• Remove the clutch disk from the flywheel along
with the clutch aligner (1).
• Install the crankshaft stopper to the flywheel
LNW21BSH011601
housing starter, and make sure the crankshaft
does not rotate.
2. Remove the crankshaft position sensor (2) form
the flywheel housing (1). NOTE:
Check that the stopper securely bites into the ring gear
• When removing the flywheel, remove to
and that it is installed.
prevent interference or damage.
• This is sensitive to shocks so do not throw or Special Tool
drop. Crankshaft stopper: 5-8840-2230-0
NOTE:
Remove it before the flywheel, so as not to damage the
sensor.

• Remove the pilot bearing from the flywheel.
LNW21BSH007701
MFWB1BSH009101
6. Remove the washer. 9. Remove the ring gear.

7. Remove the flywheel. • Attach a rod to the ring gear and remove it by
• Gradually loosen the flywheel mounting bolts in tapping with a hammer.
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.
• For Smoother vehicles, after loosening the
flexible plate bolts, remove the washers and
flexible plate in that order.
1 4
6 7
LNW21BSH012001
3 2
8 5
Inspection
1. Visual inspection
• Inspect the flywheel friction surface for cracks,
wear, and damage. Repair or replace if there
MFW81BSH000501 are abnormalities.
• Inspect the ring gear tooth surfaces. Replace
the ring gear if it shows damage or is
8. Remove the pilot bearing.
significantly worn.
•
Flywheel friction surface depth (1) mm (in)
Standard values 42.75 (1.683)

Depth :From pressure plate installation surface 3. Install the washer.
to friction surface M/T Specifications
• Align to the crankshaft knock pin, install the
flywheel, and tighten in the order shown in the
diagram.
• Apply molybdenum disulfide to the bolt
threaded portion and seat surface.
• Install the crankshaft stopper to the flywheel
1 housing starter installation section.
Special Tool
Flywheel tightening torque:

1st time :78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
2nd time : angle method 60° → 60° - 90°
MFWB1BSH002501
Installation
1. Install the ring gear.
• Tap the ring gear onto the flywheel after 4
1
uniformly heating using a gas burner.
Heating temperature should be less than 200°C 6 7
(392°F).
• When shrink-fitting the ring gear and cooling, 3 2
apply a load of 68.6 kN (6,995 kg/1,5435 lb)
and hold evenly.
8 5
NOTE:
• Install it with the chamfered side of the ring gear
facing the front.
• After shrink-fitting, check that the ring gear is airtight MFW81BSH000501
against the flywheel.
LNW21BSH007701
LNW21BSH012101
2. Install the flywheel.


Smoother specifications • Refer to "Transmission ASM" in Section 5B
• Align to the crankshaft knock pin to install the Automatic Transmission (Smoother (MZX)).
flywheel, flexible plate and washer. Refer to "Transmission ASM" in Section 5B
NOTE: Refer to "Transmission ASM" in Section 5C
When installing the flexible plate, align the flywheel Manual Transmission (MLD).
knock pin hole with the flexible plate positioning hole Refer to "Transmission ASM" in Section 5C
(dia.9 mm (0.35 in)). Manual Transmission (MZX).
• Tightening is the same as M/T specifications. Manual Transmission (MZW).
4
3
2 8. Install the crankshaft position sensor (2) to the
flywheel housing (1).
1
section.
2
MFWB1BSH003701
Legend
1. Flywheel
2. Flexible plate
3. Washer
4. Bolt
4. Tap in the pilot bearing until it touches the

crankshaft end surface. MFW71BSH004201
5. Install the clutch disk.
9. Install the starter to the clutch housing with a bolt,
• Install the clutch disk to the flywheel using the and tighten at the specified torque.
clutch aligner.
6. Install the clutch pressure plate.
• Align the pressure plate installation hole to the
knock pin in the flywheel and install the
pressure plate to the flywheel.
• Tighten the pressure plate in a diagonal line
order.


• Install the starter ground cable.
• Connect the front frame harness connector.
LNW21ESH001001
LNW21ESH001101
a MT, Smoother
MFW71BMF001101
(a) 78 N⋅m (8.0 kg⋅m/58 lb⋅ft) → 60° → 60° - 90°

(b) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Front Cover
Components
1 2
10 4
12 11
5
13 6
7
8
MFW71BLF001801
Legend
1. Adjust plate 8. Front oil seal
2. Generator 9. Crankshaft pulley
3. Front cover 10. Water pump ASM
4. Oil pan gasket 11. Fan belt
5. Oil pan 12. Water pump pulley
6. Rubber ASM 13. Fan ASM
7. Front slinger
Removal 3. Remove the water pump.

Refer to "Water Pump" in Section 1C Engine
1. Remove the front oil seal.
Cooling.
Refer to "Crankshaft Front Oil Seal" in this section.
4. Remove the front cover.
Refer to "Oil Pan" in Section 1H Engine
Lubrication.

• Remove the generator adjust plate. • Remove the oil cooler bypass valve from the
cylinder block.
MFW71BSH006601
LNW81BSH004801
• Remove the oil relief valve (arrow) and loosen

the front cover installation bolt to remove the Installation
front cover. 1. Install the oil cooler bypass valve.
• Insert the oil cooler bypass valve to the position
of the arrow on the cylinder block. At this time,
be careful not to mistake the insertion direction.
MFW71BSH006701
5. Remove the oil cooler bypass valve.

LNW81BSH004701

2. Install the front cover.
• Clean the cylinder block front side. Especially, 1 2
clean the liquid gasket that oozes out when the

(1)
crankcase is installed.
• Install the O-rings (2 pcs.) and apply liquid a
4
gasket (TB-1207B) to the groove in the front (2)
cover installation surface. 5
3
b
2
(3)
Bead width 1.5 - 5 mm (0.059 - 0.20in)
2
From aligning surface: c
Bead height
0.3 - 1.5 mm (0.012 - 0.060 in) (4)
d
minutes.
1
NOTE:
Apply the liquid gasket without applying it on the O-ring MFW81BSH001601
(1). Legend
1. a :35 mm (1.38 in)
2. b :25 mm (0.98 in)
3. c :65 mm (2.56 in)
4. d :30 mm (1.18 in)
3. Install the water pump.

1 Cooling.
1 Refer to the "Oil Pan" in Section 1H Engine
Lubrication.
5. Install the front oil seal.
Refer to "Crankshaft Front Oil Seal" in this
section.
LNW21BSH058701
Legend
1. O-ring
• Align to the cylinder block knock pin to install

the front cover.
NOTE:
At the same time as the front cover, install the water
pump ASM (before the liquid gasket dries).
• The (*) bolt should be tightened together with
the generator adjust plate.
• Tighten the oil relief valve (5) at the specified
torque.

MFW81BLF003701
(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)
Crankshaft Front Oil Seal

Components
3
2
1
MFW81BSF000101
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.
1. Discharge the coolant.
• 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.
clutch housing. 6. Remove the radiator lower hose at the engine side.
7. Remove the brackets on the left and right sides of
the radiator (with fan guide) to remove the radiator.

8. Remove the fan ASM. • Be careful not to damage the front cover oil seal
• Remove the 4 installation nuts to remove the (3) installation section and shaft. Use a
fan ASM. screwdriver 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
and that it is installed. Special Tool
Special Tool Slinger puller: 5-8840-2360-0
LNW71BSH007601
LNW21BSH012301
11. Remove the crankshaft front oil seal (3).


Installation • Insert the front slinger (3) to the leading end of
the adaptor (1) and install the adaptor (1) to the
1. Install the front slinger.
crankshaft.
• Firmly fit the slinger (1) using the oil seal
• Cover the sleeve (2) over the adaptor (1), and
installer kit.
install the washer to the center blot. Tighten
and then firmly fit in all the way to the end until
the sleeve (2) touches the adaptor (1).
4
1
2 5
3 6
LNW21BSH073201
Legend
1. Front slinger LNW21BSH013301
2. Adaptor (front)
• After firmly fitting in the front slinger (3),
3. Fixing bolt
measure the dimension from the crankshaft
4. Sleeve (front)
end to the oil seal lip touching surface. Also
5. Washer (front)
check for fluctuations in the front slinger (4
6. Center bolt
directions).
Special Tool
Oil seal installer kit: 5-8840-2703-0 Front Slinger press-fitting
measurement mm (in)
(Use the parts in the table below for the front oil seal.)
Assembly Standard 40.2 - 40.8 (1.58 -1.61)
No Parts Oil NOTE:

Part Name Slinger
. number seal Be careful not to mistake the front slinger assembly
5-8840- direction and the front and rear. There is a right, 4-
1 Sleeve (Front) { { thread screw cut at the rear side, and a left, 4-thread
2704-0
screw cut at the front side. Always replace the slinger
5-8840- (3) and oil seal as a set.
2 Adaptor (Front) { {
2705-0
5-8840- Adaptor ring
3 - {
2706-0 (front)
5-8840- Washer (Front)
4 { {
2707-0
5-8840-
5 Center bolt { {
2713-0
5-8840-
6 Fixing Bolt { {
2714-0
NOTE:
An engine sleeve (5-8840-2712-0) for engines before
‘93.5 models is included in oil seal installer kit, but it will
not be used with this engine.

• Install the adaptor (1) to the crankshaft with the
fixing bolt.
a 1
MFW81BSH001001
Legend
LNW21BSH013101
1. Adaptor
2. Sleeve Legend
3. Slinger 1. Adaptor (front)
4. a :40.2 - 40.8mm (1.58 - 1.61in)
• Thinly apply engine oil to the oil seal (1) lip
section, and set to the front adaptor.
2. Install the front oil seal.
• 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).
• Tighten until the sleeve (3) touches the adaptor
5 and firmly fit the front oil seal (1).
2 4
1 2 3 4
7
1 3 6
LNW21BSH073301
Legend
1. Oil seal
2. Adaptor (front)
3. Adaptor ring (front)
4. Fixing bolt LNW21BSH013201
5. Sleeve (front)
6. Washer (front) Legend
7. Center bolt 1. Oil seal
2. Adaptor ring
3. Sleeve
4. Washer

• Align to the crankshaft knock pin, and install the
crank pulley.
• Tighten in the order shown in the diagram.
3 4
LNW21BSH013301
2
• After firmly fitting the front oil seal (4), measure
the dimension from the crankshaft end surface
to the oil seal surface. Also check for
fluctuations in the oil seal (4 directions).
LNW71BSH007701
Front oil seal press-fitting

measurement mm (in) 4. Install and adjust the fan belt.
Refer to "Drive Belt" in Section 1C Engine Cooling.
Assembly Standard 30.7 - 31.3 (1.21- 1.23)
5. Install the fan ASM and tighten it at its specified
torque.
4 1
2
a
3
MFW81BSH001101
Legend
1. Adaptor ring LNW71CSH002001
2. Sleeve
3. Adaptor
4. Front oil seal 6. Install the radiator.
5. a :30.7- 31.3 mm (1.21- 1.23 in) • Install the left and right bracket sections of the
radiator to the frame side bracket as shown in
the diagram.
3. Install the crankshaft pulley.
Tightening torque:
• Apply engine oil to the threaded portion of the
tightening bolt. Upper side nut 41.4 N⋅m (4.2 kg⋅m/31 lb⋅ft)

2 Tightening torque: 5 N⋅m (0.5 kg⋅m/43 lb⋅in)

10. Install the air charge pipe to the intercooler.
11. Install the starter to the housing with a mounting
1 bolt, and tighten it at the specified torque.
7
3 • Install the starter ground cable.
6 • Connect the front frame harness connector.
5
4
MFWA1CSH001501
Legend
1. Nut
2. Stud bolt
3. Rubber
4. Nut
5. Frame
6. Radiator side bracket
7. Washer
LNW21BSH011601
7. Install the radiator lower hose.
8. Attach the coolant reserve tank hose.
MFW81BSF000201
(a) 200 N⋅m (20.4 kg⋅m/148 lb⋅ft)

Crankshaft Rear Oil Seal

Components
5
4
3
2
1
2
7
MFW81BLF003801
Legend
1. Starter 5. Crankshaft rear slinger
2. Transmission ASM 6. Flywheel
3. Flywheel 7. Flexible plate
4. Crankshaft rear oil seal

Removal
1. Remove the transmission ASM.
3. Remove the pressure plate and clutch disk.
4. Remove the crankshaft position sensor from the MFW81BSH000701
flywheel housing.
Refer to "Flywheel" in this section. Installation
6. Remove the rear oil seal. 1. Install the rear slinger.
• 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)
7. 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
Slinger puller: 5-8840-2360-0

• Cover the slinger over the adaptor and tighten
the center bolt all the way to the end until the
Parts Oil
No. Part Name Slinger sleeve touches the adaptor and firmly fit the
number seal
slinger.
5-8840-
1 Sleeve (Rear) { {
2708-0
5-8840-
2 Adaptor (Rear) { {
2709-0
5-8840-
3 Collar (Rear) { {
2710-0
5-8840- Adaptor Ring
4 - {
2711-0 (Rear)
5-8840-
5 Center bolt { {
2713-0
5-8840-
6 Fixing Bolt { {
2714-0
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. LNW21BSH014701
• Insert the slinger to the leading end of the rear

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

1
mm (in)
17.0 - 17.6
Assembly Standard
(0.669 - 0.693)
2
NOTE:
Be careful not to mistake the slinger assembly direction
and the front and rear. There is a right, 4-thread screw
3 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.
LNW21BSH014501
Legend
1. Collar
2. Fixing bolt
3. Adaptor
• Install the collar (1) to the fixing bolt (2), and

install the adaptor (3) to the crankshaft.
3 1
(4)
5
6 2
3
MFWB1BSH008401
Legend
1. Crankshaft
2. Adaptor LNW21BSH014501
3. 17.0 - 17.6 mm (0.669 - 0.693 in) Legend

4. 10.7- 10.9 mm (0.421- 0.429 in) 1. Collar
5. Slinger 2. Fixing bolt
6. Sleeve 3. Adaptor
7. Collar
2. Install the rear oil seal. • Thinly apply engine oil to the oil seal lip section,
• Firmly fit the oil seal using the oil seal installer and set the rear oil seal to the rear adaptor.
kit.
NOTE:
Always apply oil to the lip section of the oil seal.
• Put the rear adaptor ring (2) into the sleeve (1)
and set to the adaptor and install the center
bolt.
1 2 3
7 6 5 4
LNW21BSH073501
Legend
2
1. Adaptor (rear)
2. Fixing bolt
3. Center bolt
4. Sleeve (rear) LNW21BSH014601
5. Collar (rear)
Legend
6. Adaptor ring (rear)
1. Sleeve
7. Oil seal
2. Adaptor ring
• Tighten the center bolt all the way to the end

until the sleeve touches the adaptor, and firmly
fit the oil seal.
1
2
7
3
6
5
LNW21BSH014801
Legend
1. Crankshaft
2. Oil seal
LNW21BSH014701 3. 7.5 - 8.1 mm (0.30 - 0.32 in)
4. Collar
5. Adaptor ring
• After firmly fitting the oil seal, measure the 6. Sleeve
dimension from the crankshaft end surface to 7. Adaptor
the oil seal surface. Also check for fluctuations
in the oil seal (4 directions).
Refer to "Flywheel" in this section.
Oil seal press-fitting measurement (rear) 4. Install the crankshaft position sensor to the
mm (in) flywheel housing.
Assembly Standard 7.5 - 8.1 (0.30 - 0.32) 5. Install the clutch disk and pressure plate.
6. Install the starter.
Piston and Connecting Rod

Components
1 2
2
3
6
4
MFWB1BLF005001
Legend
1. Piston ring 5. Connecting rod cap
2. Snap ring 6. Connecting rod
3. Piston 7. Piston pin
4. Bearing 8. Connecting rod bolt
Removal 3. Remove the rocker arm shaft ASM.

Refer to "Rocker Arm Shaft ASM" in this
section.
Refer to the "Oil Pan" in Section 1H Engine 4. Remove the camshaft ASM.
Lubrication. Refer to "Camshaft ASM" in this section.
2. Remove the cylinder head cover. 5. Remove the cylinder head.
Refer to "Cylinder Head Cover" in this Refer to "Cylinder Head" in this section.
section.
6. Remove the connecting rod cap.

NOTE: 8. Remove the connecting rod bearing.
Organize the removed bearings according to the
cylinders using tags, etc. NOTE:
When reusing the bearing, organize them
according to the order of the cylinders so that
other cylinder bearings do not get mistaken.
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.
• Rotate the crankshaft, move the piston of the
cylinder to be removed to the bottom dead point
position, and remove the cap.
• Rotate the crankshaft, and move the piston of
the cylinder to be removed to the top dead point
position. Use the shank of a hammer etc. to
push out the bearing from the bottom of the
connecting rod so as not to damage it.
LNW21BSH005101
• Pull out the piston and connecting rod out to the
cylinder head side.
2. Remove the snap ring.
NOTE:
When pushing out the connecting rod, be careful not to 3. Remove the piston pin (1).
damage the oil jet and cylinder liner.
NOTE:
Organize the disassembled piston pin, piston
and connecting rods according to the cylinders.
LNW21BSH005001
2
3
MFW41BSH016101 LNW21BSH009001
Piston outer diameter

4. Remove the connecting rods from the pistons.
• Use a micrometer to measure the piston pin of
5. Clean the piston.
the specified position and the outer diameter of
• Carefully clean carbon from the piston heads the piston at the perpendicular direction.
and piston ring grooves.
• Measuring position (From top surface of the
NOTE: piston) 85 mm (3.35 in).
Do not use a wire brush to clean the pistons.
Visually inspect the pistons for cracks, seizure or other Piston outer diameter mm (in)
excessive wear. If there is an abnormality, replace the
piston. 114.944 - 114.979
Standard values
(4.5254 - 4.5267)
Inspection
1. Measure the gap between the piston and the inner Clearance between the piston and the
diameter of the cylinder liner. cylinder liner mm (in)
Inner diameter of cylinder liner
0.052 - 0.106
• Use the cylinder bore gauge to measure the Standard values
(0.0020 - 0.0042)
liner inner diameter in the thrust direction and
the radial direction at the specified position.
• Measuring position (From top surface of the NOTE:
cylinder block) • The dimensions above are of the piston and the
1. 20 mm (0.79 in), 2. 110mm (4.33 in), 3. 190 liner for service replacement.
mm (7.48 in) • If the measurement reveals that the clearance
• Find the liner inner diameter according to the between the pistons and the cylinder liners exceed
average value of the 6 locations actually the standard values, replace the pistons or cylinder
measured. liners.
Inner diameter of cylinder liner: 115.031 - 115.050 mm

(4.5288 - 4.5295 in)

• Insert the piston ring into the cylinder liner.
• Push the ring into the lower end of the cylinder
liner using the piston.
LNW21BSH009101
2. Replace the piston

LNW21BSH009301
• There is only 1 type of grade of the piston and
the inner diameter of the cylinder liner. There is • Use a thickness gauge to measure the ring
no need to select the grade. gap.
However, when replacing the cylinder liner,
there are 2 types of liner outer diameters (1x,
3x), so it is necessary to select for the cylinder
blocks (1, 2, and 3).
• Refer to section "Cylinder Block" for
replacement of the cylinder liner.
NOTE:
Grades A, B, and C are marked on the top of the piston
when shipped from the factory.
LNW61BSH000901
• Replace the piston ring if the measured value

exceeds the limit.
Piston ring gap mm (in)

Piston ring Standard values Limit
NO.1 Compression 0.27 - 0.46 1.20
1 ring (0.0106 - 0.0181) (0.047)
NO.2 Compression 0.37 - 0.61 1.20
LNW46ASH004501
ring (0.0146 - 0.0240) (0.047)
Legend
0.27 - 0.56 1.20
1. Front mark Oil ring
(0.0106 - 0.0220) (0.047)
3. Inspect the piston ring.
Measurement of the piston ring gap (remove the Measure the clearance between the piston ring
carbon from the ring gap) groove and the piston ring.

• 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

groove mm (in)
Piston ring: Standard values Limit
NO.1 Compression
— —
ring LNW21BSH009601
NO.2 Compression 0.015 - 0.055 0.15 • Check that the piston pin will pass through with
ring (0.0006 - 0.0022) (0.0059) a light pressure when the piston is at room
temperature.
0.03 - 0.07 0.15
Oil ring • Replace the piston or the piston pin if they are
(0.0012 - 0.0028) (0.0059)
loose or rattle at room temperature.
LNW21BSH009701
LNW21BSH009501
• Measure the inner diameter of the connecting
rod small end bush. If the clearance between
the bush inner diameter and pin outer diameter,
4. Inspect the piston pin. replace the bush or the connecting rod ASM,
• Visually inspect the piston pin for cracks, and pin.
scratches or other damages, and replace it as
necessary.
Clearance of connecting rod small end and
• Use a micrometer to measure the outer piston pin outer diameter mm (in)
diameter of the piston pin. Replace the piston
pin if the measured value exceeds the limit. 0.012 - 0.027
Standard values
(0.00047 - 0.00106)
Piston pin outer diameter mm (in) Limit 0.05 (0.0020)
39.995 - 40.000
Standard values
(1.5746 - 1.5748)
Limit 39.970 (1.5736)
LNW21BSH009801 LNW21BSH010401
5. Measure the clearance between the piston and the 7. Measure the bearing oil clearance.
piston pin. • Use the following method to measure the oil
• Apply engine oil to the piston pin. Then, clearance between the connecting rod bearing
manually push it into the piston hole and rotate and crank pin.
it. If the pin rotates smoothly without any - Remove the connecting rod caps. Set the
looseness, the clearance is normal. If there is removed caps in the order of the cylinder
looseness, measure the clearance. Replace the number.
piston and piston pin if the clearance exceeds
- Clean the bearing and crank pin.
the limit.
- Inspect the bearing. Replace the bearings in
sets if there is damage or excessive wear.
Clearance between piston and piston pin mm (in)
• Place the plastigage on the crank pin.
0.009 - 0.022 • Install the bearing cap, and tighten the bolt at its
Standard values
(0.00035 - 0.00087) specified torque.
Limit 0.04 (0.0016) Apply molybdenum disulfide to the threaded
portion and seat surface.
6. Measure the connecting rod alignment.

• Use the connecting rod aligner to measure the Tightening torque
twisting of the large end hole and small end 1st time 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
hole, and the degree of parallelization. Make
replacements if the measured value exceeds 2nd time Rotating angle 60 deg
the limit. 3rd time Rotating angle 30 deg
NOTE:
Connecting rod alignment Do not rotate the crankshaft.
for 100 mm (3.94 in) mm (in)
Twisting 0.05 (0.0020) 0.20 (0.0079)
Degree of
0.05 (0.0020) 0.20 (0.0079)
parallelization

• Select the bearing by carefully considering the
grade of the big end diameter of the connecting
rod for installation.
1
1
2 3
LNW21BSH010501
- Remove the cap.

- Measure the widest width area of the LNW71BSH009101
plastigage to find the oil clearance. Replace
the bearings in sets if the clearance exceeds Legend
the limit. 1. Front and back side discrimination boss
2. Diameter grade mark of big end hole
3. Cylinder number
Crank pin oil clearance mm (in)
Bearing selection table
Standard values 0.037 - 0.076
(0.0015 - 0.0030) Large end Bearing
Oil clearance
hole diameter Identification
Limit 0.10 (0.0039) mm (in)
Grade color
0.037 - 0.076
- Remove the plastigage from the bearing and A Green
(0.0015 - 0.0030)
crank pin.
0.037 - 0.076
B Yellow
(0.0015 - 0.0030)
LNW21BSH010601
1
8. Select the connecting rod bearing.

LNW21BSH010801
• Select the bearing from the table when
installing a new one or replacing a bearing in Legend
use. 1. Grade identification color

Reassembly
1. Install the piston.
2. Install the connecting rod.
• Assemble so that the piston head front mark (1)
and the connecting rod cast mark (convex) (2)
face same directions.
• Install the snap ring at one side using the long-
nose pliers.
LNW71BSH007401
5. Install the piston ring using the ring pliers.

• Install the oil ring so that the coil expander joint
is 180° in the opposite direction.
• The compression ring is installed with the "2T"
or the "T1" mark facing upward, and install in
the order of No.2 and No.1 compression rings.
MFW61BSH001601
1
1
2
2 3
MFWB1BSH008501
MFW81BSH007401 Legend
1. Compression ring No.1
Legend
2. Compression ring No.2
1. Front mark
3. Oil ring
2. Convex mark
NOTE:
3. Apply an adequate amount of engine oil to the • Check that there is no gap at the position of the
piston pin. Then, push it into the piston and arrow in the diagram when the oil ring coil expander
connecting rod small end. is installed.
4. Install the snap ring using long-nose pliers. • When reusing the piston ring, make sure it is not
inserted upside down.
NOTE:
Check that the snap ring is securely installed in the ring • There is no up or down side with the oil ring.
groove. Check that the connecting rod slides smoothly.
Special Tool
Piston installer: 5-8840-9018-0
1
4
LNW21BSH011201
Installation MFW71BSH002601
1. Install the connecting rod bearing. Legend

• Install the bearing to the connecting rod, and 1. No.1 compression ring gap
apply engine oil to the bearing. 2. No.2 compression ring gap
3. Oil ring gap
2. Install the piston and connecting rod ASM.
4. Front mark
• Thoroughly apply engine oil to the piston ring,
ring groove. 3. Install the connecting rod cap.
• Apply molybdenum disulfide or engine oil to the • Install the bearing to the connecting rod cap
piston side surface. and apply engine oil.
• Shift the piston ring gap in intervals of 120°, as • Align the cap and the connecting rod number
shown in the drawing, assigning (1) for the ring markings (1, 2, 3, 4) and install the cap.
No. 1, (3) for the ring No. 2, and (2) for the oil
ring.
• Face the piston front mark towards the front,
and insert the piston into the cylinder liner using
the setting tool.
1
NOTE:
• 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. 1
1
• Be careful not to damage the inner surface of the 2 3
liner when inserting the piston.
• Set the crank pin to top dead center with each
cylinder, when inserting piston/connecting rod.
LNW71BSH009101
• When inserting piston/connecting rod if the crank
pin is set to the bottom dead center, the oil jet might Legend
hit connecting rod and it might break. 1. Front and back side discrimination boss
2. Diameter grade of large end hole
3. Cylinder number

portion of the mounting bolts and seat surface.
Tighten at the specified torques.
Tightening torque
1st time 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
2nd time 60°
3rd time 30°
Special Tool
Angle gauge: 5-8840-0266-0
NOTE:
• Set the crank pin to the bottom dead center when
tighten connrod cap. (Because it doesn’t hit the
tightening tool to the oil jet.)
• Check that the crankshaft turns smoothly.
LNW21BSH011401

5. Install the camshaft ASM.
Refer to the "Oil Pan" in Section 1H Engine
Lubrication.

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 ASM from the vehicle.
Lubrication.
Refer to "Engine ASM" in this section.
5. Remove the water pump.
2. Remove the cylinder head.
Cooling.
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.
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.
Refer to "Crankshaft Rear Oil Seal" in this section.
10. Remove the oil pump.
Refer to "Oil Pump" in Section 1H Engine
Lubrication.
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
Puller; Crankshaft gear: 8-94396-818-0
2 6 10
14 17 13 9 5
LNW21BSH023601
13. Remove the thrust bearing lower.

14. Remove the crankshaft lower bearing.
LNW21BSH023901
Inspection
1. Thrust clearance
• As shown in the diagram, set a dial indicator
and measure the crankshaft thrust clearance.
LNW21BSH023701
• Replace the thrust bearing in sets if the thrust
clearance exceeds the standard values.
15. Remove the crankshaft ASM.

Play in the crankshaft axis direction mm (in)

Standard values 0.040 - 0.205 (0.0016 - 0.0081)
NOTE:
Measure the thrust clearance prior to disassembly.
LNW21BSH024101
• As shown in the diagram, place the plastigage

on the crankshaft journal.
• Set the lower bearing to the original position of
the crankcase.
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
bearing.
• Clean the crankshaft journal and upper and
lower bearings.
• Inspect the bearings for damage and excess
wear.
If damage and excess wear is found during the

inspection, replace the bearings in sets.
LNW21BSH024201
• Set the upper bearing and crankshaft to the • Install the crankcase and tighten the bolt at the
cylinder block. Install the crankshaft to be level. specified torque.
NOTE:
Turn the crankshaft approximately 30° to stabilize the
bearing.

• Use a torque wrench and angle gauge to NOTE:
tighten the crankcase in the order shown in the After tightening the crankcase, do not turn
diagram. the crankshaft.
• Loosen the bolts and gently remove the

crankcase.
• Measure the maximum width portion of
the plastic gauge crushed by tightening
the crankcase to determine clearance.
Journal oil clearance mm (in)

Standard values
0.039 - 0.070
No.1,2,4,5
(0.0015 - 0.0028)
0.053 - 0.084
No.3
(0.0021 - 0.0033)
LNW21BSH024301
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 LNW21BSH024401
• Replace all sets of main bearings or the

LNW21BSH022601 crankshaft if the oil clearance exceeds the limit.
• Remove the plastigage from the bearing and
crankshaft.
M14 M10
1st time 2nd time 3rd time 4th time Inspection of the crankshaft
1 - 10 1 - 10 1 - 10 11 - 27 • Inspect the crankshaft journal and crank pin
surface for wear and damage. Inspect the oil
98 N⋅m 132 N⋅m 37 N⋅m seal installation surface for excess wear and
(10.0 kg⋅m/ (13.5 kg⋅m/ 30° - 60° (3.8 kg⋅m/ damage.
72 lb⋅ft) 98 lb⋅ft) 27 lb⋅ft)
• Inspect the oil port for clogging.
• Tighten the 1 - 10 bolts (M14) in the tightening 3. Crankshaft runout
direction. Check that they are tightened at a Carefully set the crankshaft to the V-block. Slowly
torque beyond 167 N⋅m (17 kg⋅m/123 lb⋅ft). rotate the crankshaft to measure runout. Replace
the crankshaft if the crankshaft runout exceeds the
standard values.
Special Tool
Angle gauge: 5-8840-0266-0 Crankshaft runout mm (in)

NOTE:
Repairs must not be done because TUFFTRIDE (soft
nitriding) is implemented to increase the strength of the
crankshaft.
Inspection of the TUFFTRIDE layer of the

crankshaft
1. Use an organic detergent to thoroughly clean the
crankshaft. Completely remove the oil from the test
locations.
2. Prepare a solution of copper chloride ammonium
of 5 - 10% (diluted with diluting water).
3. Use an oil drop to apply the solution to the test
locations. Maintain the inspection surface at a
complete level so that the solution does not flow.
LNW21BSH054801
4. Measure the journal and crank pin diameter and

uneven wear. 2
• Use a micrometer to measure the journal and 1
pin outer diameters to calculate difference of
the maximum and minimum. Measure in 4 3
sections on the journal and on the pin.
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.
LNW21BSH024601
Determination
• Wait 30 to 40 seconds.
Crankshaft outer diameter mm (in) • If the color does not change after 30 or 40
Standard values seconds, the crankshaft can be used. If the color
changes (test surface turns copper-colored)
81.905 - 81.925 (indicating a residual layer of TUFFTRIDE),
Journal #1, #2, #4, #5
(3.2246 - 3.2254) replace the crankshaft.
81.891 - 81.911
Journal #3 CAUTION:
(3.2241 - 3.2248)
• The inspection liquid is highly corrosive, so when
72.902 - 72.922 finished, wipe it away with a cloth immediately and
Pin
(2.8702 - 2.8709) clean with water or steam.

• Do not let any inspection liquid get in your eyes, on
your hands or cloths. If some of the liquid gets in 2
1
your eyes, wash them immediately with large 3
volumes of fresh water and seek medical 4
treatment.
Selection of the crankshaft bearing

• Refer to the bearing selection table to install a new
crankshaft bearing or to replace one in use.
• Be careful of the journal hole inner diameter grade
of the cylinder block and the crankshaft journal
diameter grade in selecting a new bearing.
• The journal numbers are #1 to #5 from the left in
5
the direction that the characters are read.
6
LNW21BSH024901
Legend
1. Upper bearing
2. Oil hole
3. Grade identification color
4. Oil groove
5. Lower bearing
6. Grade identification color
LNW21BSH024701
LNW21BSH024801
NOTE:
Be careful not to mistake the bearing shape when
installing.

Bearing selection table
Grade combination Oil clearance mm (in)
Cylinder block Crank journal Bearing identification
#1,2,4,5 #3
Grade Grade color
1 1 Black 0.041 - 0.068 0.055 - 0.082
(0.00161 - 0.00268) (0.00217 - 0.00323)
1 2 Brown 0.039 - 0.065 0.053 - 0.079
(0.00154 - 0.00256) (0.00209 - 0.00311)
2 1 Blue 0.043 - 0.070 0.057 - 0.084
(0.00169 - 0.00276) (0.00224 - 0.00331)
2 2 Black 0.041 - 0.067 0.055 - 0.081
(0.00161- 0.00264) (0.00217 - 0.00319)
Reassembly • Install the upper bearing to the cylinder block

and apply oil.
1. Install the gear.
• Warm the gear to 170 - 250°C (338 - 482°F), NOTE:
and align the gear side groove with the pin When replacing the crankshaft bearing, select the
position at the backside of the crankshaft and grade upon referring to the selection of the crankshaft
install them. bearing grade. Do not apply oil to the cylinder block
• When installing, face the alignment mark "S" (1) bearing installation surface or the outer circumference
of the gear edge surface towards the outside of the bearing.
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
Installer; crankshaft gear: 8-94396-819-0
MFW81BSH006901
2. Install the thrust bearing upper.

• Install the thrust bearing upper to the cylinder
block No.5 journal section front side. When
doing so, it is acceptable to use grease to
LNW21BSH025101
adhere the bearing upper to the cylinder block.
Legend However, wipe away any excess grease.
1. Alignment mark (S)
NOTE:
Install so that the oil groove of the thrust bearing
touches the crankshaft.
Installation
1. Install the crankshaft upper bearing.

• Install so that the oil groove of the thrust
bearing touches the crankshaft.
LNW21BSH025301
LNW21BSH025501
3. Install the crankshaft ASM.
• Apply engine oil to the crankshaft journal and
gently place it on the cylinder block. 6. Install the crankcase.
• Push the installed crankshaft against the rear • Apply liquid gasket (TB-1207C) to the
side, and insert the thrust bearing upper to the crankcase in a width of approx. 3 - 4 mm
cylinder block No.5 journal section rear side. (0.12 - 0.16 in).
NOTE: minutes.
Install so that the oil groove of the thrust bearing
touches the crankshaft.
MFW81BSH006801
4. Install the crankshaft lower bearing.

5. Install the thrust bearing lower.
• Install the thrust bearing lower to the crankcase
No. 5 journal rear side.

• Gently place the crankcase on the cylinder
block.
20
20
16
16
152
148
142.5
132
136
3~4mm
142.5
2~3mm
136
152
180
38
16
20
20
LNW21BMF000401

portion of the M14 bolt and seat surface, and
tighten at the specified torque in the numbered
order in the diagram. 25 21 17 13 12 16 20
• Do not apply engine oil to the M10 bolt. 27
24
M14 M10 10 6 2 3 7
1st time 2nd time 3rd time 4th time
1 - 10 1 - 10 1 - 10 11 - 27 9 5 1 4 8
98 N⋅m 132 N⋅m 37 N⋅m
(10.0 kg⋅m/ (13.5 kg⋅m/ 30 °- 60° (3.8 kg⋅m/
72 lb⋅ft) 98 lb⋅ft) 27 lb⋅ft)
26 22 18
14 11 15 19 23
• 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). LNW21BSH022601
Special Tool 7. Install the piston and connecting rod.

Angle gauge: 5-8840-0266-0 Refer to "Piston and Connecting Rod" in this
section.
NOTE: 8. Install the oil pump.
Check that the crankshaft turns smoothly. Refer to "Oil Pump" in Section 1H Engine
Lubrication.
9. Install the timing gear train.

10. Install the crankshaft rear oil seal. 14. Install the oil pan.
Refer to "Crankshaft Rear Oil Seal" in this Refer to the "Oil Pan" in Section 1H Engine
section. Lubrication.
11. Install the front cover. 15. Install the supply pump.
Refer to "Front Cover" in this section. Refer to "Supply Pump" in Section 1D Engine
12. Install the crankshaft front oil seal. Fuel.
Refer to "Crankshaft Front Oil Seal" in this section. 16. Install the cylinder head.
13. Install the water pump. Refer to "Cylinder Head" in this section.
Refer to "Water Pump" in Section 1C Engine 17. Install the engine ASM to the vehicle.
Cooling. Refer to "Engine ASM" in this section.
MFWB1BLF004901
(a) M14; 98 N⋅m (10.0 kg⋅m/72 lb⋅ft) → 132 N⋅m (13.5 kg⋅m/98 lb⋅ft) → 30° - 60°
(b) M10; 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
Cylinder Block
Components
LNW81BLF002101
Legend
1. Cylinder liner 2. Cylinder block
Removal 5. Remove the water pump.

Refer to "Water Pump" in Section 1C, Engine
1. Remove the engine ASM from the vehicle.
Cooling.
Refer to "Engine ASM" 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 8. Remove the oil pump.
Fuel. Refer to "Oil Pump" in Section 1H, Engine
4. Remove the oil pan. Lubrication.
Refer to the "Oil Pan" in Section 1H, Engine 9. Remove the piston and connecting rod.
Lubrication. Refer to "Piston and Connecting Rod" in this
section.

10. Remove the crankshaft. 5. Measurement of cylinder liner wear
Refer to "Crankshaft" in this section. • Inspect the inner surface of the liner for
11. Remove the piston oil jet. scratches or damage.
• For the liner inner diameter, measure the
maximum wear (much wear in rotation
direction) of approximately 15 - 20 mm (0.59 -
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
BLW51BSH005401
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 values 115.031 - 115.050
2. Gently remove the liquid gasket on the crankcase (4.5288 - 4.5295)
installation surface.
3. Clean the cylinder block. Limit 115.20 (4.5283)
4. Visually inspect the cylinder block.
NOTE:
• Perform the collar check and water pressure (or
There is only 1 type of replacement cylinder liner bore
air pressure) test, and replace the cylinder
(inner diameter). There is no need to select the grade.
block if cracks or other damage is found.
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 0.10 (0.0039)
LNW81BSH004501
Cylinder block inner diameter, liner grade (reference)

mm (in)
Grade (1,2) (1X) (3) (3X)
Cylinder
118.001 - 118.020 118.021 - 118.030
block Inner
(4.64570- 4.64645) (4.64649- 4.64684)
diameter
Lining
117.991 - 118.000 118.001 - 118.010
outer
(4.64531- 4.64566) (4.64570- 4.64605)
diameter
(Reference)
When replacing the liner, replenishment with
the "liner set" can be performed by replenishing
the liner with piston grade that matches the
LNW21BSH026901
inner diameter of the liner, per cylinder, if the
liner outer diameter grade is specified.
Installation 2. Install the cylinder liner.
• Install straight into the cylinder block.
1. Selection of the cylinder liner grade
• Do not tap or apply excessive force when
• The cylinder block inner diameter grades are
inserting the liner.
marked at the arrows in the diagram of the
cylinder block. Select the liner depending on NOTE:
the outer diameter grade of that. Thoroughly clean the cylinder block and cylinder liner
• Matching grades for cylinder block and liner and install them after air-blowing.
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 (0.0012
in).
Projection amount of the cylinder liner mm (in)

Standard values 0.05 - 0.10 (0.0020 - 0.0039)

NOTE: 7. Install the oil pump.
After replacing the cylinder liner, always measure the Refer to "Oil Pump" in Section 1H, Engine
protrusion amount of the cylinder liner. Lubrication.
8. Install the timing gear train.
9. Install the front cover.
Refer to "Front Cover" in this section.
10. Install the water pump.
Refer to "Water Pump" in Section 1C, Engine
Cooling.
Refer to the "Oil Pan" in Section 1H, Engine
Lubrication.
12. Install the supply pump.
Refer to "Supply Pump" in Section 1D, Engine
Fuel.
14. Install the engine ASM to the vehicle.
Refer to "Engine ASM" in this section.
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.
Refer to "Piston and Connecting Rod" in this
section.

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-8
Failure Symptom List . . . . . . . . . . . . . . . . . . . 1C-11
Phenomenon:The Engine has Overheated. . . 1C-12
Phenomenon:The Engine has Overcooled. . . 1C-13
Primary Specifications. . . . . . . . . . . . . . . . . . . 1C-13
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-16
List of Tightening Torques . . . . . . . . . . . . . . . . 1C-18
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
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-24
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-26
Engine Coolant Replacement Guidelines . . . . 1C-27
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 system, and
coolant is hot. Steam and boiling water can burst out its main components are a water pump, thermostat and
from the radiator possibly causing burns or heat related radiator. Oil in Smoother system is cooled by the
injuries. When opening the radiator cap, place a thick coolant in the radiator.
cloth over the cap when the coolant is cooled, and turn
it gradually to release the pressure before opening it.
Euro2 specification
4
5
6
3
2 9
8
15
1
10
14
11
12
16
13
MFW81CLF000801
Legend
1. Radiator 9. Turbocharger
2. Radiator cap 10. Water jacket
3. Reserve tank 11. Cylinder block drain plug
4. Air removal plug 12. Oil cooler
5. Water outlet pipe 13. Heater core
6. Thermostat (2 units) 14. Water pump
7. Engine temperature sensor 15. Cooling fan
8. Bypass pathway 16. Drain plug

Euro3 specification
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

Euro4 specification
9 10
4
5
6
3
2 11
8
17
1
12
16
13
14
18
15
LNW71CLF001101
Legend
1. Radiator 10. EGR cooler
2. Radiator cap 11. Turbo charger
3. Reserve tank 12. Water jacket
4. Air removal plug 13. Cylinder block drain plug
5. Water outlet pipe 14. Oil cooler
6. Thermostat (2 units) 15. Heater core
7. Engine temperature sensor 16. Water pump
8. Bypass pathway 17. Cooling fan
9. EGR cooler 18. Drain plug

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
3
6
5
MFW81CMF000101
Legend
1. Fan center 4. Seal unit
2. Water pump pulley 5. Impeller
3. Liquid gasket application groove 6. Bearing

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
LNW21CMF001301
Legend
1. Jiggle 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 radiator cap with
an open valve pressure of 93 - 122 kPa (0.9 - 1.2 kg/
cm2 /13 - 17 psi) is installed.
MFW71CSH000101

Functional Inspection
Engine coolant level detection
• Inspect the coolant level in the reserve tank (1). If
the level is within its MAX (upper limit) and MIN
(lower limit), it is the appropriate amount. Note that
if there is insufficient coolant, remove the reserve
tank cap and pour in a mixture of water and engine
coolant at the appropriate proportion and fill the
tank to the MAX line. (Refer to Coolant section.)
Coolant vehicles 18.5 (4.07)

Amount (Within MIN – MAX level)
Standard L (lmp⋅gal)
value
Replacement
Every 2 years
period
LNW41CSH000101
1 Coolant concentration inspection

1. engine coolant concentration
• Because the freezing temperature of engine
coolant differs according to the concentration of
2
the coolant. The concentration should conform
3 to the lowest temperatures.
• The engine coolant is made by mixing the
coolant and water (distilled water or deionized
water) at the specified concentration ratio.
• 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.
MFW81CSH000501 • It is recommended to directly use the "50/50
Prediluted" or "50/50 Pre-Mixed" or equivalent
Legend
products which are already diluted to 50%
1. Reserve tank
concentration.
2. MAX
3. MIN • When diluting the coolant, use the distilled or
deionized water.
• When it is used at the temperature of -30°C (-
Coolant Leaks Inspection 22°F) or below, make the concentration to 55%.
• Add 200 kPa (2.0 kg/cm2 /28.4 psi) pressure using
the radiator cap tester to inspect for leaks in the Coolant
following locations. Also, inspect the radiator hose Region where used
Concentration
and heater hose for damage or wear. Check that
hose clamps are not loose. General regions, regions where the
lowest temperature is -12°C (10.4°F) 30%
Inspection locations or above
• Radiator assembly, Water pump assembly, Cold regions, regions where the
Radiator hose, Heater hose lowest temperature is -30°C (-22°F) 50%
or above
Regions where the lowest
temperature is -30°C (-22°F) 55%
or below
2. Measurements of engine coolant concentration


Hydrometry Coolant Scope Method
• Use an antifreeze hydrometer to measure the • Measure the concentration using a coolant
specific gravity and coolant temperature. scope.
CAUTION:
If you remove the cap when it is hot, be careful
NOTE:
because the coolant will burst out.
Replace the coolant every 2 years. Wash the radiator
• Use a container that is deeper than the length cap, radiator and coolant passage at the same time.
of the hydrometer.
1. Check that the engine is cool.
WARNING:
Do not loosen or remove the radiator cap when the
2 coolant is hot. Steam and boiling water can burst out
from the radiator possibly causing burns or heat related
injuries. When opening the radiator cap, place a thick
cloth over the cap when the coolant is cooled, and turn
it gradually to release the pressure before opening it.
1
2. Remove the radiator cap.
3. Open the coolant drain plug of the radiator, loosen
the air removal plug of the water outlet pipe and
drain the coolant.
4. Tighten the drain plug.
5. Fill tap water in the radiator until it is completely
full, and then tighten the air removal plug.
LNW41CSH000201 Air removal plug
Legend Tightening torque: 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
1. Radiator 6. Inspect and clean the radiator cap. If the cap is
2. Density gauge defective, replace it.
• The temperature of the coolant should be within 7. Install the radiator cap firmly.
0 - 50°C (32 - 122°F) for measurement. 8. Fill tap water in the reserve tank to its "MAX" line.
• After measuring the temperature and relative 9. Close the cap of the reserve tank.
density, find the concentration from the table 10. Start the engine, and idle the engine for 20
below. minutes. Stop the engine, and drain tap water after
it is completely cooled down.
11. Fill the coolant in the radiator until it is completely
1.100
full.
1.090
• However, remove the air removal plug of the
1.080 50% water outlet pipe when filling the coolant. After
1.070 filling the coolant, tighten the air removal plug.
SPECIFIC GRAVITY
1.060 Air removal plug

1.050 30% Tightening torque: 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
1.040
12. Install the radiator cap firmly.
1.030
13. Fill the coolant in the reserve tank to its "MAX" line.
1.020
14. Close the cap of the reserve tank.
1.010 15. Start the engine.
1.000 16. Let the engine idle for 2 to 3 minutes at a normal
0 10 20 30 40 50 60 70 idling speed, and then stop it.
TEMPERATURE 17. After confirming that the coolant is cooled down,
MFW91CSH001001
open the radiator cap and pour in more coolant if
the level has dropped.
18. After firmly closing the radiator cap, warm up the
engine at approximately 2,000 r/min.

19. After the water temperature gauge indicator has
passed the center, idle the engine for about 5
minutes at a normal idling speed, then stop the
engine and let the vehicle stand.
20. After confirming that the coolant is cooled down,
necessary. If the coolant level is excessively low,
check for the coolant leakage.
21. Firmly close the radiator cap.
22. Fill the coolant in the reserve tank again to its
"MAX" line.

Failure Symptom List
• The engine has overheated.
• The engine has overcooled.

Phenomenon:The Engine has Overheated.

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

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) 127.2 (109,400)
Heat dissipation surface
m2 (ft2) 18.15 (195.37)
area
Front surface area m2 (ft2) 0.367 (3.95)
Dry mass kg (lb) M/T vehicles:11.5 (25.4) / Smoother vehicles:11.7 (25.8)
Radiator cap
Open valve pressure kPa (kg/cm2 /psi) 93 - 122 (0.9 - 1.2 / 13 - 17)
Coolant capacity L (lmp⋅gal) 3.1 (0.69)
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)
(More than 8mm/0.315in)
Coolant total capacity
L (lmp⋅gal) 18.5 (4.07)
[reference values]
Water Pump
Components
7
6
5
LNW71CMF000901
Legend
1. Radiator lower hose 5. Water pump pulley
2. Fan guide 6. Fan belt
3. Fan assembly 7. Water pump assembly
4. Set plate

Removal 5. Loosen the adjust plate lock nut (3) and bolt (2).
Loosen the generator adjust bolt (1) to remove the
1. Drain the engine coolant.
fan belt.
1
1 2
MFW71CSH000201
MFW71CSH001601
Legend
Legend
1. Radiator drain Plug
1. Adjust bolt
2. Bolt
2. Remove the radiator lower hose at the radiator
3. Adjust plate lock nut
side.
3. Remove the fan guide from below.
4. Remove the four fan assembly tightening nuts (2) 6. Remove the set plate (3) and water pump pulley
to remove the fan assembly (1). At that time, (2).
loosen the water pump pulley (3) and set plate 7. Insert a screwdriver into the position shown in the
collective-fastening bolts (5). drawing to remove the water pump assembly by
prying it out.
1 3
1
2
2
3
MFW81CSH000601
Legend LNW71CSH002401
1. Fan assembly Legend
2. Fan assembly tightening nut (four pieces) 1. Water pump assembly
3. Water pump pulley 2. Water pump pulley
4. Set plate 3. Set plate
5. Set plate collective-fastening bolt

Inspection • Apply liquid gasket (No.1207B) to about 3 - 5
mm (0.12 - 0.20 in) width in the groove of the
1. External inspection
water pump installation surface.
• Inspect the pump body for cracks and damage.
• Install the water pump by aligning to the front
• Inspect the impeller for cracks and corrosion. cover stud.
• Inspect for water leaks from the seal unit. • After applying the liquid gasket, Install within 5
• When you find a problem, replace with the minutes.
water pump assembly. • See the drawing for the position to apply the
liquid gasket.
1 2 3
b c
LNW21CSH000901 a
2. Inspection of the bearing unit

MFW81CSH000401
• Rotate the fan while pushing the fan center to
the radius direction and inspect for any notable Legend
rattling or abnormal sounds. 1. OK
• When you find a problem, replace with the 2. OK
water pump assembly. 3. NG
4. a:0.5 - 1.5 mm (0.020 - 0.06 in)
5. b:3 - 5 mm (0.12 - 0.20 in)
6. c:1 mm (0.04 in) More than
LNW21CSH001001
Installation
1. Install the water pump Assembly.

2. Temporarily tighten the bolt until the water pump
pulley (1) is seated together with the set plate (2)
on the water pump assembly.
2
1 2
MFW71CSH001601
Legend
1. Adjust bolt
LNW71CSH002501
2. Bolt
Legend 3. Adjust plate lock nut
1. Fan pulley assembly
2. Set plate
5. After adjusting the fan belt, tighten the temporarily
tightened water pump pulley and set plate at the
3. Install the fan belt, and tighten the generator adjust specified torques.
bolts to adjust the tension of the belt.
• Refer to "Drive Belt" in this section.
4. After adjusting the fan belt, tighten the generator at 6. Install the fan assembly (1) and tighten it at the
the specified torque. specified torque.
Tightening torque
Adjust plate lock nut
76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
(3)
1 3
Tough bolt (2) 126 N⋅m (12.8 kg⋅m/93 lb⋅ft)
2
MFW81CSH000601
Legend
1. Fan assembly
2. Fan tightening nut (4 pieces)
3. Water pump pulley
4. Set plate
5. Collective-fastening bolt

7. Install the fan guide.
9. Refill the engine coolant.
MFW71CLF000301
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
(c) 126 N⋅m (12.8 kg⋅m/93 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m/17 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)
Thermostat
Components
LNW41CMF000201
Legend
1. Radiator upper hose 3. Thermostat
2. Water outlet pipe 4. Gasket
Removal • Measure the temperatures when the valve starts

opening and when it is fully opened.
1. Discharge coolant. Prepare a container for
discharge and use it for filling when installing the
thermostat. The amount of coolant to be Starting temperature
discharged should not be enough to avoid coolant
spilling from the thermostat housing. 80.0 - 84.0 °C
(without Jiggle valve)
(176 - 183 °F)
2. Remove the radiator upper hose at the radiator
side. 83.5 - 86.5 °C
(with Jiggle valve)
(182 - 188 °F)
3. Remove the water outlet pipe.
4. Remove the thermostat. Full-open temperature
5. Remove the gasket from the thermostat. (without Jiggle valve) Min. 95 °C (203 °F)
(with Jiggle valve) Min. 100 °C (212 °F)
Inspection Lift amount 8 mm (0.31 in) or more
• Place the thermostat in water, and raise the water

temperature while thoroughly stirring it.

LNW21CSH003401
Installation MFW71CSH000401
1. Install the gasket (1) to the thermostat, and install 4. Fill the coolant stored when discharged, and check
to the position in the drawing. that the coolant is at the specified level.
NOTE:
Replace the gascket as it can cause water leakage.
1
• There are 2 types of thermostats (1) with
different shapes. Make sure to install them to
the positions shown in the diagram.
• Securely insert so that the thermostat gasket
does not ride up outside of the cylinder head
side housing.
MFW71CSH000301
Legend
1. Reserve tank
1 2
LNW21CSH000201
Legend
1. Thermostat
2. Cylinder head
2. Install the water outlet pipe.

Engine Coolant Temperature Sensor

Removal Example of how to measure the thermistor
characteristics
1. Disconnect wiring connector.
2. Remove the engine coolant temperature sensor.
Inspection
ECM thermo sensor is a thermistor type whose
characteristics is that the electrical resistance
decreases as the temperature rises.
1 2
MFW71KSH000201
1 2
Resistance value at a certain temperature
(approximate value)
– 20°C (– 4°F) Approx. 15.48kΩ
3
0°C (32°F) Approx. 5.79kΩ
MFW71CSH000601 20°C (68°F) Approx. 2.45kΩ
Legend 40°C (104°F) Approx. 1.148kΩ
1. Indicates the wiring
2. Indicates the wiring 60°C (140°F) Approx. 0.5865kΩ
3. ECM thermistor 80°C (176°F) Approx. 0.3222kΩ
1. Place the temperature sensor section of the 100°C (212°F) Approx. 0.1884kΩ
sensor into water. Inspect whether the changes in
resistance value correspond to the values in the
thermistor characteristics graph while changing the Thermistor characteristic
water temperature. 30
20
NOTE:
Be careful not to allow water to get into the terminal 10
section. Wipe off the water droplets on the sensor after 7.0
)
5.0
the inspection.
Resistance value(k
3.0
2.0
1.0
0.7
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100 120
Engine coolant temperature( )
MFW81CSH000901
• If any abnormality is found in the inspection

results, replace it with a normal one.

Installation
1. Apply Loctite 262 or 962 to the engine coolant
temperature sensor threaded portion and tighten at
2
MFW81CSH000101
Legend
2. Loctite application area
2. Install the wiring connector.

Radiator
Components
2 3
MFW91CLF000501
Legend
1. Coolant reserve tank hose 5. Fan guide
2. Air removal plug 6. Intercooler
3. Radiator upper hose 7. Radiator lower hose
4. Radiator
Removal
1. Loosen the radiator drain plug (1) and air removal
plug and completely drain the coolant.
• After draining, securely tighten the drain plug
(1).

7. 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, remove the
radiator stay and then the radiator.
MFW71CSH000201
2. Remove the intercooler air charge pipe.

3. Remove the radiator upper hose at the radiator
side.
4. Remove the radiator lower hose at the radiator
side.
5. Remove the coolant reserve tank hose from the
radiator side.
• Remove the oil cooler hose for Smoother only.
A small amount of oil will come out when
removing it, so collect it using a tray.
1
MFW81CMH000201
Inspection
Radiator cap
1. Use the radiator cap tester to inspect the open
valve pressure. Replace the radiator cap if the
open valve pressure is not at the standard value.
2
3 kPa (kg/cm2/psi)
Positive pressure ;
Cap operating 93 - 122 (0.9 - 122/13 - 17)
pressure Negative pressure ;
4 Min 4.9 (0.05/0.7)
MFW71CSH001501
Legend
1. Radiator stay
2. Intercooler
3. Radiator
4. Oil hose
6. Remove the fan guide from below.


NOTE:
Do not use a high-pressure washer or brush.
3. Prepare a mild detergent.

• Use a type which contains approx. 8% of
surface acting agent.
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
LNW21BSH000201 radiator.
NOTE:
2. Inspect the condition of the negative pressure • Apply the high-pressure water in a direction
valve in the center of the cap valve seat side. If the perpendicular to the fins.
valve seat is not operating smoothly because of
• Do not bring the high-pressure water too close to
rust or foreign matter, clean or replace the radiator
the fins.
cap.
• Be careful not to deform the fins.
Radiator core
1. Deformed radiator fins can cause inefficient heat
dissipation. So, repair the fins, or it can lead to
overheating. When repairing, take sufficient care
not to damage the base of the fins.
• Remove filth or other foreign materials. 1
NOTE:
Do not perform high-pressure washing to the radiator
or intercooler, and the parts surrounding it.
Cleaning
Washing inside the radiator and the water passage.
Wash the inside of the radiator and coolant path with
water.
Wash away all scales and rust.
MFWA1CSH001101
Washing the radiator core
Legend
CAUTION:
1. Radiator
Do not perform high-pressure washing onto the
radiator, intercooler and surrounding parts when they 6. After washing is finished, inspect the fins to
are still installed on the vehicle. confirm that the dirt is removed sufficiently.
1. Seal the hose connecting section with a cap or • If washing is not sufficient, wash them again.
fabric tape.
NOTE:
2. Sufficiently wet the front and back surfaces of the If some dirt is still left, fine black particles attached on
radiator. the fins can be seen.
• Adhering matter which easily comes off with a
splash of tap water should be washed off 7. Rinse off the detergent constituents on the fins and
sufficiently in advance. 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. Be careful not to damage the radiator core with the
fan blades. Install the left and right brackets of the
radiator to the frame side stud bolt (3) as shown in
the diagram.
•
Tightening torque:
Upper side nut 41.4 N⋅m (4.2 kg⋅m/31 lb⋅ft)
7
3
6
5
4
MFWA1CSH001501
Legend
1. Nut
2. Stud bolt
3. Rubber
4. Nut
5. Frame
6. Radiator side bracket
7. Washer
2. Install the fan guide.
3. Install the coolant reserve tank hose to the

radiator.
• For Smoother, install the oil hose, too.
6. Install the charge air pipe to the intercooler.
8. Tighten the air removal plug.

Engine Coolant Replacement Guidelines
NOTE: 19. After the water temperature gauge indicator has
Replace the coolant every 2 years. Wash the radiator passed the center, idle the engine for about 5
cap, radiator and coolant passage at the same time. minutes at a normal idling speed, then stop the
engine and let the vehicle stand.
1. Check that the engine is cool. 20. After confirming that the coolant is cooled down,
WARNING:
necessary.
Do not loosen or remove the radiator cap when the
If the coolant is excessively low, check for the
coolant is hot.
coolant leakage.
Steam and boiling water can burst out from the radiator
possibly causing burns or heat related injuries. 21. Firmly close the radiator cap.
When opening the radiator cap, place a thick cloth over 22. Fill the coolant in the reserve tank again to its
the cap when the coolant is cooled, and turn it “MAX” line.
gradually to release the pressure before opening it.
2. Remove the radiator cap.

3. Open the coolant drain plug of the radiator, loosen 1
the air removal plug of the water outlet pipe and
drain the coolant.
4. Tighten the drain plug.
2
5. Fill tap water in the radiator until it is completely
full, and then tighten the air removal plug. 3
Air removal plug
6. Inspect and clean the radiator cap. If the cap is
defective, replace it.
8. Fill tap water in the reserve tank to its “MAX” line.
9. Close the cap of the reserve tank. MFW81CSH000501
10. Start the engine, and idle the engine for 20 Legend
minutes. Stop the engine, and drain tap water after 1. Reserve tank
it is completely cooled down. 2. MAX
11. Fill the coolant in the radiator until it is completely 3. MIN
full.
• However, remove the air removal plug of the
water outlet pipe when filling the coolant. After
filling the coolant, tighten the air removal plug.
Air removal plug
13. Fill the coolant in the reserve tank to its “MAX” line.
14. Close the cap of the reserve tank.
15. Start the engine.
16. Let the engine idle for 2 to 3 minutes at a normal
idling speed, and then stop it.
17. After confirming that the coolant is cooled down,
the level has dropped.
18. After firmly closing the radiator cap, warm up the
engine at approximately 2,000 r/min.
Drive Belt
Components
(50A,60A specifications)
1 2
3
4
5
6
13
7
12
11 9
10
4 9
MFW71CMF000101
Legend
1. A/C compressor 8. Tension pulley
2. Adjust plate lock nut 9. Generator drive belt
3. Adjust plate 10. Crank pulley
4. A/C 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 adjust bolt

(90A specification)
3 4 6
2
8
5
10
17
11
18
12
7 5 8 16
13
15
14
MFW81CMF000201
Legend
1. A/C compressor 10. Idle pulley (for A/C compressor)
2. Tension pulley (for freezer compressor) 11. Tension pulley (for A/C compressor)
3. Tension adjust bolt (for freezer compressor) 12. Tension adjust bolt (for A/C compressor)
4. Tension pulley lock nut (for freezer compressor) 13. For tension pulley lock nut (for A/C compressor)
5. Generator drive belt 14. Crank pulley
6. Water pump pulley (Fan pulley) 15. Tension pulley (for generator drive belt)
7. A/C drive belt 16. Tension pulley lock nut (for generator drive belt)
8. Drive belt of freezer compressor 17. Tension adjust bolt (for generator drive belt)
9. Freezer compressor 18. Generator
Inspection
Inspect the drive belt for wear and damage. Replace it
if necessary.
Also inspect belt tension. Adjust the tension if
necessary.

Inspection guidelines Belt tension adjustment value
Press on the specified position on the belt with 98 N Frequency
(10 kg/22 lb) of pressure to inspect the amount of belt Amount
of
flex. Belt types of flex
vibrations
mm (in)
(Hz)
a Generator For a new 5-7 197 - 221
1 drive belt product (0.2 - 0.3)
(50A,60A When 7-9 168 - 182
2 specifications) reused (0.3 - 0.4)
Generator For a new 5-7 190 - 212

drive belt product (0.2 - 0.3)
(90A When 7-9 163 - 175
specification) reused (0.3 - 0.4)
For a new 16 - 21 68 - 82
A/C product (0.6 - 0.8)
Drive belt When 21 - 24 59 - 67
b 1 reused (0.8 - 0.9)
Adjustment
2
When adjusting the tension of the drive belt, do so for
both the generator drive belt and the A/C drive belt.
NOTE:
After adjusting the generator drive belt, adjust the A/C
drive belt.
50A,60A specification generator drive belt

LNW71EMH000201
adjustment
Legend 1. Loosen the A/C drive belt tension pulley lock nut
1 A/C drive belt and adjust bolt to free the belts.
2 Generator drive belt 2. Loosen the adjust plate lock nut and though bolt.
(a) 50A ,60A specifications 3. Turn the adjust bolt to adjust the generator drive
(b) 90A specification belt.
4. After adjusting, tighten the adjust plate lock nut
Reference and though bolt at their specified torques.
NOTE:
• A V-ribbed belt is used for the generator drive belt, Tightening torque
which requires a more accurate tension
Lock nut 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
adjustment than conventional V belts.
Therefore, use a sonic tension meter to check that Though bolt 126 N⋅m (12.8 kg⋅m/93 lb⋅ft)
the measured frequency of vibrations is within the
adjustment value. 90A specification generator drive belt adjustment
Perform adjustment if the value is improper. 1. Loosen the A/C drive belt tension pulley lock nut
If the tension is improper, the belt life will be and adjust bolt to free the belts.
reduced, or the belt can squeak.
2. Loosen the generator drive belt tension pulley lock
• After the adjustment, securely tighten each bolt. nut.
3. Turn the generator drive belt tension pulley adjust
bolt to adjust generator drive belt.
4. After adjusting the generator drive belt, tighten the Tightening torque:
generator drive belt tension pulley lock nut at its Lock nut = 41 N⋅m (4.2 kg⋅m/ 30 lb⋅ft)
specified torque.

Adjusting the A/C 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.
Tightening torque:
Lock nut = 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Adjusting the drive belt of the compressor for the

refrigerator
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.
Tightening torque:
Lock nut = 40 N⋅m (4.1 kg⋅m/ 30 lb⋅ft)

50,60A specifications
c
MFW71CSF000101
(a) 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(c) 126 N⋅m (12.8 kg⋅m/93 lb⋅ft)
90A specification
b
c
LNW71CSF000401
(a) 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(c) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Engine Fuel (4HK1) 1D-1
ENGINE
Engine Fuel
(4HK1)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Fuel Rail Pressure (FRP) Regulator. . . . . . . . . . 1D-47
Maintenance Precautions . . . . . . . . . . . . . . . . . 1D-2 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-47
Description of Function and Operation . . . . . . . 1D-2 Maintenance Precautions . . . . . . . . . . . . . . . . 1D-47
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1D-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-48
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1D-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-49
Phenomenon: Starting is Difficult . . . . . . . . . . . 1D-9 Supply pump relearning . . . . . . . . . . . . . . . . . 1D-50
Phenomenon: Hunting when idling . . . . . . . . . 1D-10 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . 1D-51
Phenomenon: Insufficient output. . . . . . . . . . . 1D-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-51
Phenomenon: Engine does not stop . . . . . . . . 1D-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-51
Phenomenon: Exhaust Gas is Blue or Black . 1D-13 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-52
Primary Specifications. . . . . . . . . . . . . . . . . . . 1D-13 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-52
Pre-fuel Filter Element (with pre-fuel filter). . . . . 1D-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-54
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14 List of Tightening Torques . . . . . . . . . . . . . . . . 1D-57
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14 Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-60
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . 1D-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-62
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-65
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Fuel Filter Assembly. . . . . . . . . . . . . . . . . . . . . . 1D-18
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-18
Water Sedimenter Switch. . . . . . . . . . . . . . . . . . 1D-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-19
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-20
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-23
List of Tightening Torques . . . . . . . . . . . . . . . . 1D-28
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-33
Fuel Pressure Sensor (Common Rail) . . . . . . . . 1D-37
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-37
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-38
Pressure Limiter (Common Rail) . . . . . . . . . . . . 1D-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-39
Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . 1D-40
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-43
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. attach 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 "Programming" in Section 1A, Engine
Control System.
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
5
3
6
1 2 4
7
12
9
11 10
MFW81DSF000201
Legend
1. Common rail (Fuel rail) 7. Breather valve
2. Pressure limiter 8. Fuel feed pipe
3. Leak-off pipe 9. Pre-fuel filter (with pre-fuel filter type)
4. Injector 10. Fuel filter
5. Fuel return pipe 11. Recirculation valve
6. Fuel tank 12. Supply pump

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

Supply pump
2 4
1 3
7 6
MFW41DMF000101
Legend
1. Fuel temperature sensor 5. Camshaft
2. High pressure fuel outlet 6. Supply pump assembly
3. Fuel outlet (return) 7. Fuel inlet
4. Fuel rail pressure (FRP) regulator / Suction
control valve (SCV)

Injector Fuel filter (sedimenter)
1
1 2
8
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00
7 3
6 4 6
3
5 4
5
MFW71DMH000201 MFW61DMH000101
Legend Legend
1. ID plate 1. Priming pump
2. Terminal stud 2. Element
3. Injector drive section 3. Drain plug
4. Injector assembly 4. Float
5. Gasket (cone type) 5. Switch connector
6. O-ring 6. Case
7. Fuel outlet port 7. Body assembly
8. Recirculation valve

Pre-fuel filter
MFW91DMH000401
Legend
1. Filter body
2. Gasket
3. Filter element
4. O-ring
5. Clear element case
6. Magnet float

Air removal • Prepare a container at the end of the vinyl hose
1. Loosen the air removal plug of the fuel filter. attached to the drain plug.
2. Operate the priming pump to feed the fuel by • Loosen the drain plug.
pressure. Confirm that the fuel containing air • Press the priming pump several times to discharge
bubbles comes out from the air removal plug. the water.
3. When there is no more air bubble coming out, • After discharging, tighten the drain plug.
tighten the air removal plug. • Press the priming pump several times to check
that no fuel is leaking.
Tightening torque: 7 N⋅m (0.7 kg⋅m/ 61 lb⋅in)
• Check that the warning light is extinguished.
4. After tightening the plug, operate the priming pump
for about 150 times (until it gets heavy enough). NOTE:
5. Wipe off the leaked fuel. • The discharged water contains fuel. Therefore,
6. Start the engine. follow processing regulations established by your
heck that there is no fuel leakage. If the engine local area when discarding the water.
does not start, repeat the procedures from step 1. • If fuel sticks to the vehicle body, etc. wipe it clean.
MFW81DMH000101
Legend
1. Priming pump
2. Air removal plug (with a rubber cap)
Moisture removal
If more than the specified amount of water builds up in
the sedimenter, the warning light will turn on. In such
cases, use the following procedures to remove the
water.
• Install a plastic hose, etc. to the end of the drain
plug.

• Starting is difficult
• Hunting 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
Clogging of the fuel tank breather Clean the fuel tank breather
Air entering into the fuel Remove the air in the fuel system
Clogging of or damage to the fuel line. Repair or replace the fuel line
Loose fuel line connection
Feed pump problem Replace the supply pump
Regulating valve is open Replace the regulating valve
Locking of the injector nozzle Replace the injector

Phenomenon: Hunting when idling

Hunting 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
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
Clogging of the fuel filter element Replace the element (excluding when
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. Injector opening valve pressure drop, Replace the injector
atomizing problem
Fuel system
Item Specifications
Engine type 4HK1-TC
Fuel system Electronically controlled fuel injection system
(common rail type)
Pre-fuel Filter Element (with pre-fuel filter)

Component Parts
7 6
MFW81DMF001801
Legend
1. Filter body 5. Clear element case
2. Gasket 6. Float switch connector
3. Filter element 7. Drain plug
4. O- ring
Removal Inspection
1. Loosen the drain plug at the bottom of the fuel • Check any damage or scratch on the clear element
filter. case.
• Drain the fuel completely. • Check dirt, break and distortion on the filter
2. Disconnect the water separator switch connector. element.
3. Carefully turn the clear element case • Check any clog in the through hole of filter body.
counterclockwise, then remove the clear element • The O-ring of water separator is exchanging at the
case and the filter element from the filter body as a time of decomposition.
single unit.
Inspect the water in float switch
NOTE:
When remove the case, do not use any tools for the • The wires red (+) and black (-) are connected to
projection part under the case to prevent the case 24V DC.
being damaged.
Voltage DC 24V
4. Remove the filter element from the clear element Water
case. warning Float switch /
80 – 120 cc (0.0176 –
5. Remove the O-ring from the clear element case. level Direct connection
0.0264 Imp⋅gal)
(warning ON)

Installation
NOTE:
Drain out water, when fuel filter will be covered with
water. If driving is continued not draining, there is a
possibility of damaging a fuel injection system.
In addition, surely use the genuine filter for engine at
the time of element exchange.
1. Install the new O-ring to the clear element case.
NOTE:
Use care not to damage the O-ring.
2. Install the filter element.

• After light coating the gasket of the new filter
element with diesel fuel, place the element until
it touches the filter body.
3. Install the clear element case to the filter body.
• After light coating the O-ring of element case
with diesel fuel, slowly turn the clear element
case clockwise.
NOTE:
Be careful not to let the O-ring catch in the screw
threads.
• Slowly tighten the clear element case with a

filter wrench until it touches the filter body.
OK
3
2
NG
1
4
MFW91DSH002501
Legend
1. Clear element case
2. Filter body
3. No gap
4. Gap
4. Tighten the drain plug and connect the water

separator switch connector, then bleed the fuel
system.
Fuel Filter Element

• Replace the fuel filter element timing is in the table
below. 1
2
Fuel filter element replace timing
3
Except for Indonesia 30,000 km
(18,000 mile) or every 9
4
For Indonesia 20,000 km months
(12,000 mile)
5
Removal
1. Drain the fuel in the element case
a. Loosen the drain plug at the bottom of the
element case.
6
b. Loosen the air removal plug on the filter body to 9
remove the fuel.
2. Disconnect the switch connector from the element
case.
3. Use a socket wrench [“a” section width across flat: 7
29 mm(1.14in)] or a general-purpose filter wrench 8
to remove the element case.
a
NOTE:
Check that the float in the element case moves BLW61DMH000101
smoothly. Legend
• Refer to “Water sedimenter switch inspection” for 1. Cap
alarm switch inspection. 2. Air removal plug
3. Filter body
4. Pull the element downward to remove the O-ring 4. O-ring
around the outer surface of the filter body. 5. Fuel filter element
5. If foreign material has accumulated on inner 6. Element case
surface of the filter body, wipe it with a clean cloth. 7. O-ring
8. Drain plug
NOTE: 9. Switch connector
Do not use an air blower to remove the foreign
material. If you do, that foreign material can be blown
into the path on the clean side and cause failure of the
supply pump. 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.

• Make sure to use a genuine Isuzu fuel filter, and
replace the O-ring at the same time.
• Please abandon exchanged filters, and process
it by a regulated method.
4. Install the element case, and tighten at the
specified torque.
5. Tighten the drain plug of the element case and

connect the switch connector.
Tightening torque: 0.4 N⋅m(0.04 kg⋅m/3.5 lb⋅in)
6. Remove the air in the fuel system.

1
2 • Refer to “Air removal” in Fuel System.
7. Start the engine and confirm that the Warning light
is turned off.
7
4
5
MFWA1DLH000101
Legend
1. Socket mounting position
2. Float
3. Gasket (outside)
4. Gasket (inside)
5. Hole on the clean side
6. Element kit
7. O-ring groove
3. Apply clean fuel to the inner circumference of the

element case or to the O-ring, and tighten 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.
WARNING:
Be careful so as not to pinch the O-ring when installing
the element case. If the O-ring gets stuck, fuel may leak
to cause fire.
Fuel Filter Assembly

Components
2
1
3
MFWB1BMF004101
Legend
1. Fuel filter assembly 4. Fuel return hose
2. Air removal plug 5. Water sedimenter switch connector
3. Fuel feed pipe (from the fuel tank)
Removal Installation
1. Remove the filler cap. 1. Install the fuel filter assembly.
2. Disconnect the switch connector. 2. Install the fuel filter installation bolt.
3. Disconnect the feed hose and return hose from the Tightening torque: 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
fuel filter.
3. Install the feed hose and the return hose.
• Plug the hoses so that fuel does not spill.
4. Install the switch connector.
At this time, do not let foreign material get
inside. Do not use rusted bolts etc. 5. Remove the air in the fuel system.
Refer to "Fuel System" in this section.
CAUTION:
Make sure that foreign material does not enter the fuel
feed hose (engine side) when it is removed, as this
may cause the supply pump to fail. (Inserting a rusty
bolt, etc. is strictly prohibited)
4. Remove the fuel filter installation bolt.

5. Remove the fuel filter assembly.
Water Sedimenter Switch

Inspection
1. Remove the fuel filter case and turn it upside
down. When the float rises, check that there is
continuity between the switch connector terminals.
2. Turn the engine control 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 light.
• If any abnormality is found in the inspection
results, replace the fuel filter case, or repair
defective connections or open circuits between
the circuits.
2
5
4 3
MFW61DMH000201
Legend
1. Fuel filter assembly
2. Drain plug
3. Lead switch terminal
4. Lead switch terminal
5. Water sedimenter switch connector
Injector
Components
1 4
7
6
9
5
8
10
MFW91DLF000901
Legend
1. Injector terminal 6. Injector clamp bolt
2. Injector harness bracket 7. Leak-off pipe
3. Noise cover (with noise cover type) 8. Injector
4. Cylinder head cover 9. Injection pipe
5. Injector clamp 10. Injection pipe clip

1 4
8 7
11
10
13
9
12
14
MFW91DLF001001
Legend
1. Injector terminal 8. Gasket
2. Injector harness bracket 9. Injector clamp
3. Noise cover (with noise cover type) 10. Injector clamp bolt
4. Cylinder head cover 11. Leak-off pipe
5. EGR adaptor 12. Injector
6. EGR valve 13. Injection pipe
7. Gasket 14. Injection pipe clip
Including the inside of the injector, the holes and gaps Removal
that are the fuel paths for the fuel system have an
1. Disconnect the EGR valve connector and injector
extremely precise finish. Therefore, because there is
connector (Euro3 specification and Euro4
the possibility of damage if foreign material becomes
specification).
mixed in, cover the cap after removing parts, etc. to
prevent the entry of foreign material. 2. Remove the EGR adaptor (2) and EGR valve (1)

• Use packing tape, etc. to cover the EGR case 7. Loosen the injector harness bracket bolts, and
side opening to prevent foreign material from remove the inside connector (4) to remove the
entering. harness bracket (2).
8. Disconnect the injector leak-off pipe (3).
1
2
4 3
MFW71FSH000301
MFW81DSH000201
3. Remove the harness bracket (with harness bracket Legend

type). 1. Terminal nut
4. Remove the noise cover (with noise cover type). 2. Harness bracket
3. Leak-off pipe
4. Harness connector
2
1 9. Remove the injection pipe clip (2) to remove the
injection pipe (1).
2
3
MFW71BSH007201
Legend
2. Harness bracket (with harness bracket type)
3. Cylinder head cover MFW81DSH000801
6. Remove the injector terminal nut (1). 10. Loosen the injector clamp tightening bolt.
11. When it is difficult to remove the injector, set a
NOTE: special tool injector remover:5-8840-2826-0 (2) on
ID codes are unique to each injector. Put a the injector (3) leak-off pipe installation. Pull the
corresponding number tag on each ID code plate when injector clamp upward using a sliding hammer:5-
storing injectors to avoid mix-up. 8840-0019-0 (1).

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.
LNW46CSH000501
Installation
1. Install a new gasket and O-rings and install to the
3 cylinder head with the injector clamp sandwiched
as shown in the drawing.
• Apply engine oil to the threaded portion of the
clamp bolt and seat surface, and temporarily
tighten.
LNW46CMH000301
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
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 assembly it.
• Lightly tighten the sleeve nut with spanner so 1
that it is attached airtight to the injector and
common rail side.
• Tighten the injection pipe clip at the specified
torque.
MFW91DSH002401
Legend
1. Clamp bolt
2
2. Injection sleeve nut
5. Install the injector leak-off pipe sandwiching the

new gasket and tighten it at the specified torque.
MFW81DSH000801
Legend
1. Injection pipe
2. Injection pipe 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. Record the fuel injector ID codes of the new

injector.
• Only when injector are replaced, it does.

a. Records 24 figures of fuel injector ID plate. The CAUTION:
correct order for the fuel injector ID codes of the If the nut is over-tightened, the terminal stud can be
following illustration is as follow: damaged. Never over-tighten.
64 DA A5 05 2F 4C 0F 36 FA 17 25 8C
1 1
2
64DA A505
2F4C 0F36
FA17 25 00
0000 8C
3
3
LNW76ESH002601 MFW81DSH000401
Legend Legend
1. Fuel injector ID plate 1. Terminal nut
2. Fuel injector ID codes 2. Injector
3. Fuel injector 3. Harness
9. Install the gasket to the cylinder head cover, and

7. Install the injector harness connector from the tighten at the specified torque.
inside and tighten the harness bracket at the
specified torque.
10. Tighten the noise cover at the specified torque
(with noise cover type).
11. Tighten the harness bracket at the specified torque
(with harness bracket type).
LNW71DSH003701
8. Install the terminal nut to the injector and tighten it


14. Install the gasket to the EGR adaptor (2), and
2
tighten at the specified torque (Euro3 specification
1 and Euro4 specification).
MFW71BSH007201
Legend
2. Harness bracket (with harness bracket type) 2
3. Cylinder head cover
MFW71FSH000301
12. Paint out fuel injector ID codes of the cylinder that

15. Connect the engine harness connectors.
replaced injector among the fuel injector ID codes
written in the code label. • Check that there is a clicking sound when
attaching the connector joints to securely
• Only when injector are replaced, it does.
connect them.
Programming Fuel Injector ID Codes (Euro4

specification)
NOTE:
• When injector replaced, fuel injector ID codes is
1 SAMPLE written in ECM with scan tool.
1. Install a scan tool.

2 64 FB 00
4HK1
00 0A 00 04 F4 F0 00 01 94
64 0B 08 10 2B 28 1E 26 17 16 31 7C 2. Turn ON the ignition, with the engine OFF.
3 64
64
CB
21
1A
17
00 2F
16 2B
3C
3A
29
2D
3DFF
4A 14
27
25
5A
65
F0
66 3. Select Diagnostics > Appropriate Vehicle
4 identification > appropriate engine model >
Programming > Injector Programming.
4. In order to get programming approval, the on
5 screen displays a message to user. Get
programming approval from the TIS 2000 using
the following procedure.
LNW81ASH000101
a. Cannot a scan tool to the terminal that installed
Legend TIS 2000 with the latest software and the
1. Cylinder #1 fuel injector ID code hardware key is plugged into port.
2. Cylinder #2 fuel injector ID code b. Turn ON the scan tool and keep at title screen.
3. Cylinder #3 fuel injector ID code
c. Launch the TIS application.
3. Cylinder #4 fuel injector ID code
5. Injector ID code label d. Select the Security Access at the main screen.
e. Highlight the Tech 2 on the Diagnostic Tool
Selection screen and click Next.
13. Install the gasket to the EGR valve (1), and tighten f. Click Close on the Security Access Enabled
at the specified torque (Euro3 specification and screen.
g. Turn OFF the scan tool.
Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) h. Disconnect the scan tool from the engine OFF.

5. Install a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle
identification > appropriate engine model >
Programming > Injector Programming.
8. Verify the fuel injector ID code, input 24 digits of
replaced fuel injector ID code.
9. After complete the programming, turn OFF the
ignition for 30 seconds.
10. Start the engine and let idle.
11. Inspect for a proper engine running condition and
for no DTC’s. Refer to Diagnostic System Check -
Engine Controls if needed.
Programming Fuel Injector ID Codes (Euro3

specification and Euro2 specification)
NOTE:
• When injector replaced, fuel injector ID codes is
written in ECM with scan tool.

identification > appropriate engine model >
Programming > Injector ID Code > ID Code
Registration.
4. Input 24 digits of each fuel injector ID codes.
NOTE:
The number of places required for input is 22 digits
except last 2 digits.
5. After complete the programming, turn OFF the

ignition for 30 seconds.
6. Start the engine and let idle.
7. Inspect for a proper engine running condition and
for no DTC’s. Refer to Diagnostic System Check -
Engine Controls if needed.

a
c
b
MFW91DLF000801
(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) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(f) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
(g) 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
(h) 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
(i) 12 N⋅m (1.2 kg⋅m/106 lb⋅in)

a
c
b
j e
g
h
MFW91DLF001101
(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) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(g) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(h) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
(i) 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
(j) 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
(k) 12 N⋅m (1.2 kg⋅m/106 lb⋅in)
Common Rail
Components
2
1
MFW81DLF000901
Legend
1. Common rail (Fuel rail) 4. Injection pipe clip
2. Common rail (Fuel rail) bracket 5. Fuel leak-off pipe
3. Injection pipe 6. Fuel pipe (High pressure)

7
3
2 4 6
1
MFW71DLF000201
Legend
1. Common rail (Fuel rail) 6. EGR valve gasket
2. Common rail (Fuel rail) bracket 7. EGR adaptor
3. Injection pipe 8. Fuel leak-off pipe
4. Injection pipe clip 9. Fuel pipe (High pressure)
5. EGR valve
Including the inside of the injector, the holes and gaps 2. Disconnect the fuel pressure sensor connector and
that are the fuel paths for the fuel system have an EGR valve connector (Euro3 specification and
extremely precise finish. Therefore, because there is Euro4 specification).
the possibility of damage if foreign material becomes 3. Disconnect the fuel leak-off hose from the leak-off
mixed in, cover the cap after removing parts, etc. to pipe.
prevent the entry of foreign material.
• Put a cover over the removed fuel hose and
fasten it facing upward using a wire.
Removal 4. Remove the EGR adaptor (2) and EGR valve (1)
1. Remove the air intake hose.

• Use packing tape, etc. to cover the EGR case 8. Remove the clip, and remove the fuel leak-off pipe
side opening to prevent foreign material from (2).
entering.
1 2
1
2
MFW71BSH003601
MFW71FSH000301
Legend
1. Fuel pipe (High pressure)
5. Remove the oil level gauge and guide tube. 2. Fuel leak-off pipe
6. Remove the injection pipe clip (2) and remove the
injection pipe (1).
9. Remove the common rail (2) and the common rail
bracket (1).
1 • Do not hold the flow damper, pressure limiter
and fuel pressure sensor. Make sure to hold the
common rail.
• Be careful not to damage the pressure sensor
connector.
MFW81DSH000801
Legend
1. Injection pipe
2. Injection pipe clip 1
2
7. Remove the fuel pipe (1).

MFW81DSH000501
Legend
1. Bracket
2. Common rail (Fuel rail)

Installation
1. Install the common rail bracket (1) and tighten it at 1 2 3
2. Install the common rail (2) and tighten it at the
specified torque.
MFW71BSH004601
Legend
1. Fuel pipe (High pressure)
2. Fuel leak-off pipe
3. Eye-bolt
4. Eye-bolt
1
2 5. Install the injection pipe and injection pipe clip, and
tighten them at the specified torques.
MFW81DSH000501 Common rail side
Legend tightening torque: 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
1. Bracket Injector side
2. Common rail (Fuel rail) tightening torque: 30 N⋅m (3.1kg⋅m/22 lb⋅ft)
3. Install the fuel leak-off pipe (2), and then tighten

the eyebolt and clip at their specified torque. Injection pipe clip
Tightening torque (3): 20 N⋅m (2.0 kg⋅m/14 lb⋅ft) Tightening torque: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(4): 20 N⋅m (2.0 kg⋅m/14 lb⋅ft) • Thinly apply engine oil to the outer
Cylinder head department: circumference of the injector side sleeve nut
12 N⋅m (1.2 kg⋅m/104 lb⋅in) and assembly it.
Clip tightening : 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
4. Install the fuel pipe (1) and tighten the sleeve nut at
Tightening torque: : 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
NOTE:
The fuel pipe (1) 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.

11. Install the air intake duct.
1
2
1
MFW81DSH000801
MFW71JSH000801
Legend
1. Injection pipe
6. Install the oil level gauge and guide tube.

7. Temporarily install the gasket to the EGR valve (1)
8. Insert the gasket into the EGR adaptor (2), install it
so that the both ends are firmly attached, and
tighten at the specified torque (Euro3 specification
and Euro4 specification).
• Tighten the EGR valve at the specified torque.
MFW71FSH000301
9. Install the fuel leak-off hose to the leak-off pipe and

fasten with the clips.
10. Check that there is a clicking sound when
connecting each connector with the engine
harness to securely connect them.

d
h
b
e f
g
m i
k j
MFW81DLF002001
(a) 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)

(b) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
(c) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(d) 22N⋅m (2.2 kg⋅m/16 lb⋅ft)
(e) 172 N⋅m (17.5 kg⋅m/127 lb⋅ft)
(f) 98 N⋅m (10.0 kg⋅m/72 lb⋅ft)
(g) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(h) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(i) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(j) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft))
(k) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
(l) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(m) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)

n b
f
m
d p
e
l o g
i h
MFW81DLF000601
(a) 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)

(b) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(c) 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
(d) 172 N⋅m (17.5 kg⋅m/127 lb⋅ft)
(e) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(f) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
(g) 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
(h) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
(i) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
(j) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(k) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
(l) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(m) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(n) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
(o) 20 N⋅m (2.0 kg⋅m/14 b⋅ft)
(p) 98 N⋅m (10.0 kg⋅m/72 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 DTC
code is extinguished and the operations are
Precautions for Maintenance
normal with the scan tool.
• Add a cleaning agent to the steam cleaner and
thoroughly clean the sensor and common rail
areas. Removal
• Completely remove the moisture with an air Fuel pressure sensor
blower.
1. Disconnect the harness connector of the fuel
• Start work after checking that all foreign material pressure sensor.
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. Connect 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.
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 or 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
1 2
6 5
MFW81DMF001601
Legend
1. Fuel pipe (High pressure) 4. Supply pump bracket
2. Fuel leak-off pipe 5. Oil level gauge guide tube
3. Air compressor 6. Supply pump

1 2
6 5 MFW71DMF000101
Legend
1. Fuel pipe (High pressure) 4. Supply pump bracket
2. Fuel leak-off pipe 5. Oil level gauge guide tube
3. Air compressor 6. Supply pump
Including the inside of the injector, the holes and gaps

that are the fuel paths for the fuel system have an
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. Remove the intake duct (2) that is located between
the intercooler and intake throttle valve.
1 2
MFW71DSH000901
7. Remove the fuel return pipe (1).

MFW71JSH001201
Legend
1. Rubber hose
2. Intake duct
2. Remove the oil separator together with the

bracket.
3. Remove the oil level gauge guide tube. 1
4. Remove the fuel pipe (Between the supply pump

and common rail).
• Remove the clip.
MFW71DSH001001
8. Remove the fuel temperature sensor.

9. Remove the supply pump and bracket.
• Remove the coupling and O-ring.
LNW71DSH001101
5. Disconnect the fuel temperature sensor connector

and suction control valve connector from the
supply pump.
6. Remove the fuel feed hose (1).
• Remove the fuel return hose (2) that is located
between the supply pump and fuel filter.
MFW81DSH000601 LNW71DSH001501
Legend
10. Remove the coupling from the supply pump. 1. Supply pump
2. O-ring
• Tighten the 2 bolts in the coupling screw holes
and after applying a turn stopper, remove the
nut.
• Put the puller on the 2 tightened bolts of the
coupling and remove the coupling. Installation
1. Install the O-ring (2) to the supply pump (1) with
the 3 mounting bolts and tighten to the supply
pump bracket (3) at the specified torque.
• Be careful of the O-ring protruding.
LNW71DSH001401
11. Remove the 3 bolts to remove the supply pump

bracket (3).
• Remove the O-ring (2).
LNW71DSH001501
Legend
1. Supply pump
2. O-ring

2. Install the alignment coupling to the supply pump 5. Install the fuel return pipe(1).
shaft key and tighten the nut at the specified
torque.
• Tighten 2 bolts to the coupling screw holes as a
turn stopper.
MFW81DSH001101
(a) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

(b) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
LNW71DSH001401
Tightening torque: 64 N⋅m (6.5 kg⋅m/47 lb⋅ft) 6. Install the fuel feed hose (1).
• Install the fuel return hose (2).
3. Install the O-ring to the supply pump and bracket,

and install to the air compressor via the coupling.
NOTE:
There is no need to align the position of the supply
pump claw.
MFW71DSH000901
7. Connect the fuel temperature sensor connector

and suction control valve connector to the supply
pump.
8. Install the fuel pipe (Between the supply pump and

common rail).
MFW81DSH000601
4. Install the fuel temperature sensor.


5. Start the engine and let idle until engine coolant
temperature reads 70°C (158°F) or higher while
observing the Fuel Supply Pump Status parameter
with a scan tool. The scan tool parameter changes
status Not Learned > Learned.
LNW71DSH001101
9. Install the oil separator together with the bracket.
10. Install the oil level gauge guide tube.

11. Install the intake duct (2) between the intercooler
and intake throttle valve.
1 2
MFW71JSH001201
Legend
1. Rubber hose
2. Intake duct
Supply Pump Relearn

3. Command the Fuel Supply Pump Learn Resetting
with the scan tool.
4. Observe the Fuel Supply Pump Status Parameter
with the scan tool. Confirm the scan tool indicates
Not Learned.

a b
c
i
g
e
MFW81DLF000701
(a) 52 N⋅m (5.3 kg⋅m/38 lb⋅ft)

(b) 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
(c) 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
(d) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(e) 20 N⋅m (2.0 kg⋅m/14 lb⋅ft) Common rail side
20 N⋅m (2.0 kg⋅m/14 lb⋅ft) Supply pump side
(f) 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
(g) 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(h) 44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
(i) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
Fuel Rail Pressure (FRP) Regulator

Component Parts
7
6
5
4
3
8
9
1 10
11
LNW71DMF002301
Legend
1. Bolt 7. Supply pump
2. Fuel rail pressure (FRP) regulator / Suction 8. O-ring
control valve (SCV) (Type A) 9. Gasket
3. Adapter 10. Fuel rail pressure (FRP) regulator / Suction
4. O-ring (large) control valve (SCV) (without adapter) (TypeB)
5. Spacer 11. Bolt
6. O-ring (small)
Maintenance Precautions • When replacing the FRP regulator, identify FRP

regulator type so that incorrect operation may be
• Add cleaning agent to the steam cleaner and
avoided. Refer to the following figures for
thoroughly clean the sensor and supply pump
identification.
areas.
• Completely remove the moisture with an air
blower.
• Start work after checking that all foreign matter has
been removed.
• After starting the engine, check to be sure that
there is no fuel leaking.
• After replacing valves, use a scan tool to check
that the trouble code is cleared and that operations
are normal.

Type A
1 2 3
1 2
6 5 4
LNW71DSH004801
MFW91DSH002801
Legend
1. Paint color Legend
2. Housing color 1. Adapter
2. Spacer
control valve (SCV)
Identification 4. Bolt
FRP regulator type
Paint color Housing color 5. O-ring (large)
6. O-ring (small)
Non paint or Brown
White A Type B
Pink Black
Non paint Black B 1
3 2
MFW91DSH002901
Legend
control valve (SCV)
2. Bolt
3. O-ring
Removal
1. Remove the band clip.
2. Disconnect the harness connector from the FRP
regulator.

3. Remove the FRP regulator and gasket from the 2. Install the adapter (1) to the FRP regulator.
supply pump (without adapter).
4. Remove the FRP regulator, spacer and adapter
from the supply pump (with adapter).
NOTE: 1
In some cases, the adapter may remain on the supply
pump side when FRP regulator is removed from the
supply pump. In such cases, insert the pick tool into a
cap hole (1) and pull it out.
At that time, do not pull with excessive force. If the
adapter is stuck, attach FRP regulator again (manually)
and straighten the FRP regulator adapter. This will
make pulling out the adapter easier.
LNW71DSH004701
3. Install the O-ring (large) (1) to the deeper groove of

the spacer as shown in figure.
2
1
LNW71DSH005101
5. Remove the O-ring (small) from the supply pump

(with adapter).
Installation
Installation (for A type FRP regulator) LNW71DSH004901
1. Install the O-ring (small) to the supply pump. Legend

• Clean O-ring groove before installing. 1. O-ring (large)
control valve (SCV)
4. Install the spacer to the FRP regulator.

• The O-ring side of spacer should face to the
FRP regulator.
NOTE:
Use care not to damage the O-ring when installing.
5. Install the FRP regulator with adapter to the supply

pump.
• Apply new engine oil to the FRP regulator O-
rings.
• Install two bolts hand-tight.

• Tighten both bolts in two stages, as follows: 3. Tighten the FRP regulator to the specified torque.
Tightening torque N⋅m (kg⋅m/lb⋅in) Tightening torque N⋅m (kg⋅m/lb⋅in)

Stage 1: Tighten both bolts to 4 (0.4 / 35) 9 (0.9 / 78)
Stage 2: Tighten both bolts to 9 (0.9 / 78)
4. Connect the harness connector to the FRP
NOTE: regulator.
Use care not to damage the O-ring when installing.
6. Connect the harness connector to the FRP Supply pump relearning

regulator. 1. Install a scan tool.
7. Install the band clip to the wiring harness. 2. Turn ON the ignition, with the engine OFF.
• The band clip should be installed in original 3. Command the Fuel Supply Pump Learn Resetting
position. with the scan tool.
4. Observe the Fuel Supply Pump Status Parameter
NOTE: with the scan tool. Confirm the scan tool indicates
Add a band clip to FRP regulator wiring to prevent its Not Learned.
interference with engine harness bracket. When adding
the clip, be careful not to pull the harness at the edge of 5. Start the engine and let idle until engine coolant
the FRP regulator connector. Cut extra portion of the temperature reads 70°C (158°F) or higher while
band clip. Ensure that the cut extra portion does not observing the Fuel Supply Pump Status parameter
interfere with other parts. with a scan tool. The scan tool parameter changes
status Not Learned > Learned.
MFW91DSH002601
Legend
1. Band clip
2. Do not let it be pulled
Installation (for B type FRP regulator)

1. Install the O-ring to the supply pump.
• Clean O-ring groove before installing.
2. Install the FRP regulator to the supply pump, and
temporarily tighten two bolts.
NOTE:
• Be careful so as not to pinch the O-ring during
installation.
• Temporarily tighten by hand until the FRP regulator
adheres the supply pump.
Fuel Temperature Sensor

Removal
1. Remove the supply pump.
• Refer to "Supply Pump" in this section.
2. Remove the fuel temperature sensor(1).
LNW81DSH000201
Installation
1. Install the fuel temperature sensor.
2. Install the supply pump.

• Refer to "Supply Pump" in this section.
Fuel Tank
Components
140L (30.8 Imp.gal) Tank type
2
1
7 6
MFW81DLF001201
Legend
1. Fuel feed hose or pipe 6. Drain plug
2. Fuel return hose or pipe 7. Fuel tank
3. Fuel tank bracket 8. Fuel tank unit
4. Fuel tank band 9. Outlet breather hose
5. Fuel filler cap

200L (44 Imp.gal) - Tank type: N
2 4
1
7
8
MFW81DMF001001
Legend
1. Fuel return hose or pipe 6. Fuel filler cap
2. Fuel feed hose or pipe 7. Drain plug
3. Outlet breather hose 8. Fuel tank
4. Fuel tank bracket 9. Fuel tank unit
5. Fuel tank band

200L (44 Imp.gal) - Tank type: M
3
2
MFWB1DLF000501
Legend
1. Fuel tank 4. Filler cap
2. Fuel tank band 5. Drain plug
3. Fuel tank bracket
Removal 5. Disconnect the fuel tank unit connector.

1. Disconnect the battery negative terminal. 6. Remove the fuel feed hose or pipe.
2. Loosen the fuel filler cap. 7. Remove the fuel return hose or pipe.
3. Drain the fuel from the drain plug. • Plug the hose or pipe so fuel does not spill, and
tie to the frame facing upward.
4. After the fuel has been drained, tighten the drain
plug at the specified torque. 8. Remove the fuel tank installation band nut and the
leading end of the band on the frame side.
Drain plug
9. Pull the fuel tank to the outside.
Tightening torque
NOTE:
140L Tank type 73.5 N⋅m (7.5 kg⋅m/54 lb⋅ft)
If the fuel tank cannot be pulled out, remove the bracket
200L Tank type: N 73.5 N⋅m (7.5 kg⋅m/54 lb⋅ft) to pull the fuel tank to the bottom side.
200L Tank type: M 19.6 N⋅m (2.0 kg⋅m/15 lb⋅ft)
1
a
3
MFW81DSH001001 MFW81DSH001201
Legend
1. Frame
(a) 1345 mm (53 in)
2. Fuel tank unit
3. Band
Bracket tightening torque
Installation 97.1 N⋅m (9.9 kg⋅m/71.6 lb⋅ft)
1. Install the fuel tank.
NOTE:
When removing the fuel tank, and the bracket is a
removed, install the bracket and tighten at the specified
torque.
When placing the fuel tank on the bracket, securely
place the rubber section attached to the fuel tank on to
the bracket.
140L (30.8 Imp.gal) - Tank type
47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

47.1 N⋅m (4.8 kg⋅m/35 lb⋅ft)
MNWB1DSH000201
(a) 720 mm (28.4 in)
2. Install the band to the fuel tank and tighten the nut
CAUTION:
• Make sure to tighten the nuts on both right and left
sides evenly.
• Tighten the tightening nut while holding the band
with a wrench to prevent it from turning.
• Tighten the lock nut while holding the fixing nut with
a wrench.
140L (30.8 Imp.gal) Tank type

Inside nut (3) 17.7 (1.8 / 13.0)
Outside nut (4) 20.6 (2.1/ 15.2)
200L (44 Imp.gal) Tank type: N

Inside nut (3) 17.7 (1.8 / 13.0)
Outside nut (4) 20.6 (2.1/ 15.2)

Tightening torque
Inside nut 16.5 N⋅m (1.7 kg⋅m/12 lb⋅ft)
Outside nut 16.5 N⋅m (1.7 kg⋅m/12 lb⋅ft)
2
4 3
MFW81BSH001801
Legend
1. Band
2. Bracket
3. Inside nut
4. Outside nut
3. Install the fuel return hose or pipe.

4. Install the fuel feed hose or pipe.
• The hose should fit more than 25 mm (0.98 in)
into the pipe.
5. Connect the fuel tank unit connector.
6. Fill the fuel tank with fuel, and replace the fuel filler
cap.
7. Connect the battery ground cable.
8. After starting the engine, check that there is no fuel
leak from the hose connections.

140L (30.8 Imp.gal) tank type
b
c
MFW81DLF001301
(a) 47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13.0 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)

b
c
MFW81DMF001101
(a) 47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)

c
d
MFWB1DLF000601
(a) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)

(b) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)
(c) 16.5 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(d) 16.5 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(e) 19.6 N⋅m (2.0 kg⋅m / 15 lb⋅ft)
Fuel Tank Unit

Component Parts
MFW81DMF000901
Legend
1. Fuel tank unit 2. Fuel tank

MFWA1DMF000601
Legend

1 2
MFWB1DMF001301
Legend
Removal Inspection
1. Disconnect 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 installment screw, and remove the fuel meter indicator.
fuel tank unit. 1. While moving the float from "E" to "F", inspect the
resistance value between the connector terminals.
NOTE: 2. Check that the low fuel level warning light lights up
• When removing and replacing the fuel tank unit, when the float is at the "E" position.
make sure there is no interference around the If any abnormality is found in the inspection
perimeter, and be sure not to distort the shape of the results, replace the meter with a normal one.
arm.
• After removing the fuel tank unit, cover it to ensure
debris does not enter the tank.
F point 3/4 point 1/2 point 1/4 point E point SE point
Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 66.0 139.6 215.5 291.5 368.8 379.9
mm (in)
flange (2.60) (5.50) (8.48) (11.48) (14.52) (14.96)
129.0 100.5 71.0 41.5 12.0 8.0
Tank capacity L (lmp⋅gal)
(28.4) (22.1) (15.6) (9.1) (2.6) (1.8)
Resistance value (Ω)
6.0 28 50 86 141 150
(Between terminal 2 and 3)
140L (30.8 Imp⋅gal) Tank type
2
h1
3 1
F
h2
h3
3/4
h4
h5
h6
1/2
1/4
SE
MFW81ELF000101

F point 3/4 point 1/2 point 1/4 point E point SE point
Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 53.5 114.1 171.6 233.0 295.8 303.4
mm (in)
flange (2.11) (4.49) (6.76) (9.17) (11.65) (11.94)
182.0 143.0 102.0 60.5 19.0 13.8
Tank capacity L (lmp⋅gal)
(40.0) (31.5) (22.4) (13.3) (4.2) (3.0)
6.0 28 50 86 141 150

3 2 1
h1
h2
F
h3
h4
3/4
h5
h6
1/2
1/4
SE
MFW81ELF000601

F point 3/4 point 1/2 point 1/4 point E point
Float position
(h1) (h2) (h3) (h4) (h5)
Distance from the 32.8 139.6 255 370.3 477.2
mm (in)
flange (1.29) (5.50) (10.04) (14.58) (18.79)
0 22.7 50 95.4 150

h1
1
2
F
h2
h3
3/4
h4
h5
1/2
1/4
MFWB1DLF000901
Installation
Follow the disassemble procedure in reverse order to
reassemble.
1. Install the fuel tank unit.
2. Connect the wiring connector to the fuel tank unit.
MEMO
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
Engine Electrical (4HK1) 1E-1
ENGINE
Engine Electrical
(4HK1)
TABLE OF CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1E-2
Description of Function and Operation . . . . . . . 1E-2
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1E-5
Phenomenon: The starter does not work even
when the engine control 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
engine control switch is turned OFF . . . . . . . . 1E-10
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-10
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-14
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1E-15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-21
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-22
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Maintenance Precautions . . . . . . . . . . . . . . . . 1E-24
Description of Function and Operation . . . . . . 1E-24
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 1E-26
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-26
Functional Inspection: . . . . . . . . . . . . . . . . . . . 1E-27
Failure Symptom List . . . . . . . . . . . . . . . . . . . 1E-28
Phenomenon: Does not charge at all . . . . . . . 1E-29
Phenomenon: Charge is insufficient . . . . . . . . 1E-30
Phenomenon: Overcharged . . . . . . . . . . . . . . 1E-31
Phenomenon: Charged current is unstable. . . 1E-32
Phenomenon: Abnormal sound in generator . 1E-33
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-34
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-37
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-45
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-46
1E-2 Engine Electrical (4HK1)
Starting System
Maintenance Precautions Starter
When performing maintenance on the electrical The starter is a magnetic shift type starter and is an
system, check that the engine control switch and outer gearing mesh method reduction starter.
lighting switch are off, and always disconnect the When the engine control switch is turned ON, the
battery negative terminal before working. plunger is drawn in, the contact point of the magnetic
switch closes and the armature rotates. At the same
time, the pinion is pushed to the front via the shift lever
Description of Function and Operation to mesh with the ring gear. When the ring gear rotates,
Starter circuit the crankshaft is turned to start the engine. After the
engine starts, the plunger returns, the pinion separates
The starting system is composed of the batteries, from the ring gear, and the armature stops rotating
starter, engine control switch, inhibitor switch (A/T when the engine control switch is turned OFF. When
vehicles only) and starter relay. Each of these main the engine rotation increases faster than the pinion, the
components are wired as shown in the starter circuit pinion will be caused to turn in reverse, but because
diagram. the pinion is idling by the one-way clutch operation, it
does not drive the armature.
4 5
ST
8
3
B
2
10
1
9
MFW51EMF000101
Legend
1. Pinion clutch 6. B terminal
2. Ring gear 7. Starter relay
3. Shift lever 8. Engine control switch
4. Magnetic switch 9. Batteries
5. S terminal 10. Armature

Starter motor
24V 4.5kW
3
4
5
6
2
1
MFW51EMF000201
Legend
1. Brush 5. Clutch
2. Yoke 6. Pinion
3. Magnetic switch 7. Armature
4. Torsion spring
Output characteristics
S25-511
P T1 N TV
Performance diagram
kW Nm r/min V
P
4.8 118 6000 24
TV
4.0 98 5000 20
3.2 78 4000 16
2.4 59 3000 12
T1
1.6 39 2000 8
N
0.8 20 1000 4
0 0 0 0
0 100 200 300 400 500 600 700 800 900 1000 1100
I (A)
MFW81ESF000101

Engine control switch
IG1 B2
ACC ST
B1
IG2
MFW71ESF000201
Starting circuit diagram
Engine control switch
Conne
ctor nu FL61
Ter mber
min
Engine al n
um
Te ber 4 5 6 1 2 3
control rm
ina
switch key ls
Batteries ign
position B1 ACC IG1 IG2 ST B2
When you extract

the key
OFF
ACC
When you
insert the key
ON
START
ENGINE
CONTROLLER
Slow blow fuse 6 F-20
50A
Slow blow fuse 5
30A
Slow blow fuse 2 STARTER

Starter relay F-13
60A
Starter cut relay

ECM
B S
ECM MAIN
F-33
Magnetic switch
Starter motor
MFW91ELF000201

• 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 engine control switch is turned OFF.

Phenomenon: The starter does not work even when the engine control switch is turned ON

The starter does not work even when Complete battery discharge Replace the battery
the engine control switch is turned ON Wiring circuit open circuit, improper Repair
connection
Defective contact of the engine control Repair or replace
switch 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 engine control
switch is turned OFF

After the engine starts, the starter does Improper return of the engine control Replace the engine control switch
not stop even if the engine control switch contact point
switch is 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.) S25-505G, S25-511

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

LNW21ESH001001
• Remove the 2 bolts on the top and bottom, and
remove the starter from the clutch housing.
LNW21ESH001101
2. Remove the harness terminal. LNW21ESH001001
• 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.
MFW81ESH000301 RTW46DSH003401
Legend
1. Brush
Inspection and Repair
8. Remove the yoke along with the armature and the Make the necessary adjustments, repairs, and part
brush holder from the gear case. replacement if excessive wear or damage is discovered
9. Remove the brush holder from yoke and armature. during inspection.
10. Remove the armature from yoke.
Armature
1. Measure the commutator runout.
Replace the commutator if the measured runout
exceeds the specified limit.
Commutator Runout 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

excessive wear.
3. Measure the mica segment depth.

If the measured outside diameter is less than the
specified limit, the commutator must be replaced.
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
3
HCW51ESH000901
4 5. Use a circuit tester to check the armature for

grounding.
a. Hold one probe of the circuit tester against the
commutator segment.
b. Hold the other circuit tester probe against the
5 armature core.
If the circuit tester indicates continuity, the
armature is grounded.
RTW56DSH000701 The armature must be replaced.
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. (4 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
2. Use the circuit tester to check the field winding RTW46DSH004001

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.
If the negative brushes have excessive wear, the 1. Attach the torsion spring to the hole in the
entire brush holder assembly must be replaced. magnetic switch as illustrated.
If the positive brushes have excessive wear, the 2. Insert the shift lever into the plunger hole of the
entire yoke must be replaced. magnetic switch.
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 Torque N⋅m (kg⋅m/lb⋅in)

10.6 (1.08 / 78)
LNW61DSH002701

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

RTW46DSH004501
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 Torque N⋅m (kg⋅m/lb⋅in)

8.1 (0.83 / 69.7)
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 Torque N⋅m (kg⋅m/lb⋅in)

8.6 (0.88 / 74.9)

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 3 to 5 seconds).
Temporarily connect the solenoid switch
between the clutch and the housing and run the
following test.
Complete each test within 3 to 5 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
Inspection After Reassembly S
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

• Disconnect the battery positive lead at the S • Tighten the B terminal (1) at the specified
terminal. torque.
The pinion should return to its home
position. Tightening torque: 7.5 - 10 N⋅m
(75 - 100 kg⋅cm / 65 - 87 lb⋅in)
1
2
MFWB1ESH000401
LNW21ESH001401
Installation Legend
1. B terminal
1. Install the starter ASM. 2. S terminal
• 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.
Tightening torque: 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
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
(10 - 15 kg⋅cm / 8.7 - 13.1 lb⋅in)

a b
c
d
MFW71EMF000201
(a) 7.5 - 10 N⋅m (75 - 100 kg⋅cm / 65 - 87 lb⋅in)

(b) 1 - 1.5 N⋅m (10 - 15 kg⋅cm / 8.7 - 13.1 lb⋅in)
(c) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
(d) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
Starter Switch
Removal Inspection
1. Remove the steering cowl. Inspect the continuity between the engine control
• Refer to “Steering Column and Shaft” in Section switch connector terminals.
6B, Power Steering. If any abnormality is found in the inspection results,
repair or replace it.
2. Remove the immobilizer control unit (1).
B2 ST IG2
+B
UNIT
KEYLESS 10mA
BUZZER 10mA
IG1 ACC B1
ENGINE CONTROL SWITCH KEYSWITCH
REMINDER
KEY B1 ACC IG1 IG2 ST B2 W W

PUT OFF
LOCK
ACC
PUT ON
ON
1 START
MFW81ESH000401
MFW76BSH000501
3. Remove the steering engine control switch (1).

• Disconnect the connector. Installation
• As a share bolt (of a type with a head that can Installation is in the reverse order of the removal.
be twisted off after it is tightened) is used for the
tightening bolt, use an extractor, reverse tap,
etc., to remove it.
MFW76BSH000601
Charging System
Maintenance Precautions • When charging from external equipment in such
cases as quick charge, disconnect the battery
When handling the generator, pay attention to the
terminal before working.
following points.
• Do not directly pour steam cleaner, water, etc.
• If the battery poles are reversely connected, the
diode of the generator will be damaged. • After the wiring, tighten B and E terminals at the
following tightening torques.
• Never disconnect the battery terminal and the
50A , 60A , 90A specifications
wiring of the charging circuit when the engine is
running. B terminal 11 N⋅m (1.1 kg⋅m / 96 lb⋅in)
• Make sure to connect each terminal wiring E terminal 4 N⋅m (0.4 kg⋅m / 35 lb⋅in)
according to the terminal symbol.
• Do not perform a megger test on semiconductor
devices. Description of Function and Operation
• When inspecting the equipment, make sure to Multi-function IC regulator
disconnect the battery negative terminal.
• Trouble diagnosis function
• Do not open and close the battery relay switch Trouble diagnosis is added to light the charge
when the engine is running. warning light when the feed coil circuit is open and
there is excessive voltage.
50A and 60A specifications
2 3
1 4
11
10
8
7 6
MFW71EMF000301
Legend
1. Regulator 7. Rotor
2. Field coil 8. Rear bracket
3. Stator 9. Rectifier
4. Ball bearing 10. B terminal
5. Pulley 11. Ball bearing
6. Front bracket

90A specification
3
2
1
4
11
5
10
8
6
7
MFW71EMF000401
Legend
1. Regulator 7. Rotor
2. Field coil 8. Rear bracket
3. Stator 9. Rectifier
4. Ball bearing 10. B terminal
5. Pulley 11. Ball bearing
6. Front bracket

Circuit Diagram
50A,60A,90A specifications
1
2
7 L
B S L
P
3
F
6
MIC
4
E
E
MFW71EMF000101
Legend
1. Charge warning light (LED) 5. Generator
2. Engine control switch 6. Field coil
3. Batteries 7. Stator coil
4. IC regulator
Nominal output V-A 24 - 50 24 - 60 24 - 90

Rated speed r/min 5,000 5,000 5,000
Regulator type IC Type
Adjusted voltage V 28 - 29
Mass kg (lb) 9.8 (21.6) 9.8 (21.6) 18.0 (39.7)

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 engine control 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.

• 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 the battery
Open circuit, short circuit and Repair
disconnection of connecting section of
wiring or current meter
Open circuit in each coil, ground short Replace the generator
circuit, or damaged diode of the
generator
Defective regulator Replace the regulator
Regulator terminal contact problem Repair

Phenomenon: Charge is insufficient

Charge is insufficient Defective battery Replace the battery
Open circuit, short circuit and Repair
disconnection of connecting sections of
wiring
Loose generator drive belt Adjust belt tension
Stator coil layer short Replace the stator coil
Diode failure Replace the diode
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 the diode
Short circuit in stator coil, or near open Replace the stator coil
circuit
Generator
Components
1
2
3
4
5
6
7
8
9
10
11
12
13
24
23
22
21
20
19 18
17 16
15
14
MFW61ELF000101
Legend
1. Pulley nut 13. Nuts (for tightening the cover)
2. Pulley 14. Rear cover
3. Fan 15. Screws (for installing the regulator)
4. Through bolts 16. Screws (for tightening the regulator)
5. Collar 17. Clamp
6. Front bracket 18. Regulator
7. Front bearing 19. Nut (for installing the rectifier)
8. Retainer 20. Rectifier
9. Screws (for tightening the retainer) 21. Screws (for installing the field coil)
10. Collar 22. Rear bracket
11. Rotor assembly 23. Stator
12. Rear bearing 24. Field coil

90A specification
1
2 3
4
5
6
7 8
9
10
11
12
13
14
23
15
26
25
17
24
23
22
21
20 19
18
16
MFW61ELF000201
Legend
1. Pulley nut 14. Rear bearing
2. Spring washer 15. Nuts (for tightening the cover)
3. Washer 16. Rear cover
4. Pulley 17. Screws (for installing the regulator)
5. Fan 18. Screws (for tightening the regulator)
6. Through bolts 19. Clamp
7. Collar 20. Regulator
8. Front bracket 21. Nut (for installing the rectifier)
9. Front bearing 22. Rectifier
10. Retainer 23. Screws (for installing the field coil)
11. Screws (for tightening the retainer) 24. Rear bracket
12. Woodruff key 25. Stator
13. Rotor assembly 26. Field coil

Removal • Disconnect the A/C compressor harness
connector, and remove the compressor from
1. Remove the A/C drive belt.
the A/C compressor bracket to fasten to any
• After loosening the tension pulley nut (1), position together with the hoses using a wire,
loosen the adjust bolt (2) and remove the drive etc.
belt (3).
1
2
MFW51ESH000301
MFW71ESH000101
90A specification 3. Disconnect the generator harness.

• Disconnect the B terminal cable and harness
connector from the generator.
1 4. Remove the fan belt.
2 3
• Loosen the nuts (2) and (3).
• Loosen the AC generator adjust bolt (1) and
remove the belt.
4 1
5
6
MFW71ESH000201
Legend
1. Tension pulley (Refrigerated vehicles)
2. Adjust bolt 3
3. Tension pulley nut
4. Tension pulley (Other than refrigerated vehicles)
5. Adjust bolt
6. Tension pulley nut MFW71ESH000301
2. Remove the A/C compressor. • After loosening the tension pulley (3) nut (2),
loosen the adjust bolt (1) and remove the belt.

90A specification 90A specification
1
1
3 2
2
MFW71ESH000401 MFW71ESH000601
5. Remove the tension pulley

(90A specifications).
Disassembly
• Remove 3 bolts and remove the tension pulley.
Disassembly Procedures
6. Remove the generator.
NOTE:
• Remove the nuts at 2 locations, pull out the
Place alignment marks to the front bracket and rear
bolts, and remove the generator.
bracket before disassembly to make it easy to
reassemble.
1 2
1. Remove the through bolts.
• Remove 3 though bolts (50A, 60A).
• Remove 4 though bolts (90A).
2. Remove the rear side cover.
• Remove 3 nuts.
• Remove 2 nuts of B terminal (90A).
3
MFW71ESH000501
Legend
1. Adjust bolt
2. Adjust plate lock nut
3. Though bolt
• After loosening the bolt (1) and though bolt (2),

pull out each bolt to remove the generator.

50A and 60A specifications 5. Remove the pulley nut with an impact wrench.
6. Remove the spring washer and flat washer (90A).
1 7. Remove the pulley.
8. Remove the fan.
9. Remove the woodruff key (90A).
10. Remove the collar.
11. Remove the rotor from the front bracket assembly.
B • Use a press, etc. when removing.
• Do not use a vise because the rotor will be
E deformed when it is fixed with a vise.
12. Remove the collar from the rotor (50A, 60A).
2 13. Remove the rotor from the front bracket assembly.
14. Remove the front bearing.
4 3
• When the front bearing has to be removed,
remove the retainer mounting screw and use an
MFW61ESH000501
appropriate socket to push out the bearing.
Legend NOTE:
1. Connector Do not remove it unless it is necessary. Do not reuse
2. B terminal the removed bearing.
3. Nuts
4. Cover 15. Remove the stator.
• Disconnect the stator coil lead wire at 4
90A specification
locations to remove the stator from the rectifier.
• Disconnect the stator coil lead wire at 7
1 locations to remove the stator from the rectifier
(90A).
NOTE:
Use a soldering iron to remove it quickly (within 5
seconds) so as not to overheat the rectifier and
damage the diode.
16. Remove the field coil terminal lead wire.

• Remove the screws (M4) that are connected to
the rectifier at 2 locations.
2
4 • Remove the soldering at 1 location that is
connected to the IC regulator.
3
NOTE:
Use a soldering iron to remove it quickly (within 5
MFW61ESH000701
seconds) so as not to overheat the IC regulator and
Legend damage the semiconductor.
1. Nuts
2. B terminal • Disconnect the IC regulator side lead wire from
3. Cover the clamp.
4. Nuts 17. Remove the mounting screw for the IC regulator.
18. Remove the IC regulator.
3. Remove the collar of B terminal (90A).
19. Remove the nut (at 1 location) that fixes the
4. Separate the front side and rear side.
rectifier.
• Use a dryer, etc. to warm the bearing room
before separating them.
• Separate them with a press using the hole that
the though bolt is removed.
NOTE:
Be careful not to damage the stator coil.

20. Remove the rectifier. 23. Remove the field coil.
50A and 60A specifications 24. Remove the rear bearing.
• When the rear bearing has to be removed, use
2 a press to remove it.
1
NOTE:
Do not remove it unless it is necessary. Do not reuse
7 the removed bearing.
Inspection method
1. Inspect the stator.
3
• Visually inspect for damage, loose connection
6 or discoloration of wiring.
4 • Inspect the continuity between the 2 stator coil
lead wires using a circuit tester.
If there is no continuity, replace the stator.
5
MFW61ESH000801
Legend
1
1. Screws
2. Soldering section
3. IC regulator
4. Rectifier
5. Nut
6. Screws
7. Clamp
90A specification
MFW61ESH000301
Legend
1. Stator coil lead
7
3 • Inspect the continuity between the stator coil
lead wire and the core using a circuit tester.
If there is continuity, replace the stator.
6
4
MFW61ESH000901
Legend
1. Screws
2. Soldering section
3. IC regulator
4. Rectifier
5. Nut
6. Screws
7. Clamp
21. Remove 3 mounting screws for the field coil.

22. Remove 4 mounting screws for the field coil (90A).

• Inspect the continuity between 4 diode
terminals of the positive diode using a circuit
tester.
If there is continuity in both directions,the
positive diode is shorted, so replace the
1
rectifier assembly. If there is no continuity in
both direction, the positive diode is open, so
replace the rectifier assembly.
• Inspect the continuity between 4 diode
terminals of the negative diode using a
circuit tester.
If there is continuity in both directions,the
negative diode is shorted, so replace the
rectifier assembly. If there is no continuity in
2 both direction, the negative diode is open, so
replace the rectifier assembly.
MFW61ESH000201
Legend
1. Core
2. Stator coil lead 1
3
2. Inspect the rotor.
• Inspect the bearing for abnormal noise,
looseness or grease leakage (if the amount is
small, just wipe it off), and replace it if an
abnormality is detected. For abnormal noise
and looseness, it is easier to inspect when it is
firmly fitted in the shaft rather than when it is 2
separated.
3. Inspect the field coil assembly.
• Measure the resistance between both ends of
the terminal section using a circuit tester. MFW61ESH000601
If the value is not within the standard value,
Legend
replace the field coil assembly.
1. Positive heat sink
2. A part of negative heat sink
3. Diode terminals
MFW61ESH000101
Legend
1. Terminal
MFW61ESH000401
4. Inspect the rectifier assembly.

5. Inspect the front bearing. 3. Tightening torque for each section
• Inspect the bearing for abnormal noise,
looseness or grease leakage (if the amount is
small, just wipe it off), and replace it if an Tightening torque N⋅m (kg⋅m/lb⋅ ft)
abnormality is detected. For abnormal noise Pulley nut (50A,60A
137 (14 / 101)
and looseness, it is easier to inspect when the specifications)
bearing is firmly fitted in the bracket rather than (90A specification) 245 (25 / 181)
when it is separated.
Though (50A specification) 6 (6.0 / 4)
6. Inspect the IC regulator.
bolt (60A,90A
• IC regulators cannot be inspected by a circuit 14 (1.4 / 10)
specifications)
tester.
After reassembling the generator, test the Bearing retainer 5 (0.5 / 4)
generator and inspect that the IC regulator is Field coil (50A,60A
controlling the generator voltage. 3 (0.3 / 2)
assembly specifications)
(90A specification) 5 (0.5 / 4)
Reassembly Rectifier 3 (0.3 / 2)
Reassembly can be performed in the reverse order of IC regulator 3 (0.3 / 2)
the disassembly. Only the important points are IC regulator and
described here. Also, be careful of the following points. 2 (0.2 / 1)
Rectifier mounting screw
1. Bearing is filled with grease and sealed, so there is
Cover 3 (0.3 / 2)
no need to apply grease.
B terminal nut 11 (1.1 / 8)
NOTE:
Never apply oil to the bearing of the rotor shaft with a NOTE:
resin band. Be careful not to tighten excessively.
If oil is attached to the bearing box section of the rear
bracket, completely wipe it off because it will cause the 4. Reassembly of rear bracket, stator assembly and
rear bearing to turn together. front bracket rotor assembly
• Since the rear bearing and the rear bracket
2. Use a high temperature solder (melting point
have to be fitted tightly, heat the bearing box
230°C / 440°F specification).
section of the rear bracket to 50 - 60°C (122 -
Perform soldering quickly (within approx. 5
140°F) before assembly.
seconds) using a 180 to 270 watt soldering
iron so that the rectifier will not be • After reassembling the generator, turn the
overheated. pulley by hand and confirm that the rotor
rotates smoothly.

Generator bench test
5
4
8
(3W less than) 6
MFW81EMF000101
Legend
1. Load resistance 5. Switch1
2. Generator 6. Switch2
3. Voltage meter 7. Battery (24V)
4. Current meter 8. Light (24V)
• Confirm that the light turns off before the speed

1. Adjusted voltage inspection reaches approximately 1,300 r/min.
Pay attention to the voltage. If the voltage
• Perform the wiring as shown in the diagram.
exceeds 30 V without being controlled, failures
Use a current meter with the rated current of
in IC regulator could be considered.
150 A, and a voltage meter with the rated
If the voltage does not exceed the battery
voltage of 30V.
voltage, the generator is not generating power.
Use a variable type with the rated current of
Inspect the generator again.
150 A or higher for the load resistance.
If the light does not turn off, inspect the
• Close the switch 1. Open the switch 2. generator again.
At this time, the light turns on.
• Increase the generator rotation speed to
If it does not turn on, inspect the L terminal
approximately 5,000 r/min and read the current
voltage.
meter.
If the voltage is close to the battery voltage,
If it is 5 A or lower, read the voltage meter. This
inspect the generator.
value is the adjusted voltage.
If the voltage is low, there is an open circuit in
If the voltage does not exceed the battery
the light or the light circuit.
voltage, the generator is not generating power.
If the current meter reading is 5 A or higher,
continue charging until it is 5 A or lower, or
replace the battery with a fully charged one.
If the adjusted voltage is not within the standard
value, replace the regulator.

2. Output current test 90A specification
Output current test is performed to inspect whether
Rotation 2,500 5,000
the generator can output as rated.
Speed r/min r/min
• After inspecting the adjusted voltage, decrease
the generator rotation speed and stop it. Output Voltage 27 V
characteristics
• Close the switch 1. Confirm that the light turns 80 A or 90 A or
(When heated) Current
on. more more
• Maximize the load resistance value (the current Field coil resistance
is minimized), and close the switch 2. 8.8 - 9.5 Ω
(At 20°C / At 68°F)
• Increase the generator rotation speed and
IC regulator
adjust the load resistance so that the output 28 - 29 V
Adjusted voltage
current is maximized while keeping the
generator speed at 5,000 r/min. Rotation direction (when seen
Clockwise
While keeping this condition, run the generator from the pulley side)
for 15 minutes to increase the generator
temperature.
After 15 minutes, set the generator rotation Installation
speed to the maintenance standard value
1. Install the generator.
(2,500 or 5,000 r/min). While keeping this
speed, adjust the load resistance so that the • Install the generator to the bracket and adjust
output current is maximized. If the current plate and temporarily tighten.
meter reading is within the maintenance
standard value, generator is normal. NOTE:
If it is below the maintenance standard value, • Insert the lower side mounting bolt (3) from the
follow the procedures in "Inspection Method" to front, and tighten it with a nut at the rear side as
inspect the generator again. shown in the diagram.
3. Maintenance standard values • Tighten the generator after adjusting the fan belt.
50A specification
Speed r/min r/min
2
Output Voltage 27 V
characteristics
42 A or 50 A or
(When heated) Current
more more
Field coil resistance 1
8.3 - 9.1 Ω
(At 20°C / At 68°F)
IC regulator
28 - 29 V
Adjusted voltage
3
Rotation direction (when seen
Clockwise
from the pulley side)
60A specification
Speed r/min r/min MFW71CSH001701
Output Voltage 27 V Legend

characteristics 1. Bolt
42 A or 50 A or
(When heated) Current 2. Adjust plate lock nut
more more
3. Though bolt
Field coil resistance
8.3 - 9.1 Ω • Temporarily tighten the mounting bolt to the
(At 20°C / At 68°F)
lower and upper generator brackets.
IC regulator
28 - 29 V
Adjusted voltage NOTE:
Rotation direction (when seen • Insert the lower side mounting bolt (2) from the
Clockwise
from the pulley side) front, and tighten it with a nut at the rear side as
shown in the diagram.

90A specification Belt tension adjustment value
Belt types Amount of Frequency
1
flex of vibrations
(mm / in) (Hz)
Generator New 5-7/ 197 - 221
drive belt belt 0.2 - 0.3
a ; 50, 60A
Reused 7-9/ 168 - 182
specifications
belt 0.3 - 0.4
Generator New 5-7/ 190 - 212
b ; 90A
Reused 7-9/ 163 - 175
specification
2 belt 0.3 - 0.4
A/C New 16 - 21 / 68 - 82
3 Reused 21 - 24 / 59 - 67
MFW71ESH000701
belt 0.83 - 0.94
Legend
1. Adjust bolt NOTE:
2. Though bolt
• A V-ribbed belt is used for the generator drive belt,
3. Lower generator bracket
which requires more accurate tension adjustment
than conventional V belt. Therefore, use a sonic
2. Install the tension pulley (90A specifications).
tension meter to check that the measured frequency
• Temporarily install the fan belt to each pulley of vibrations is within the adjustment value. Perform
(crank, water pump, and generator) and tighten adjustment if the value is improper.
the tension pulley with 3 bolts so that the belt Improper tension causes the belt life to shorten or
contacts the backside of the tension pulley. the belt to squeak.
Tightening torque: 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft) • After the adjustment, securely tighten each bolt.
NOTE:
• Consider the 5th re-tightening of the tension pulley
fixing bolt as the recommended time for
replacement.
• Be careful as the threaded portion may be damaged
or loose if it is reused continuously.
3. Install the fan belt.

• Install the fan belt and adjust belt tension.
• Refer to "Drive Belt" in Section 1C, Cooling
System.
Adjust it so that the amount of flex is within the
proper values as shown in the following table when
the arrow section in the engine layout diagram is
pressed with a pressure of 98 N (10 kg / 22lb).
a
1
b 1
MFW51ESH000301
2 6. Connect the A/C compressor harness connector.

7. Install the A/C drive belt.
Inspection
Inspect the drive belt for wear or damage and replace it
with a new one as necessary.
Also inspect the belt tension. Adjust the tension if
LNW71EMH000201 necessary.
Legend
1. A/C drive belt
2. Generator drive belt
4. Connect the generator harness.

• Connect 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.

c
MFW71CSF000101
(a) 76 N⋅m (7.7 kg⋅m / 55.7 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
(c) 126 N⋅m (12.8 kg⋅m / 92.6 lb⋅ft)
90A specification
b
c
LNW71CSF000401
(a) 40 N⋅m (4.1 kg⋅m / 29.7 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
(c) 41 N⋅m (4.2 kg⋅m / 30.4 lb⋅ft)
Emission Control (4HK1 Euro4 specification and Euro3 specification) 1F-1
ENGINE
Emission Control
(4HK1 Euro4 specification and Euro3 specification)
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-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6
List of Tightening Torques . . . . . . . . . . . . . . . . 1F-10
1F-2 Emission Control (4HK1 Euro4 specification and Euro3 specification)
EGR System
Maintenance Precautions Description of Function and Operation
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.
Cooling water outlet Cooling water inlet
5
6
Engine speed
Engine load
MFW81FLF000301
Legend
1. ECM 4. EGR cooler
2. EGR position sensor 5. Intake pipe
3. EGR valve 6. IAT sensor

Cooling water outlet Cooling water inlet
5
6
Engine speed
Engine load
MFW81FLF000201
Legend
1. ECM 5. Intake throttle valve
2. EGR position sensor 6. MAF sensor
3. EGR valve 7. Intake throttle position sensor
4. EGR cooler
EGR Valve and EGR Cooler

Components
4
3
5
4
6
7
4
8
4
MFWB1BLF005301
Legend
1. EGR valve 5. EGR cooler assembly
2. EGR valve gasket 6. Right side EGR cooler duct
3. Left side EGR cooler duct 7. EGR cooler bracket
4. EGR cooler duct gasket 8. EGR cooler pipe

4
13
5
6
13 13
7
8
10
13 14
11 9
12
MFWB1BLF005201
Legend
1. EGR valve 8. EGR cooler heat protector
2. EGR valve gasket 9. EGR cooler duct ;1st
3. EGR pipe gasket 10. EGR cooler assembly ;1st
4. EGR pipe 11. Bracket
5. EGR cooler assembly; 2nd 12. EGR cooler duct; 2nd
6. Plate 13. EGR cooler gasket
7. Bracket 14. EGR cooler duct gasket
Removal 5. Remove the front side EGR cooler duct (Euro4

specification).
1. Drain the coolant.
2. Disconnect the EGR valve connector. Remove the EGR pipe (Euro3 specification).
3. Remove the water rubber hose.
4. Remove the EGR cooler heater protector (Euro4 NOTE:
specification only). After removing the EGR cooler duct, seal it so that
foreign material does not get in.

Euro3 specification • For details on the EGR valve electro-magnetic
system, refer to "Engine Control System" in
Section 1A, Engine Control System.
3
4
2 Installation
If the procedures or methods for assembling the EGR
5
device are mistaken, that can lead to cracks of pipe or
6 gas leaks. Always follow the procedures.
Euro3 specification
1. Install the EGR valve to the inlet cover.
1
• Insert the gasket and temporarily install the
EGR valve.
2. Install the Left side EGR cooler duct.
• Insert the gasket and temporarily install the Left
side EGR cooler duct.
MFW81FSH000101
3. Install the right side EGR cooler duct.
Legend • Insert the gasket and temporarily install the
1. EGR pipe right side EGR cooler duct.
2. EGR cooler duct 4. Install the EGR cooler Assembly.
3. EGR cooler
• Fit the gasket into both ends of the EGR cooler
4. EGR cooler duct
Assembly and temporarily install it.
5. EGR valve
5. Install the EGR pipe.
6. Remove the EGR cooler Assembly; 1st. (Euro4 • Insert the gasket and temporarily install the
specification only) EGR pipe.
7. Remove the right side EGR cooler duct. After temporarily installing, securely tighten it.
NOTE: 6. Tighten the EGR valve and inlet cover at the

After removing the EGR cooler duct, seal it so that specified torque.
foreign material does not get in.
8. Remove the EGR cooler Assembly; 2nd. (Euro4
specification)
Remove the EGR cooler Assembly. (Euro3

specification)
9. Remove the Left side EGR cooler duct.
10. 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, LNW71FSH000401
repair it or replace the part.
Inspection of the EGR valve 7. Tighten the EGR pipe, EGR cooler Assembly and
EGR cooler duct at the specified torque in the
• Clean if there is carbon buildup.
order numbered in diagram.

a. Left side EGR cooler duct and EGR valve bolt e. Bracket mounting bolt (5)
(1)
Tightening torque: 24 N⋅m(2.4 kg⋅m/17 lb⋅ft)
f. Right side EGR cooler duct and EGR cooler
b. Left side EGR cooler duct and cylinder head Assembly (6)
bolt (2)
g. EGR pipe and exhaust manifold nut (7)
c. Left side EGR cooler duct and EGR cooler
Assembly bolt (3) Tightening torque: 31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) h. Right side EGR cooler duct and EGR pipe bolt
(8)
d. Right side EGR cooler duct and bracket bolt (4)
Tightening torque: 24 N⋅m (2.4 kg⋅m/17lb⋅ft)
4
5
1
6
8
7
MFWB1BMF004601
3. Install the right side EGR cooler duct.

8. Install the water pipe rubber hose. • Insert the gasket and temporarily install the
• Install the clip to the specified position. right side EGR cooler duct.
9. Connect the EGR valve connector. 4. Install the EGR cooler Assembly; 2nd.
10. Refill the coolant. • Fit the gasket into both ends of the EGR cooler
Assembly and temporarily install it.
5. Install the front side EGR cooler duct.
Euro4 specification • Insert the gasket and temporarily install the
1. Install the EGR valve to the inlet cover. front side EGR cooler duct.
• Insert the gasket and temporarily install the 6. Install the EGR cooler Assembly; 1st.
EGR valve. • Fit the gasket into both ends of the EGR cooler
2. Install the Left side EGR cooler duct. Assembly and temporarily install it.
• Insert the gasket and temporarily install the Left
side EGR cooler duct.

After temporarily installing, securely tighten it. h. Front side EGR cooler duct and EGR cooler
Assembly;1st bolt (7)
7. Tighten the EGR valve and inlet cover at the Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
specified torque.
i. Front side EGR cooler duct and bracket bolt (9)
LNW71FSH000401
8. Tighten the EGR cooler Assembly and EGR cooler

duct at the specified torque in the order numbered
in diagram.
a. Left side EGR cooler duct and EGR valve bolt
(1)
b. Left side EGR cooler duct and cylinder head
bolt (2)
c. Right side EGR cooler duct and bracket bolt (3)
d. Left side EGR cooler duct and EGR cooler
Assembly bolt (4)
e. Right side EGR cooler duct and EGR cooler
Assembly; 2nd bolt (5)
f. Right side EGR cooler duct and EGR cooler
Assembly;1st bolt (6)
g. Front side EGR cooler duct and exhaust
manifold nut (8)
9
5
2
1 6
3
6 8
MFWB1BMF004701
9. Install the EGR cooler heat protector and tighten it

10. Install the water pipe rubber hose.
• Install the clip to the specified position.
11. Connect the EGR valve connector.

Euro3 specification
h d
e
g
f
MFWB1BLF005501
(a) 24 N⋅m (2.4 kg⋅m/17 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) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(f) 31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
(g) 28 N⋅m (2.9 kg⋅m/21 lb⋅ft)
(h) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(i) 104 N⋅m (10.8 kg⋅m/78 lb⋅ft)
(j) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)

Euro4 specification
k
j
i h g f
MFWB1BLF005701
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(d) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(e) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(f) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(g) 35 N⋅m (3.6 kg⋅m/26 lb⋅ft)
(h) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(i) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
(j) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(k) 104 N⋅m (10.6 kg⋅m/77 lb⋅ft)
(l) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
MEMO
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
Engine Exhaust (4HK1 Euro4 specification) 1G-1
ENGINE
Engine Exhaust
(4HK1 Euro4 specification)
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
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
List of Tightening Torques . . . . . . . . . . . . . . . . 1G-12
Diesel Particulate Defuser (DPD). . . . . . . . . . . . 1G-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Exhaust Temperature Sensor. . . . . . . . . . . . . . . 1G-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-18
Exhaust Differential Pressure Sensor . . . . . . . . 1G-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-19
1G-2 Engine Exhaust (4HK1 Euro4 specification)
Exhaust System
Vibrations and looseness of the exhaust system are Exhaust brake assembly adjusts the exhaust pressure
caused by miss positioning when assembling. to perform brake assistance,, etc. Diesel particulate
Temporarily install all bolts until all components are diffuser (DPD) is equipped at the rear side of the
positioned. After positioning is completed, tighten them exhaust brake valve. The DPD is an integrated
from the engine side to the rear side. structure with the oxidation catalyst and filter. The
oxidation catalyst and filter clean exhaust gas. The
trapped PM (particulate matter) is combusted to
regenerate the filter when a certain pressure difference
between front and back of the filter is detected, and
when traveling a fixed distance. The tail pipe is
equipped with the silencer to increase the silencing
effect. The main components are: a front exhaust pipe,
exhaust brake, DPD, exhaust throttle, rear exhaust
pipe and tail pipe.
3 4
2
1
MFW81GMF000701
Legend
1. Front exhaust pipe A 5. Exhaust throttle
2. Exhaust brake assembly 6. Exhaust silencer
3. Front exhaust pipe B 7. Tail pipe
4. DPD assembly

• 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, DPD 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.
• If a DTC relating to DPD is detected, inspect and
repair according to the troubleshooting of the DPD.
NOTE:
Before disassembling, use the scan tool to check the
DPD pressure difference, status and inspection/
maintenance contents. For details, refer to "Engine
Control System" in Section 1A, Engine Control System
(4HK1).

• Vibrations and Rattling Sounds from the Exhaust
System
• Clogging of the Exhaust System
• Exhaust Gas Leak, Noise

Phenomenon: Vibrations and Rattling Sounds from the Exhaust System

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

Phenomenon: Clogging of the Exhaust System

Clogging of the exhaust system The exhaust brake and exhaust throttle Inspect and repair the control system.
are ON Refer to "Engine Control System" in
Section 1A, Engine Control System
Also, inspect the exhaust brake and
exhaust throttle shaft for strain. Replace
if there is a problem
Clogging of the exhaust pipe Repair or replace the exhaust pipe
DPD related DTC detection Inspect and repair according to the
engine control version troubleshooting
relating to DPD. Refer to "Engine
Control System" in Section 1A, Engine
Control System

Phenomenon: Exhaust gas Leak, Noise

Exhaust gas leak, noise Improper installation or connection Retighten after aligning the connections
Exhaust pipe, silencer or DPD damage, Replace the damaged parts
burning
Defective exhaust system components Replace the defective
(clamps, pipe, silencer)
Internal damage on DPD or silencer Replace the damaged parts
Exhaust Pipe
Removal 4. Remove the exhaust pipe adaptor (3).
NOTE:
Before disassembling, use the scan tool to check the
DPD pressure difference, status and inspection/
maintenance contents. For details, refer to "Engine
Control System" in Section 1A, Engine Control System
(4HK1).
1. Remove the tail pipe (1) from the silencer.

2. Remove the exhaust silencer assembly (2).
1 2 3 4 5 6 7
1
MFW81GSH001701
2 Legend
1. DPD assembly
2. Gasket
3. Exhaust pipe adaptor
4. Gasket
5. Exhaust throttle assembly
6. Gasket
7. Exhaust silencer
MFW81GSH001501
5. Disconnect the DPD exhaust temperature sensor
3. Remove the exhaust throttle assembly. connectors (2 pieces).
6. Remove the DPD differential pressure hoses (2
pieces).

7. Remove the DPD assembly (6) from the front pipe.
4 1 2
2 3
6
MFW81GSH002501
MFW81GSH001601
Legend
Legend 1. Differential pressure sensor assembly
1. Exhaust temperature sensor 2 (Catalyst inlet 2. Tightening screw (never loosen)
side)
2. Exhaust temperature sensor 1 (Catalyst outlet
side) 8. Remove the front exhaust pipe A (1) and B (3).
3. Differential pressure hose (Front) • Remove the clamp, and remove the front
4. Differential pressure sensor assembly exhaust pipe.
5. Differential pressure hose (Rear)
• Remove the exhaust brake assembly (2).
6. DPD assembly
NOTE:
If it is unavoidable to remove the differential pressure
sensor assembly, be careful of the following points.
• Absolutely never loosen the 4 differential pressure
sensor installation screws (2). If they are loosened,
replace the differential pressure sensor assembly. 3
2
• Do not reuse the differential pressure sensor ASM if
it was dropped. 1
• Do not use a tool such as an impact wrench which

causes vibrations when removing the sensor
assembly.
MFW81GSH001801
Installation
NOTE:
• Vibrations and looseness of the exhaust system
are caused by miss positioning when assembling.
Therefore, temporarily tighten all bolts until all
components are positioned, and completely
tighten from the engine side to the tail pipe side.
• Do not reuse the removed gasket and nut.
1. Install the front exhaust pipe A.


• Install the front exhaust pipe A to the exhaust
manifold and tighten it at the specified torque. 2
1
NOTE:
Uniformly tighten the front exhaust pipe so that there is 3
no exhaust gas leak.
2. Install the exhaust brake assembly.

• Install the exhaust brake assembly (2) and front 4
exhaust pipe B (3) to the front exhaust pipe A
(1), and tighten them at the specified torque.
5
6
MFW81GSH002601
Legend
1. Differential pressure sensor assembly
2. Tightening screw (Never loosen)
3 3. Differential pressure hose (Rear)
2 4. Differential pressure hose (Front)
1
5. Clip for differential pressure hose
6. Bulge section
5. Install the DPD exhaust temperature sensor

harness connector.
NOTE:
Do not mistake the front and rear directions.
MFW81GSH001801
3. Install the DPD assembly to the front pipe. 6. Install the exhaust pipe adaptor to the DPD.
Tightening torque: 85 N⋅m (8.7 kg⋅m/63 lb⋅ft) Tightening torque: 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
4. Install the DPD differential pressure hose. 7. Place the exhaust throttle assembly in the exhaust
• Insert the differential pressure hose surely to pipe adaptor and install the exhaust silencer
the bulge part of the pipe. assembly.
• Insert the clip of hose surely. Tightening torque: 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
NOTE:
• Do not mistake the front and rear directions.
• Do not use cracked hoses.
• Absolutely do not over-tighten or remove the
differential pressure sensor ASM tightening screw.
• There is the danger of the sensor miss operation
when there is a gas leak from the joint sections.
After starting the engine, check that no gas is
leaking.
it was dropped.
• Do not use a tool such as an impact wrench, etc., to
apply vibrations when installing the differential
pressure sensor.

9. Install the exhaust silencer assembly.
10. Install the tail pipe.
• Tighten the clamp.
NOTE:
• The clamp bolts in sequence, upper and lower.
• Install the clamp on an even keel.
1 2 3 4 5 6 7
MFW81GSH001701
Legend
1. DPD assembly
2. Gasket 1
3. Exhaust pipe adaptor
4. Gasket 2
5. Exhaust throttle assembly
6. Gasket
7. Exhaust silencer assembly
8. Install the air pipe to the air cylinder of the exhaust

throttle assembly.
MFW81GSH001501
4
Legend
3
1. Tail pipe
2 2. Exhaust silencer assembly
1
NOTE:
Start the engine after assembling each part, and check
5 for gas leakage from each joint and for vibration. When
the DPD assembly is disassembled, carefully check for
gas leakage as follows.
• Adequately warm up the engine.
• Rev the engine to its maximum speed. While
keeping this state, spray soapy water on differential
6 pressure hose connections and sleeve nut tightened
section to check for gas leakage.
MFW81GSH001201
Legend
1. Exhaust temperature sensor 2 (Catalyst inlet
side)
2. Exhaust temperature sensor 1 (Catalyst outlet
side)
3. Differential pressure hose (Front)
4. Differential pressure sensor
5. Differential pressure hose (Rear)
6. DPD assembly

e f
a c
b
MFW81GLF000701
(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) 85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
(e) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(f) 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
(g) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
Diesel Particulate Defuser (DPD)

Removal a. Paint the arrow mark (1) on the filter case so
that exhaust gas flow direction may be
1. Remove the DPD assembly.
distinguished.
Refer to “Exhaust Pipe” in this section.
Disassembly
1
1. Remove the differential pressure pipe.
a. Loosen the sleeve nuts (3),(5) fastening the
differential pressure pipe.
b. Remove the clips (4) that are fastening the
differential pressure pipe.
c. Remove the differential pressure pipe (1),(2).
1 2 3
MFW81GSH004201
b. Loosen the nuts tightening the oxidation

catalyst section and separate the oxidation
catalyst section (1), and filter section.
c. Loosen the nuts that are tightening the filter to
separate the filter (3) and the rear case (5).
NOTE:
Do not apply a strong impact to the DPD assembly or
5 4 drop it.
MFW71GSH003401
Legend
1. Differential pressure pipe (Front) 4 5
3
2. Differential pressure pipe (Rear )
3. Sleeve nut (Rear )
2
4. Clip
5. Sleeve nut (Front)
2. Remove the exhaust temperature sensors

1
(Catalyst inlet side, catalyst outlet side).
Refer to "Exhaust Temperature Sensor" in this
section.
3. Disassemble the DPD assembly.
MFW71GSH003301
Legend
1. Oxidation catalyst section
2. Gasket
3. Filter section
4. Gasket
5. Rear case

Inspection NOTE:
Set the DPD assembly so that arrow mark, which was
1. Externally inspect the exhaust pipe components.
painted at disassembly operation, face up.
cabin. Be careful.
exhaust gas leaks.
cracks or damage.
• Inspect the pipe or silencer for dents, or cracks
caused by corrosion. If damaged, repair or replace
them.
2. Inspect the DPD related parts.
• Visually check the filter for erosion, damage or
clogging.
• Shine light on the filter from the opposite side. If
the light is visible from the other side of the filter
(1), replace the filter.
MFW81GSH004101
2. Supply air up to the given pressure of 0.4 MPa(4.0

kg/cm2 / 58 psi) in the air tank.
1 Stop supplying when the air is pressurized up to
given pressure.
CAUTION:
Do not supply air exceed 0.5MPa (5.0 kg/cm2 / 73 psi)
to the tank as indicated by the manometer mounted on
the pressure regulator.
At this point, check for air leaks from the pipe without
fail.
2 3. Press the device’s mechanical valve for three

seconds. Implement backwashing and cleanse the
DPD filter.
MFW41GSH001101 4. Repeat the work described in STEP2 and STEP3
Legend three times.
1. Filter
CAUTION:
2. Filter case
Ash may escape from the exhaust filter and
backwashing noises may be heard while in use.
Wear protective equipment, such as dust masks, safety
3. Install the oxidation catalyst section.
goggles and earplugs and operate the equipment while
• Visually check the oxidation catalyst for keeping the face and hands at a safe distance.
erosion, damage or clogging.
Reassembly
Filter cleaning
1. Reassemble the DPD assembly.
Ash cannot be regenerated by combustion unlike
particulate matter (PM). NOTE:
Because the ash is calcined (tightly stuck) to the DPD • The DPD assembly must be installed with arrow
filter. mark (1), which was painted at disassembly
In order to remove ash, use a DPD ash removal device. operation, in the opposite direction of exhaust gas
Refer to DPD ash removal device handling manual for flow.
the handling of DPD ash removal device. • Do not reuse the removed gasket, nut and bolt.
1. Set the DPD filter to the DPD ash removal device.
4 5
3
1
2
MFW81GSH004301 MFW41GSH001001
a. Insert a new gasket (4) between the filter Legend

section (3) and the rear case (5), and 1. Oxidation catalyst section
temporarily tighten it using new nuts and bolts. 2. Gasket
b. Insert a new gasket (2) between the filter 3. Filter section
section (3) and the oxidation catalyst section 4. Gasket
(1), and temporarily tighten it using new nuts 5. Rear case
and bolts.
2. Install the exhaust temperature sensors (catalyst
NOTE: inlet side, catalyst outlet side).
Refer to "Exhaust Temperature Sensor" in this
• Check that assembly position of the filter, and the
section.
rear case and the filter and oxidation catalyst
section. Tighten both pipe brackets at 2 locations. Tightening torque: 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
c. Tighten the nuts and bolts at the specified 3. Install the differential pressure pipe.
torques.
CAUTION:
• Tighten all nuts and bolts twice.
• If the procedures above are not observed, there is
Tightening torque: 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) the danger of the sleeve nut coming loose.
NOTE: a. Tighten the sleeve nuts of the differential

After tightening all nuts and bolts, within specified pressure pipes (Front) (Rear) with your hand.
tightening torque be sure to tighten them again to the
same torque. (Tighten twice) NOTE:
Wipe away the old seizure inhibitor and apply new
inhibitor on the sleeve nut threaded portion .
Used seizure inhibitor:

Bostik Never-Seez high temperature stainless grade
5-87411-039-0
b. Fasten differential pressure pipe with a clip.

Tightening torque: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
c. Install the sleeve nuts (3),(5) of the differential
pressure pipe by specified torque.
Tightening torque
Sleeve nut front 35 N⋅m (3.6 kg⋅m / 26 lb⋅ft)
Sleeve nut rear 35 N⋅m (3.6 kg⋅m / 26 lb⋅ft)
1 2 3
5 4
MFW71GSH003401
Legend
1. Differential pressure pipe (Front)
2. Differential pressure pipe (Rear)
3. Sleeve nut (Rear)
4. Clip
5. Sleeve nut (Front)
Installation
1. Install the DPD assembly.
Refer to “Exhaust Pipe” in this section.

Inspection
0-point correction of the differential pressure
sensor
Perform 0-point correction on the differential pressure

sensor when the differential pressure sensor ASM has
been replaced. (on vehicle) 1
1. Turn the key from the OFF state to the ON state.

(Engine does not start.)
2. DPD light turns on, and then turns off after
approximately 30 seconds.
3. After checking that the DPD light is extinguished,
turn the key off and leave for at least 15 seconds.
NOTE: 2
Performing 0-point correction tend to receive the
4 3
influence by heat easily. Do not perform corrections
until 2 hours after regenerating DPD.
MFW81GSH004001
DPD Regenerate Programming Procedure Legend

DPD Regenerate data reset 1. Pressure hoses
2. Sleeve nut (Rear)
• Carry out the following steps when changing the 3. Clips
DPD. 4. Sleeve nut (Front)
1. Install the scan tool.
Filter Inspection
identification > Engine > 4HK1-TC (C/Rail) > Inspect the differential pressure.
Programming > DPD Regeneration data Perform after installing the DPD to the vehicle.
reset. 1. Start the engine and confirm there is no exhaust
4. Initiate the reset function in accordance with leakage from the DPD related parts (such as DPD
the onscreen instructions. sensor, differential pressure sensor, and
connecting parts of hoses).
5. After the reset is complete, if the “Programming
Completed Successfully” message is displayed, 2. Inspect the differential pressure.
follow the onscreen instructions to advance the a. Observe the Exhaust Temperature 1 parameter
end procedure. with a scan tool. Make
sure the temperature is less than
Air-tightness check 150°C (302°F). If more than 150°C
(302°F), let increase 1,000 r/min without load.
Check for air-tightness when the DPD is disassembled
(Rotate the idle up sensor clockwise.)
and reassembled (when installed to vehicle).
b. Accelerate the engine to W.O.T. (accelerator
1. Warm up the engine and rev the engine to the
pedal full travel) and read the Exhaust
maximum speed with no load.
Differential Pressure parameter when the
2. With the engine revved, check the pressure hoses Exhaust Temperature 1 parameter is reached
(1) connections, sleeve nuts (2) and (4) to 200°C (392°F).
connections, for gas leaks by spraying soapy
3. If the inspection value is higher than limit value,
water on them.
replace the filter.
Limit; 4HK1-TC 4.0 kPa(0.041 kg/cm2 /0.58 psi)
NOTE:
After replacement of the DPD filter, perform DPD status
resetting.
Exhaust Temperature Sensor

Removal
1. Remove the exhaust temperature sensor 4
connectors (2 pieces).
2. Remove the clip that is holding the exhaust 5
temperature sensor harness in place.
2 3
3. Remove the exhaust temperature sensor (2
pieces). 1
NOTE:
• Wipe away the old seizure inhibitor and apply new
inhibitor on the sleeve nut threaded portion.
Used seizure inhibitor:

Bostik Never-Seez high temperature stainless grade
5-87411-039-0
6
However, it is not necessary to apply the anti-seize
compound when using a new sensor, as it is already
MFW81GSH001601
applied.
Legend
• When assembling, do not hit the tip of the sensor to
1. Exhaust temperature sensor 2 (Catalyst inlet
the other boss.
side)
• Do not use a sensor which has flaws or dents from 2. Exhaust temperature sensor 1 (Catalyst outlet
dropping or hitting. side)
• Do not hit the protruded section after assembling 3. Differential pressure hose (Front)
the sensor to the DPD assembly. 4. Differential pressure sensor
• Be careful not to mix up sensors (catalyst inlet side, 5. Differential pressure hose (Rear)
catalyst outlet side) when assembling. 6. DPD assembly
Screw size Connector Installation

color 1. Install the exhaust temperature sensor (2 pieces).
Sensor M12 – 1.75
Dark gray Tightening torque : 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
(Catalyst inlet side) (0.47–0.069)
Sensor M12 – 1.25 2. Install the exhaust temperature sensor connectors
Light gray (2 pieces).
(Catalyst outlet side) (047–0.049)
3. Fasten the exhaust temperature harness with the
clip.
4. Check for gas leakage and confirm that it is
securely sealed.
Exhaust Differential Pressure Sensor

Removal NOTE:
1. Disconnect the differential pressure hoses (2 • Do not mistake the front and rear directions.
pieces). • Do not use cracked hoses.
2. Disconnect the differential pressure sensor • Absolutely do not over-tighten or remove the
harness connector. differential pressure sensor ASM tightening screw.
3. Remove the differential pressure sensor. • There is the danger of the sensor miss operation
• Remove the installation bolts. when there is a gas leak from the joint sections.
After starting the engine, check that no gas is
• Remove the differential pressure sensor.
leaking.
1
it was dropped.
2 apply vibrations when installing the differential
pressure sensor.
3
MFW81GSH001401
Legend
1. Differential pressure sensor
2. Installation bolts 5 4
3. Differential pressure hoses 3 2
NOTE: MFW81ESH000901
If it is unavoidable to remove the differential pressure Legend
sensor (1), be careful of the following points. 1. Front mark
• Absolutely never loosen the 4 differential pressure 2. Rear side differential pressure hose insertion
sensor installation bolts. If they are loosened, section
replace the differential pressure sensor. 3. Front differential pressure hose insertion section
• Do not reuse the differential pressure sensor ASM if 4. Bracket
it was dropped. 5. Installation bolts
apply vibrations when removing the differential 0-point correction of the differential pressure
pressure sensor. sensor
Installation Perform 0-point correction on the differential pressure

sensor when the differential pressure sensor ASM has
1. Install the differential pressure sensor.
been replaced. (on vehicle)
• Tighten installation bolt by rule torque.
1. Turn the key from the OFF state to the ON state.
Tightening torque : 20 N⋅m (2.0 kg⋅m/14 lb⋅ft) (Engine does not start.)
2. DPD light turns on, and then turns off after
2. Connect the differential pressure sensor harness
connector.
3. After checking that the DPD light is extinguished,
3. Connect the differential pressure hoses (2 pieces).
turn the key off and leave for at least 15 seconds.

NOTE:
Performing 0-point correction tend to receive the
influence by heat easily. Do not perform corrections
until 2 hours after regenerating DPD.
Engine Exhaust (4HK1 Euro3 specification and Euro2 specification) 1G-1
ENGINE
Engine Exhaust
(4HK1 Euro3 specification and Euro2 specification)
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
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
List of Tightening Torques . . . . . . . . . . . . . . . . 1G-11
Exhaust Brake Magnetic Valve . . . . . . . . . . . . . 1G-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-12
1G-2 Engine Exhaust (4HK1 Euro3 specification and Euro2 specification)
Exhaust System
Vibrations and looseness of the exhaust system are The exhaust brake includes a valve inside the exhaust
caused by miss 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 The main components are: a front exhaust pipe,
completed, tighten them from the engine side to the exhaust brake, silencer and tail pipe.
rear side.
1 6
5
MFWB1BMF004201
Legend
1. Front exhaust pipe A 4. Silencer
2. Exhaust brake ASM 5. Tail pipe
3. Exhaust pipe B 6. Silencer (for Indonesia)

• When inspecting or repairing the exhaust system,
check that there is an adequate gap between the
floor and body.
cabin. Be careful.
exhaust gas leaks.
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

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 and
exhaust throttle shaft for strain. Replace
if there is a problem
Clogging of the exhaust pipe Repair or replace the exhaust pipe

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
Exhaust Pipe
Components
2
1
4
MFWB1BLF004101
Legend
1. Front exhaust pipe A 5. Silencer
2. Exhaust brake assembly 6. Exhaust bracket
3. Exhaust pipe 7. Silencer (for Indonesia)
4. Tail pipe
Removal
1. Remove the tail pipe. (Except Indonesia)
• Remove the clamps and tail pipe.
2. Remove the silencer.
3. Remove the exhaust pipe B (3).
4. Remove the exhaust brake assembly (2).
• Remove the flexible hose and the exhaust
brake assembly.

cracks or damage.
• Inspect the pipe or silencer for dents, or cracks
caused by corrosion. If damaged, repair or replace
them.
1
2
Installation
3
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 exhaust pipe.
NOTE:
MFW81GSH002001 Uniformly tighten the front exhaust pipe so that there is
Legend no exhaust gas leak.
1. Front exhaust pipe A
2. Install the exhaust brake flexible hose.
2. Exhaust brake assembly
3. Exhaust pipe B 3. Temporarily install the silencer.
4. Temporarily install the tail pipe.
5. Remove the front exhaust pipe A (3).
• Remove the clamp, and remove the front After temporary installation, securely tighten it.
exhaust pipe A.
5. Turbocharger from the front exhaust pipe A
2
1
3
2
3
MFW81GSH001901
Legend
1. Gasket
2. Nut MFW81GSH001901
3. Front exhaust pipe A Legend
1. Gasket
2. Nut
Inspection 3. Front exhaust pipe A
1. Externally inspect the exhaust pipe components. 6. Transmission right side bracket from the clamp of
• Damage caused by heat from the body panel or the front exhaust pipe A
cabin. Be careful. Tightening torque: 47 N⋅m (4.8 kg⋅m / 35lb⋅ft)
exhaust gas leaks.

7. Exhaust brake
1
2
MFW81GSH002001
Legend
1. Front exhaust pipe A
2. Exhaust brake assembly
3. Exhaust pipe B
8. Silencer (Front side)

NOTE:
• First tighten the bolts at the upper side of the
vehicle, then tighten the bolts at the lower side.
• Install the clamp without tilting.
9. Tail pipe (except Indonesia)

10. 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.

c
a
g d
MFWB1BLF004201
(a) 47 N⋅m (4.8 kg⋅m / 35lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(c) 85N⋅m (8.7 kg⋅m/63 lb⋅ft)
(d) 20N⋅m (2.0 kg⋅m/14 lb⋅ft)
(e) 20N⋅m (2.0 kg⋅m/14 lb⋅ft)
(f) 41 N⋅m (4.2 kg⋅m / 30lb⋅ft)
(g) 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
Exhaust Brake Magnetic Valve

1. Disconnect the front frame harness (5) from the 1. Install the exhaust brake magnetic valve to the
exhaust brake magnetic valve. bracket.
2. Disconnect the exhaust brake flexible hose (2)
from the exhaust brake magnetic valve (4).
3. Remove the air pipe (3) located between the union
and exhaust brake magnetic valve (4).
1 6
MFW81GSH002401
2. Install the air pipe (2) located between the union

and exhaust brake magnetic valve.
3. Connect the exhaust brake flexible hose (4) to the
MFW81GSH002201 exhaust brake magnetic valve.
4. Remove the exhaust brake magnetic valve. 4. Connect the front frame harness (3) from the
exhaust brake magnetic valve.
4
MFW81GSH002401
MFW81GSH002301
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:(Euro4 Specifications) . . 1H-3
Functional Inspection:(Euro3 Specifications
and Euro2 Specifications) . . . . . . . . . . . . . . . . . 1H-4
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . 1H-5
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-5
List of Tightening Torques . . . . . . . . . . . . . . . . . 1H-6
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1H-7
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-7
List of Tightening Torques . . . . . . . . . . . . . . . . . 1H-8
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-9
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-12
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-15
List of Tightening Torques . . . . . . . . . . . . . . . . 1H-17
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-20
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-21
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . 1H-25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-25
1H-2 Engine Lubrication (4HK1)
Lubrication System
• Use a scraper to completely scrape off old liquid A full-flow filter element, water-cooling oil cooler, and
gasket from the locations where it is used. After piston coolant oil jet are adopted for the lubrication
cleaning using a rag, etc., to completely remove 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

40 (0.4/6)
Battery
Engine control
100 (1.0/14) Oil pressure
switch
indicator light
Relief valve
Full flow filter Oil cooler Oil gallery (2nd)
Oil gallery (1st) Bypass valve
440 (4.5/64)
Crank Relief
Gear Valve
shaft valve
train train
bearing (Front cover)
Check
valve
780 (8.0/114)
Turbo Air
Oil pump Relief valve Conrad
charger compressor
bearing
Oil
strainer
Oil jet
Oil pan
kPa (kg/cm2/psi)
MFWA1HLF000201

Functional Inspection:(Euro4 Specifications)
Inspecting the oil pressure - If the oil is insufficient, refill it to the “MAX for
1. Inspect whether the engine oil is dirty, or contains refuel” marking.
diesel oil or water. If the engine oil is dirty, or If the oil level exceeds the “MAX for inspection”
contains diesel oil or water, (after investigating the marking, make sure to replace the oil.
causes and taking appropriate measures for diesel
oil or water contained,) change the oil.
2. Inspect the engine oil level. If the oil level is low,
replenish the engine oil.
3. Install the oil pressure gauge. 3 4
4. Warm up the engine.

5. Measure and confirm that the oil pressure is 210 2
5
kPa (2.1 kg/cm2/29.9 psi) or higher at 1,400 r/min. 6
6. Stop the engine.
7. Remove the oil pressure gauge. 1
8. Install the pressure switch. 7
9. Start the engine and check that there is no oil leak.
Engine oil used

Euro4 specification
LNW71HSH000201
• Low ash oil for DPD
10W-40 Besco Clean Super 10W-30 Besco Clean Legend
1. MIN
Euro3 specification and Euro2 specification 2. Supply purpose MAX
• Besco Engine Oil 3. Inspection purpose MAX (Euro4 specification
only)
NOTE: 4. Oil replacement is needed (Euro4 specification
Always use this engine oil for this engine. only)
5. Good oil level (Euro4 specification only)
Engine oil level 6. Can be replenished up to supply purpose MAX
• Park the vehicle on a level area. Inspect the 7. Requires replenishment
engine oil level with a level gauge prior to starting
the engine or following more than 30 minutes after Engine oil leakage
stopping the engine.
• Inspect for oil leakage from the oil seals, cylinder
• Vehicles installed with this engine are equipped
head cover, and oil pan, etc. while the vehicle is
with DPD, so the method in inspecting the engine
lifted up.
oil level is different.
When a fixed amount of particulate matter (PM)
accumulates in the DPD filter, the DPD vehicle
automatically performs regeneration (combustion).
To perform this regeneration, a slight amount of
fuel is injected into the combustion chamber after
combustion in the engine and is fed to the DPD
filter as exhaust-mixed gas. A portion of the fuel is
mixed into the engine oil causing the engine oil
increase from when it is filled, but this is not a
problem.
• Oil amount inspection method
- Oil level inspection method using a level gauge
- Remove the oil level gauge and wipe off any
adhering oil.
- Insert it all the way in again, and pull it out.
If the oil is between the “MAX for inspection”
and “MIN” markings, the level is acceptable.

Functional Inspection:(Euro3 Specifications and Euro2 Specifications)
Oil pressure inspection
1. Inspect the engine oil level. Add more engine oil if
there is insufficient oil.
2. Remove the oil pressure switch.
3. Attach an oil pressure gauge.
4. Sufficiently warm up the engine.
5. Measure whether the oil pressure indicates more
than 210 kPa (2.1 kg/cm2 / 30 psi) at 1,400 r/min.
6. Stop the engine.
7. Remove the oil pressure gauge.
8. Attach the oil pressure switch.
1 2
9. Start the engine, and check for oil leaks.
NOTE:
Inspect the engine oil for abnormal dirt, or whether fuel
or water is mixed into it. If an abnormality is found,
LNW61HSH000401
investigate the cause, take the appropriate action to
remedy the cause, and replace the oil. Legend
1. MAX for supplying
Engine oil used 2. An MIN level
• Grade (API) CD Class
Viscosity (SAE) 10W-30 Besco Clean Engine oil leak
NOTE: • Inspect the oil seal, cylinder head cover, oil pan
Only use one of the engine oils listed above in this etc. for oil leaks.
engine.
Amount of engine oil

• Park the vehicle on a level surface, and inspect the
amount of engine oil using a level gauge after
more than 30 minutes has passed since the engine
was stopped. If engine oil adheres to the level
gauge at a level between the upper limit and lower
limit, the oil level is OK.
However, if the level of engine oil is below the
lower limit, add more oil. Also, check how dirty the
oil is.
NOTE:
If the engine oil has increased in quantity, fuel or water
may have become mixed in it. The cause must be
investigated.
Oil Filter Cartridge

Components
1
LNW21HSF000101
Legend
1. Oil filter cartridge
Removal • Tighten the cartridge at the specified torque.

1. Place a pan under the oil filter cartridge. Tightening torque: 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
2. Use the oil filter wrench:1-85221-097-0 to remove or
the oil filter cartridge. After touching the oil seal, further tighten 1 and 1/4
turns.
NOTE:
When attaching and removing the cartridge, be careful
not to sandwich the CKP sensor harness.
LNW21HSH000601
Installation
1. Install the oil filter cartridge.
• Apply grease (Besco L2 or L3) or engine oil to
the cartridge seal and use the oil filter
wrench:1-85221-097-0 to install.

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

Oil Filter Assembly

Components
MFWB1HMF000201
Legend
1. Oil pressure switch 4. Nut
2. O-ring 5. Oil filter cartridge
3. Oil filter body 6. Bolt
1. Remove the oil pipe eye bolt. 1. Install the O-rings (1) and (2) to the oil filter body.
2. Place a pan under the oil filter assembly.
3. Remove the oil pressure switch. 1
4. Remove the oil filter body.
5. Remove the O-ring.
MFW51HSH000201

• Apply liquid gasket (Loctite No. 262) to 2 or 3
2. Install the oil filter body to the cylinder block and threads from the leading end of the threaded
tighten it at the specified torque. portion of the oil pressure switch, and install it
to the position shown in the diagram.
LNW21HSH000301
LNW21HSH000401
3. Install the oil pressure switch to the oil filter body. 4. Install the oil pipe.
MFWB1HMF000301
(b) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)

(a) 13 N⋅m (1.3 kg⋅m/113 lb⋅in) (c) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
Oil Cooler
Components
1 2
5
4
3
MFW81HMF000101
Legend
1. Bypass hose 4. Oil cooler
2. Common rail 5. Water inlet pipe
3. Supply pump

2 3 4
5
7 6
MFW71HMF000101
Legend
1. Bypass hose 5. Supply pump
2. EGR cooler water pipe (IN) 6. Oil cooler
3. EGR cooler water pipe (OUT) 7. Water inlet pipe
4. Common rail
Removal • Remove the A/C drive belt and the bracket

mounting bolt to remove the bracket with the
1. Remove the common rail.
tensioner and idle pulley.
Refer to "Common Rail" in Section 1D, Fuel
System.
2. Remove the air compressor.
Refer to "Timing Gear Train" in Section 1B, Engine
Mechanics.
3. Remove the A/C drive belt.
4. Remove the idle pulley bracket.
LNW41BSH003401

5. Remove the EGR cooler water pipes (IN/OUT) Disassembly
1. Remove engine mounting bolts.
6. Remove the clip of the head side for the water
2. Remove the element (1).
bypass hose and remove using the water inlet pipe
and the assembly (Euro3 specification and Euro4 3. Remove the O-rings (2).
specification).
• Remove the water inlet pipe (Euro2
1
2
2
1 3
LNW21HSH001201
Legend
1. Element
MFW71HSH000301 2. O-rings
Legend
1. Bypass hose
2. EGR cooler water pipe (IN) Reassembly
3. EGR cooler water pipe (OUT) 1. Install the O-rings (2) to the oil cooler case.
4. Water inlet pipe
2. Install the element (1).
3. Tighten the element mounting bolt at the specified
7. Remove the oil cooler assembly. torque.
• Twist in the removed oil cooler mounting bolt Tightening torque: 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
into the replacer hole (1) shown in the diagram
and remove the oil cooler.
LNW21HSH001201
LNW21HSH006401 Legend
1. Element
8. Remove the O-ring. 2. O-rings

Installation
1. Install the O-rings (1) and (2).
• Apply liquid gasket (TB-1207B) along the
groove in the flange surface (3).
• Install the O-ring to the oil path entrance / exit 11 8 4 1 5 9 12
areas.
NOTE: 13
The liquid gasket should not adhere to the O-ring.
14
• After applying the liquid gasket, install within 5
minutes. 7 3 2 6 10 15
• Refer to the diagram for the tolerance range for
miss positioning the liquid gasket.
1 2
3
LNW21HSH006301
3. 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 - 5 mm
(0.079 - 0.197 in)
4 5 6 • Refer to the diagram for the tolerance range for
miss positioning the liquid gasket.
b c
a
1
MFW81HSH000201
Legend
1. O-ring
2. O-ring
3. Liquid gasket
4. OK
5. OK 2 3 4
6. NG
7. a : 0.1 - 2.0 mm (0.004 - 0.079 in) b c
8. b :2 - 4 mm (0.079 - 0.15 7in)
9. c : 1 mm (0.039 in)
a
MFW81HSH000101
2. Install the oil cooler assembly.
Legend
• Align to the cylinder block stud (13), install the
1. liquid gasket
oil cooler, and tighten it at the specified torque
2. OK
in the order shown in the drawing.
3. OK
Tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft) 4. NG
5. a : 0.5 - 2.0 mm (0.020 - 0.079 in)
6. b : 2 - 5 mm (0.079 - 0.197 in)
7. c : 1 mm (0.039 in)
• Install to the position shown in the drawing and

tighten together with the oil cooler.
• indicates the nut (1).

NOTE:
The installation of the water inlet pipe is directly after
the installation of the oil cooler (because liquid gasket
is used with the tightening).
LNW41BSH003401
1
6. Install and adjust the A/C drive belt.

Refer to "Drive Belt" in Section 1C, Coolant
LNW21HSH005201 System.
Legend 7. Install the air compressor.
1. Nut Refer to "Timing Gear Train" in Section 1B, Engine
2. Bolt Mechanics.
Refer to "Common Rail" in Section 1D, Fuel
4. Install the EGR cooler water pipe (Euro3 System.
specification and Euro4 specification).
MFW71HSH000201
5. Install the idle pulley bracket and tighten it at the

specified torque.
Oil Pan
Components
5
6
MFW81HLF000301
Legend
1. Oil level switch (Euro4 specification only) 5. Gasket
2. Oil pan gasket 6. Drain plug
3. Oil pan 7. Oil pan rubber
4. Clip
Removal 2. Disconnect the oil level switch connector (Euro4

1. Drain the engine oil.
• After draining the oil, tighten the drain plug at
the specified torque. 4. 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(Euro4
oil pan gasket (3) and install the oil pan (2).
Next, tighten the oil pan rubber assembly (1)
Tightening torque: 9 N⋅m (0.9 kg⋅m/78 lb⋅in) with the mounting bolt and nut to fasten.

• Apply a bead of liquid gasket (TB1207C) in the
width of 3 mm (0.1 in) to the joints (arrows at
3
four locations) of the cylinder block, front cover
and flywheel housing.
• After applying the liquid gasket, install the oil
2
pan within 5 minutes.
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.)
1 2
4
3
LNW21BSH013801
NOTE:
Recheck the tightening of the oil pan drain plug.
3. Connect the oil level switch connector (Euro4

4. Fill the engine oil.

MFW71HLF000401
(a) 9 N⋅m (0.9 kg⋅m/78 lb⋅in)

(b) 83 N⋅m (8.5 kg⋅m/83 lb⋅ft)
(c) 11 N⋅m (1.1 kg⋅m/95 lb⋅in)
(d) 11 N⋅m (1.1 kg⋅m/95 lb⋅in)
Oil Pump
Components
4
3
1
LNW21HMF000601
Legend
1. Oil pump assembly 5. Driven gear and shaft
2. Spring 6. Oil pump body
3. Ball 7. Slinger
4. Split pin
Removal • Refer to "Transmission ASM" in Section 5B

1. Drain the engine oil.
2. Remove the coolant. Automatic Transmission (Smoother (MZW)).
3. Remove the cylinder head assembly. Refer to "Transmission ASM" in Section 5C
Refer to "Cylinder Head" in Section 1B, Engine Manual Transmission (MLD).
Mechanics. Refer to "Transmission ASM" in Section 5C
4. Remove the transmission assembly. Manual Transmission (MZX).
5. Remove the clutch pressure plate.

clutch disk.
• Remove the pressure plate mounting bolts in a
diagonal line order.
• Remove the pressure plate from the flywheel.

• Do not forget to remove the bolt shown in the
6. Remove the clutch disk. drawing.
• Remove the clutch disk from the flywheel along
with the clutch aligner.
7. Remove the supply pump assembly.

Refer to "Supply Pump" in Section 1B, Engine
Mechanical.
Refer to "Flywheel" in Section 1B, Engine
Mechanics.
9. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal" in Section 1B,
Engine Mechanics.
11. Remove the power steering pump.
12. Remove the power steering pump idle gear cover.
13. Remove the power steering pump idle gear. LNW21BSH053601
15. Remove the idle gear A.
MFW71BSH007601
14. Remove the flywheel housing. LNW21HSH005501


16. Remove the oil pump assembly.
LNW21HSH001901
LNW21HSH001801
2. Measure the clearance between the drive gear

Disassembly shaft and bush.
• Use a micrometer to measure the outer
1. Remove the driven gear and shaft.
diameter of the driven gear shaft.
2. Remove the split pin.
3. Remove the spring.
Outer diameter of the drive gear shaft mm(in)
4. Remove the ball.
15.989 - 16.000
Standard values
(0.62949 - 0.62992)
Inspection Limit 15.900 (0.62598)
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Use a thickness gauge to measure the
clearance between the gear and the oil pump
body.
• If the clearance between the gear and the inner
wall of the body exceeds the limit, replace the
gear assembly or driven gear assembly.
Clearance between gear and the inner

wall of the body mm (in)
0.125 - 0.221
Standard values
(0.00492 - 0.00870)
Limit 0.30 (0.012)
LNW21HSH002101
• Use a dial indicator to measure the inner

diameter of the oil pump body and cylinder
block bush.
• If the clearance between the drive gear shaft
and the bush exceeds the limit, replace the
driven gear assembly.

4. Apply engine oil to the driven gear and shaft, and
install them to the oil pump body.
Clearance between the driven gear shaft
and the bush mm (in)
0.04 - 0.07
Standard values
(0.0016 - 0.0028)
Limit 0.20 (0.0079)
LNW21HSH002401
Installation
1. Install the oil pump assembly.
• Apply liquid gasket (TB1141E or TB1207C) as
LNW21HSH002201 shown in the drawing, and install it to the
cylinder block within 5 minutes.
After that, tighten it at the specified torque.
Reassembly Tightening torque: 31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
1. Install the ball.
2. Install the spring. NOTE:
Apply liquid gasket so that it does not get in the hole at
3. Install the split pin (1) and bend as shown at (1).
the arrow in the drawing, to the gear, and inside the oil
pump body.
LNW21HSH006201
Legend
1. Split pin LNW21HSH002501
2. Install the idle gear A.

• Fit the idle gear shaft into the position shown in
the drawing and apply engine oil to the shaft.

• Rotate the crankshaft in the forward direction to • As shown in the drawing, uniformly apply liquid
align the first cylinder piston to the top dead gasket (No. 1207C) to the inside of the bolt hole
center. (excluding the bolt hole at the arrow).
• After applying the liquid gasket, install it quickly.
Bead width 3.5 mm (0.14 in)

Bead height 2.0 - 4.0 mm (0.08 - 0.16 in)
LNW21HSH005601
• Align the crankshaft gear and idle gear A

alignment marks and install to the cylinder
block.
LNW21BSH033201
• Position with the cylinder block knock pin to

install the flywheel housing.
Flywheel housing tightening torque

L N⋅m (kg⋅m/lb⋅ft)
(1), (2) (3) (4)
96 (9.8/71) 38 (3.9/28) 48 (4.9/35)
LNW21HSH002601
• It is oil application, and the application range

does things more than 17 mm (0.67 in) to bolt
from the bolt tip.
• It is oil application to the washer both sides.
• Tighten the mounting bolt at the specified
torque.

• Clean the cylinder block back side. Particularly,
clean the liquid gasket that projects out when
the crank case is installed.

• Tighten (3) and (4) from the cylinder block side.
1
1
2
4
MFWA1BMF000801
4. Install the power steering 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, install to the flywheel
housing and tighten it at the specified torque.
LNW21BSH053601
5. Install the power steering pump idle gear cover.

• Install the O-ring to the cover, install it to the
flywheel housing and tighten the mounting bolt
LNW21BSH004301

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.
• Tighten the pressure plate at the specified
torque in a diagonal line order.
13. Install the transmission assembly.

MFW81BSH007501 Refer to "Transmission ASM" in Section 5C
6. Install the power steering pump and tighten it at its Manual Transmission (MZX).
specified torque. Refer to "Transmission ASM" in Section 5C
Power steering pump mounting bolts (1) Manual Transmission (MZW).
Tightening torque: 50 N⋅m (5.1 kg⋅m/37 lb⋅ft) Refer to "Transmission ASM" in Section 5C
14. Install the cylinder head assembly.

Refer to "Cylinder Head" in Section 1B, Engine
Mechanics.
16. Fill the engine oil.
1
MFW71BSH003301

Refer to "Oil Pan" in this Section.
8. Install the crankshaft rear seal.
Refer to "Crankshaft Rear Oil Seal" in Section 1B,
Engine Mechanics.
Refer to "Flywheel" in Section 1B, Engine
Mechanics.
10. Install the supply pump assembly.
Refer to "Supply Pump" in Section 1B, Engine
Mechanics.
11. Install the clutch disk.
12. Install the clutch pressure plate.
Oil Pressure Switch

Inspection
Inspect the continuity between the switch terminal and
body ground without a load applied.
Replace with a normal part if there is no continuity in
the inspection.
LNW21HSH003301
Inspection of the circuit

1. Turn the engine control switch ON.
2. Disconnect the oil pressure switch connector
connection, and inspect whether the oil pressure
warning light lights up when the harness side
connect is connected to the ground.
If it does not light up, inspect the circuit between
the meter and the oil pressure switch. Repair any
open circuit.
LNW21HSH003401
MEMO
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
..................................................................................................................
Engine Speed Control System (4HK1) 1I-1
ENGINE
Engine Speed Control System
(4HK1)
TABLE OF CONTENTS
Accelerator Pedal Position Sensor. . . . . . . . . . . . . 1I-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-3
Idle Up Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-4
1I-2 Engine Speed Control System (4HK1)
Accelerator Pedal Position Sensor

Components
1
4
MFW71IMF000201
Legend
1. Bolt 4. Pedal
2. Control link and bracket assembly 5. Pedal stopper bolt
3. Accelerator pedal position sensor
Removal 2. Remove the control link and bracket assembly

installation nut.
1. Turn the engine control switch OFF.
MFWB1ISH000101
Engine Speed Control System (4HK1) 1I-3

3. Remove the accelerator pedal installation bolts. NOTE:
4. Disconnect the accelerator pedal position (APP) • After adjusting the accelerator pedal, make sure to
sensor harness connector. perform accelerator pedal learning with the scan
tool.
• Refer to “Section 1A, Engine Control System” for
Installation adjustment of the accelerator pedal position sensor,
1. Connect the accelerator pedal position (APP) accelerator pedal, etc.
sensor harness connector.
2. Install the accelerator pedal installation bolt.
3. Install the control link and bracket assembly.
MFWB1ISH000101
4. After installing the pedal, check that the gap (a) is

at the specified value when the pedal is fully
depressed.
Gap (a) [reference value] : 1.0 mm (0.039 in)

• When adjusting, loosen the nut (2), turn the bolt
(1) to adjust, and fix the nut (2).
1
2
a
MFWB1ISH000201
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.
3. Install the knob (3).
LNW81ISH000101
4. Connect the idle up sensor harness connector.

Induction (4HK1) 1J-1
ENGINE
Induction
(4HK1)
TABLE OF CONTENTS
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-4
List of Tightening Torques . . . . . . . . . . . . . . . . . .1J-6
Turbocharger Assembly . . . . . . . . . . . . . . . . . . . . .1J-8
Maintenance Precautions . . . . . . . . . . . . . . . . . .1J-8
Failure Symptom List . . . . . . . . . . . . . . . . . . . .1J-10
Phenomenon: When Output has Dropped
Although the Engine Appears Normal. . . . . . . .1J-11
Phenomenon: When Output has Dropped
Although the Turbocharger Generally
Appears Normal . . . . . . . . . . . . . . . . . . . . . . . .1J-12
Phenomenon: When There are Abnormal
Turbocharger Vibrations . . . . . . . . . . . . . . . . . .1J-13
Phenomenon: When Oil is Leaking from
the Exhaust or Intake and Exhaust Gas is
White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-14
Phenomenon: When Noise is Generated
from the Turbocharger . . . . . . . . . . . . . . . . . . .1J-15
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
List of Tightening Torques . . . . . . . . . . . . . . . . .1J-26
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-28
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-29
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-29
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-30
Turbocharger Control Module
(Euro4 specification) . . . . . . . . . . . . . . . . . . . . . .1J-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-31
IAT(Inlet Air Temp) Sensor
(Euro2/3 specifications) . . . . . . . . . . . . . . . . . . . .1J-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-32
MAF Sensor(Euro4 specification) . . . . . . . . . . . .1J-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-33
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . .1J-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-34
1J-2 Induction (4HK1)
Air Cleaner Element

Components
1 2 3 4
7 6
MFW81JMF000101
Legend
1. Body assembly 5. Match mark
2. Element 6. Inner element
3. Wire clamp 7. Water drain valve
4. Air cleaner cover
Removal
1. Tilt the cab.
2. Remove the air cleaner cover.
• Remove the clips (1) at 4 locations by pressing
them inside to remove the air cleaner cover.
1
2
1
MFW81JSH000301
Legend
1. Air cleaner assembly
2. MAF sensor
2. IAT (Inlet Air Temp) sensor inspection (Euro2

specification and Euro3 specification)
• Refer to “Engine Control System” in Section 1A,
IAT sensor inspection.
MFW81JMH000101
3. Remove the element. 1

• Do not remove the inner element when the
outer element is cleaned.
• Never clean the inner element. replace the
inner element at the same time of replacing the
outer element.
NOTE:
• Make sure to use a genuine dry type element
because an MAF sensor is used. Do not use a wet
type element because it may cause the sensor to
become dirty (Euro4 specification only).
• Use a genuine air cleaner element. If other
element is used, it may cause the sensor to send a
wrong signal.
MFWB1JSH000401
Inspection Legend
1. IAT (Inlet Air Temp sensor)
1. MAF (Mass air flow) sensor inspection (Euro4
specification only) 3. Air cleaner inspection
• Refer to “Engine Control System” in Section 1A, • Inspect the element on a regular basis or when
MAF sensor inspection. the air cleaner warning light turns on.
CAUTION: 4. Clean the element.
Do not touch the sensing section of the sensor with • When it is dirty with dry dust (dust sand etc.),
hand because it is heated to 170 -300°C (338 - 572°F) clean it by blowing the compressed air.
when the sensor is conduct electricity. • Blow the compressed air from the inside of the
element while rotating the element.

NOTE: NOTE:
• Do not hit or strike the element to clean. • Make sure to replace the element if an abnormality
• Do not exceed an air pressure of 686 kPa (7.0 kg/ is found.
cm2 /99.5 psi) • Replace the element after using it for a year or after
• It exchanges, when an air cleaner element is cleaning it 6 times, whichever is earlier, or when it is
cleaned 6 times or more. damaged.
HCW310SH000101 HCW31BSH057601
• When blackened by oil burnt smoke such as 6. Inspect the water drain valve (1) at the lower side
soot of the air cleaner for clogging.
Dissolve a mild detergent in water and soak for Moreover, it checks whether the adhesion of water
approximately 30 minutes. Thoroughly rinse drain valve is good.
with water and allow to dry naturally (for 2 to 3
days).
Do not exceed a water pressure of 275 kPa (2.8
kg/cm2 /40 psi)
1
MFW81JSH000401
Installation
HCW31BSH057501 1. Install the air cleaner element.
5. Inspect the element for breakage or damage. 2. Install the air cleaner cover.
• Place a light in the element to inspect the • Face the ISUZU mark on the cover upward and
element for damage or pin hole, and inspect the engage the concave and convex sections (3) at
seal section for breakage. the left side of the cover.

• Hook the wire clips to the body assembly (1) at
4 locations, and pull it towards you to install the
air cleaner cover (2).
1
2
3
MFW81JMH000201

Day cab
b c e
a
i h g
MFW71JLF000401
(a) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)

NORMA W1 Steel clamp: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(b) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅ft)
(d) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(e) 8 N⋅m (0.8 kg⋅m / 69 lb⋅ft)
(f) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(g) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(h) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(i) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
NOTE:
Tighten (c) and (e) when the hose is cool.

Full cab
d
b c
g
i h
j
MFW71JLF000501
(a) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)

(b) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅ft)
(d) 8 N⋅m (0.8 kg⋅m / 69 lb⋅ft)
(e) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(f) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(g) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(h) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(i) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
(J) ABA W4 Stainless clamp: 6.4 N⋅m (0.65 kg⋅m / 56 lb⋅in)
NOTE:
Tighten (c) and (d) when the hose is cool.
Turbocharger Assembly
Maintenance Precautions • Take measures to prevent foreign material from
entering the turbine housing, compressor housing,
• The turbocharger has an extremely precise finish
the oil filler and outlet while performing the
and rotates at high speeds (approx. 100,000 r/
maintenance work.
min), and therefore, it cannot be disassembled.
Replace the whole turbocharger assembly, if even • After maintenance of the turbocharger, pour in 3 -
small abnormalities such as bent fins, bent 5 cc (0.00066 - 0.0011 lmp⋅gal) of clean engine oil
housing or scratches are found. Also, when into the turbo oil inlet hole before installing the oil
removing the turbocharger assembly or performing pipe.
maintenance for other parts, do not loosen or
remove the actuator or bracket of the turbocharger.
MFW81GMF000601
Legend
1. Actuator (W/G valve) 3. Compressor housing
2. Turbine housing

MFW71JMF000101
Legend
1. Compressor housing 3. Actuator
2. Turbine housing

• Output has Dropped Although the Engine Appears
normal.
• Output has Dropped Although the
Turbocharger generally appears normal.
• There are Abnormal Turbocharger Vibrations.
• Oil is Leaking from the Exhaust or Intake.
The Exhaust gas is White.
• 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 interfere Replace the turbocharger assembly
There is a large amount of carbon Clean or replace the turbocharger
deposit adhering to the turbine scroll assembly
and are in contact with the turbine fins
The turbine shaft sticks or doesn’t Replace the turbocharger assembly
rotate smoothly
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 from 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
Air leakage from the compressor outlet Repair
side
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 the boost sensor
Cause due to the vehicle side, such as Repair
dragging of the brakes
Decrease in battery performance, low Repair or replace
or excess voltage due to defective
generator

Phenomenon: When There are Abnormal Turbocharger Vibrations

When there are abnormal turbocharger The cause is bearing damage and Replace the turbocharger assembly
vibrations contact of the rotating section with the
surrounding sections
The cause is degraded oil, or entry of
foreign material in the oil 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 of turbine wheel or
compressor wheel by foreign material

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

When oil is leaking from the exhaust or Raised oil level due to dirty or clogged Clean or replace
intake. oil separator
Exhaust gas is white (normal engine) Clogging, collapsing or deformation of Repair or replacement
the oil return pipe
Diluted 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
Euro2 specification and Euro3 specification (Turbocharger)
2 3
5
6
MFW81JLF000401
Legend
1. Oil feed pipe 5. Exhaust adaptor Assembly
2. Turbocharger 6. Oil return pipe
3. Water return pipe 7. Water feed pipe
4. Exhaust manifold

2 3
7 6 5
MFW71BLF000701
Legend
1. Oil feed pipe 5. Exhaust adaptor Assembly
2. Turbocharger 6. Oil return pipe
3. Water return pipe 7. Water feed pipe
4. Exhaust manifold

Removal Euro4 specification only (With flywheel PTO)
1. Remove the oil pipe assembly (3). 2 3
3
2
1
1
MFW71JSH001601
Legend
MFW81GSH003801 1. Eyebolts
2. Clamps
Legend
3. Oil pipe assembly (Feed)
1. Eyebolts
2. Clamps Euro2 specification and Euro3 specification
Euro4 specification only (Without flywheel 1

PTO)
2
1
MFW81GSH003501
Legend
MFW71JSH000701 2. Eyebolt
Legend
1. Eyebolts
2. Clamps

MFW71JSH000601 MFW71JSH000501
Legend Legend
1. Oil pipe assembly (Feed) 1. Water pipe assembly (Return)
2. Eyebolt 2. Water pipe assembly (Feed)
2. Remove the water pipe assemblies (1, 2).

Euro2 specification and Euro3 specification 3. Remove the oil return pipe (1).
2
MFW81GSH003301
MFW81GSH003401
Legend
1. Water pipe assembly (Return)
2. Water pipe assembly (Feed)

4
4. Remove the turbocharger assembly (4). Legend

Euro2 specification and Euro3 specification 1. Nuts
2. Exhaust manifold
3. Bolt
1
4. Turbocharger assembly
1
2
MFW81GSH003601
Legend
1. Nuts 3 2
2. Exhaust manifold
3. Bolt MFW81GSH003701
Legend
1. Exhaust manifold
2. Nuts

1
1
2 3 4
2
Legend Legend
1. Exhaust manifold 1. Turbocharger assembly
2. Nuts 2. Gasket
3. Turbocharger assembly 3. Exhaust adaptor assembly
4. Heat protector
5. Remove the heat protector and exhaust adaptor
assembly.
Inspection
Visual and aural inspection
Remove the turbine outlet adaptor, and compressor
inlet rubber hose to visually inspect the turbocharger.
Do not disassemble or adjust the turbocharger main
unit. Do not disassemble the actuator. loosen the
bracket as these may cause improper operation.
• Inspect for abnormal sounds coming from the
turbocharger while it is running.
• Inspect the compressor housing and turbine
1 2 housing and fins whether there is interference,
3 damage and cracking.
4 • Inspect for oil leaking to the scroll of the housing.
5
• Inspect for large amounts of carbon deposit
adhering to the turbine scroll and whether they are
not in contact with the fins.
MFW81JSH001001
• Manually turn the turbine shaft to inspect for
Legend contact or catching.
1. Heat protector • Move the shaft to inspect for too much clearance in
2. Turbocharger assembly the shaft and rotating directions.
3. Gasket
4. Exhaust adaptor assembly NOTE:
5. Heat protector The engine blow-by gas is returned to the compressor
inlet, so the oil content that is slightly contained in the
blow-by gas may adhere to the inner walls of the
compressor inlet and outlet, but this is not a failure of
the turbocharger.
Play in the shaft direction of the wheel shaft

• Use a dial indicator to measure the play of the
shaft direction of the wheel shaft.

• Apply approximately 12 N (1.2 kg/2.6 lb) of force
alternately on the compressor wheel ends.
Play mm (in)
1
Standard values 0.03 - 0.10 (0.0012 - 0.0039)
Limit 0.13 (0.0051)
LNW21BSH022301
Legend
1. Oil outlet
2. Oil inlet
Installation
1. Install the heat protector and exhaust adaptor
LNW21BSH022201
assembly.
•Adapter tightening torque: 33N⋅m (3.4 kg⋅m/25 lb⋅ft)
Clearance between turbine shaft and bearing
• Use a dial indicator to measure the clearance Euro2 specification and Euro3 specification
between the wheel shaft and bearing.
Gap mm (in)
0.08 - 0.11
Standard values
(0.0031 - 0.0043)
Limit 0.17 (0.0067)
Euro4 specification
Clearance mm (in) 1 2
Standard values 0.08 - 0.11 (0.0031 - 0.0043) 3
4
Limit 0.17 (0.0067) 5
MFW81JSH001001
Legend
1. Heat protector
3. Gasket
4. Exhaust adaptor assembly
5. Heat protector

1
2
2 3 4
1
4
Legend Legend
1. Turbocharger assembly 1. Nuts
2. Gasket 2. Exhaust manifold
3. Exhaust adaptor assembly 3. Bolt
4. Heat protector 4. Turbocharger assembly
2. Install the turbocharger assembly (4). Nut (2) tightening torque: 52 N⋅m (5.3 kg⋅m/38 lb⋅ft)
Nut (1) tightening torque: 52 N⋅m (5.3 kg⋅m/38 lb⋅ft) Euro2 specification and Euro3 specification
Bolt (3) tightening torque: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
1
3 2
4
MFW81GSH003701
Legend
MFW81GSH003601 1. Exhaust manifold
Legend 2. Nuts
1. Nuts 3. Turbocharger
2. Exhaust manifold
3. Bolt

Legend 4. Install the water pipe assemblies (1, 2).

1. Exhaust manifold
2. Nuts Turbocharger side eyebolt tightening torque:
3. Turbocharger 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Block side eyebolt tightening torque:
3. Install the oil return pipe (1). 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Tightening torque
Turbocharger side: 9 N⋅m (0.9 kg⋅m/78 lb⋅in) 1
Cylinder block side: 21N⋅m (2.1 kg⋅m/15 lb⋅ft)
1
2
MFW81GSH003301
Legend
1. Water pipe assembly (Return)
2. Water pipe assembly (Feed)
MFW81GSH003401

Legend Legend
1. Water pipe assembly (Return) 1. Oil pipe assembly (Feed)
2. Water pipe assembly (Feed) 2. Eyebolt
5. Install the oil pipe assembly (1). Eyebolt (1) tightening torque:
Eyebolt (2) tightening torque: 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
17 N⋅m (1.7 kg⋅m/12 lb⋅ft) Clamp bolt (2) tightening torque:
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
3
2
1
2
MFW81GSH003501
MFW81GSH003801
Legend
1. Oil pipe assembly (Feed) Legend
2. Eyebolt 1. Eyebolts
2. Clamps

Euro4 specification only (Without flywheel
PTO)
MFW71JSH000701
Legend
1. Eyebolts
2. Clamps
Euro4 specification only (With flywheel PTO)
2 3
MFW71JSH001601
Legend
1. Eyebolts
2. Clamps

d
a b
f
e
m
h
k i
l
j
MFW81JLF000301
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(d) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(e) 33 N⋅m (3.4 kg⋅m/25 lb⋅ft)
(f) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(g) 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
(h) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(i) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
(j) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(k) 9 N⋅m (0.9 kg⋅m/78 lb⋅in)
(l) 21 N⋅m (2.1 kg⋅m/15 lb⋅ft)
(m) 52 N⋅m (5.3 kg⋅m/38 lb⋅ft)
(n) 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)

n
e
d
a b
m g
l
j i
MFW81JLF000101
(a) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)

(b) 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(d) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(e) 33 N⋅m (3.4 kg⋅m/25 lb⋅ft)
(f) 7.8 N⋅m (0.8 kg⋅m/69 lb⋅in)
(g) 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(h) 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
(i) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(j) 9 N⋅m (0.9 kg⋅m/78 lb⋅in)
(k) 21 N⋅m (2.1 kg⋅m/15 lb⋅ft)
(l) 52 N⋅m (5.3 kg⋅m/38 lb⋅ft)
(m) 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
(n) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Intercooler
Components
2
4
1 6 7
11
9
10
MFW71JLF000301
Legend
1. Rubber hose (Inlet) 7. Intercooler outlet duct
2. Inlet pipe (Turbocharger - Intercooler) 8. Rubber hose (Outlet)
3. Rubber hose (Turbocharger outlet) 9. Intercooler
4. Radiator assembly 10. Nut
5. Radiator stay 11. Bolt
6. Boost sensor

Removal 2. Inspect the inside of the intercooler for filth. If it is
significantly dirty, clean it.
1. Disconnect the boost sensor connector (1) of the
intercooler outlet duct. NOTE:
Do not perform high-pressure washing to the radiator
or intercooler, and the parts surrounding it.
Cleaning
1
Washing the intercooler core
CAUTION:
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
MFW71JSH001401
splash of tap water should be washed off
sufficiently in advance.
2. Remove the boost sensor (1).
Refer to the "Boost Pressure Sensor" in this NOTE:
section. Do not use a high-pressure washer or brush.
3. Prepare a mild detergent.

• Use a type which contains approx. 8% of
surface acting agent.
1
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.
MFW71JSH001501
NOTE:
• Apply the high-pressure water in a direction
3. Remove the inlet and outlet rubber hoses of the
perpendicular to the fins.
intercooler.
• Do not bring the high-pressure water too close to
4. Remove the intercooler outlet duct.
the fins.
5. Remove the radiator assembly.
• Be careful not to deform the fins.
Refer to "Radiator" in Section 1C, Engine Cooling.
6. Remove the intercooler installation nut and bolt 6. After washing is finished, inspect the fins to
from the radiator assembly and remove the confirm that the dirt is removed sufficiently.
intercooler. • If washing is not sufficient, wash them again.
NOTE:
Inspection If some dirt is still left, fine black particles attached on
1. If the intercooler fins are deformed, this can lead to the fins can be seen.
a drop in heat dissipation and reduce engine
performance. Repair the fins. When repairing, be 7. Rinse off the detergent constituents on the fins and
careful not to damage the base of the fins. 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.
2. Install the radiator assembly.
Refer to "Radiator" in Section 1C, Engine Cooling.
3. Install the inlet and outlet rubber hoses of the
intercooler.
4. Install the intercooler outlet duct.
5. Install the boost sensor (1).
Refer to the "Boost Pressure Sensor" in this
section.
MFW71JSH001501
6. Connect the boost sensor connector (1).
MFW71JSH001401
Turbocharger Control Module (Euro4 specification)

Removal
2. Disconnect the harness connector (1).
3. Remove the turbocharger control module (2) from
the bracket.
MFW81BSH002201
Installation
1. Install the turbocharger control module (2).
Tightening torque: 6.5 N⋅m (0.66 kg⋅m/4.8 lb⋅in)
2. Connect the harness connector (1).
MFW81BSH002201
IAT(Inlet Air Temp) Sensor (Euro2/3 specifications)

Removal
1. Turn OFF the ignition switch. 1
2. Disconnect the harness connector.
3. Remove the IAT (Inlet Air Temp) sensor. 2
MFW81JSH000801
Legend
1. IAT (Inlet Air Temp) sensor
2. Sensor adapter
2. Install the harness connector.

MFW81JSH000801
Legend
1. IAT (Inlet Air Temp) sensor
2. Sensor adapter
Installation
1. Install the IAT (Inlet Air Temp) sensor.
Tightening torque N⋅m (kg⋅m / lb⋅in)

3.5 (0.36 / 31)
MAF Sensor(Euro4 specification)

Removal
2. Disconnect the harness connector.
3. Remove the MAF sensor.
MFW81JSH000101
Installation
1. Install the MAF sensor.
2. Connect the harness connector.
Boost Pressure Sensor

Removal 2. Connect the boost pressure sensor connector.
1. Disconnect the boost pressure sensor connector
(2).
2. Remove the boost pressure sensor (1).
1 2 3
MFW81JSH000501
Legend
1. Boost pressure sensor
2. Boost pressure sensor connector
3. Air intake duct
Installation
1. Install the boost pressure sensor.
1 2 3
MFW81JSH000501
Legend
1. Boost pressure sensor
2. Boost pressure sensor connector
3. Air intake duct
Pre-Heating System (4HK1) 1K-1
ENGINE
Pre-Heating System
(4HK1)
TABLE OF CONTENTS
Pre-Heating System . . . . . . . . . . . . . . . . . . . . . . . 1K-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1K-2
Description of Function and Operation . . . . . . . 1K-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1K-3
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1K-5
Phenomenon: The Glow Indicator Light
Does not Light . . . . . . . . . . . . . . . . . . . . . . . . . . 1K-6
Phenomenon: Preheating Does not Operate . . 1K-7
Phenomenon: The Preheating Time is
too Long or too Short . . . . . . . . . . . . . . . . . . . . 1K-8
Primary Specifications. . . . . . . . . . . . . . . . . . . . 1K-8
1K-2 Pre-Heating System (4HK1)
Pre-Heating System
Be careful because the glow plug can be damaged if it
is over-tightened.

Quick On Start (QOS) System
The QOS 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 engine control 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.

Preheat system inspection and repair • If the measurement reveals that the resistance
1. Disconnect the system value is not at the standard value, replace the
glow relay.
• Remove 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 engine control 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
• 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
3. Engine coolant temperature sensor inspection
LNW21KSH000201
2. Glow relay inspection

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

• ECM engine coolant temperature sensor is a NOTE:
thermistor type whose characteristic is that the Be careful not to allow water to get into the terminal
electrical resistance decreases as the section.
temperature rises. Wipe off the water droplets on the sensor after the
inspection.
1 2 Thermistor characteristic
30
20
10
7.0
)
5.0
Resistance value(k
3.0
2.0
1 2
1.0
0.7
0.5
0.3
3 0.2
0.1
MFW71CSH000601
-20 0 20 40 60 80 100 120
Legend Engine coolant temperature( )

MFW81CSH000201
1. Indicates the wiring
2. Indicates the wiring • Replace it if any abnormality is found during the
3. ECM thermistor inspection.
• Place the temperature sensor portion of the 4. Glow plug inspection

engine coolant temperature sensor into water,
• Use a circuit tester to measure the resistance
and inspect whether the resistance value
value of the glow plug.
changes as in the graph while changing the
water temperature. • 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 4-piece set of genuine glow plugs.
MFW71KSH000201
Resistance value at a certain temperature

(approximate value)
Approx. 2.45kΩ 20°C (68°F)
Approx. 0.81kΩ 50°C (122°F)
Approx. 0.32kΩ 80°C (176°F)
LNW21KSH000701

• 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 "Engine Control System" in

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
Power Take-Off (PTO) (4HK1) 1L-1
ENGINE
Power Take-Off (PTO)
(4HK1)
TABLE OF CONTENTS
Flywheel PTO(Euro4 specification only) . . . . . . . 1L-2
Functional and Operational Description . . . . . . 1L-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1L-11
List of Tightening Torques . . . . . . . . . . . . . . . . 1L-16
1L-2 Power Take-Off (PTO) (4HK1)
Flywheel PTO(Euro4 specification only)

Functional and Operational Description
The PTO crank gear is added to the end of the
crankshaft, and the flywheel PTO is tightened to the
crankshaft together with the flywheel.
Motive energy is outputted from the PTO gear located
in the upper section of the flywheel housing, from the
PTO crank gear via the idle gear. There is no
mechanism for turning the motive power ON/OFF
partway; motive power is output by direct coupling to
the engine, regardless of the clutch and transmission
being ON/OFF.

Components
3 4
2 5
8
9
15
10
11
12
14
13
MFW71LLF000501
Legend
1. Front bearing 9. Idle gear shaft
2. PTO gear 10. Idle gear bearing
3. O-ring 11. Spacer
4. Bearing case 12. PTO crankshaft gear
5. Rear bearing 13. Flywheel housing
6. PTO shaft 14. Crankshaft
7. Oil seal 15. Idle gear A
8. Idle gear

Removal
Removal of the PTO assembly
2
3
4
5
6
7
8
9
1 10
11
21
20
19 18
17
16
15 14
13
12
MFW71LLF000601
Legend
1. Flywheel housing 12. Idle gear cover
2. Front bearing 13. Bolt
3. PTO gear assembly 14. Nut
4. Rear bearing 15. Lock washer
5. Oil thrower 16. Idle gear
6. O-ring 17. Rear bearing
7. Bearing case 18. Outer spacer
8. Oil seal 19. Inner spacer
9. Flange 20. Front bearing
10. O-ring 21. Shaft
11. Nut
1. Remove the oil pipe of the PTO gear section. • Loosen the assembly case tightening bolt, and
• Remove the clip. remove the O-ring, oil seal, rear bearing, PTO
gear, front bearing inner race in an assembled
2. Remove the PTO assembly.
state.

Removal of the PTO idle gear assembly
2 3
1 2
1
4
6
3
10
MFW71LMH000101
9
Legend MFW71LMH000501
1. PTO gear assembly Legend

2. Oil pipe 1. Idle gear A
3. Idle gear cover 2. Front bearing
3. Idle gear
3. Remove the O-ring. 4. Rear bearing
5. Lock washer
Removal of the PTO crankshaft gear assembly 6. Shaft
1. Remove the transmission. 7. Bolt
• Refer to "Transmission ASM" in Section 5B 8. Nut
Automatic Transmission (Smoother (MZX)). 9. Inner spacer
Refer to "Transmission ASM" in Section 5B 10. Thrust collar
• Refer to "Flywheel" in Section 1B, Engine
Mechanical.
3. Remove the oil seal.
• Refer to "Crankshaft Rear Oil Seal" in Section
1B, Engine Mechanical.
4. Remove the PTO crankshaft gear and spacer.

1. Remove the idle gear cover (1). 2. Remove the PTO gear assembly from the bearing
Use replacer holes (M10 x 1.5) (2) to remove it. case.
3. Remove the oil seal from the bearing case.
4. Remove the front bearing and rear bearing from
1 the PTO gear assembly.
2
1
2 3
4
5
6
7
8
9
10
11
MFW71LSH000101
2. Remove the flywheel housing.

3. Remove the baffle plate and adaptor.
MFW71LSH000201
NOTE: Legend
Do not remove it when there is no need for removal. 1. Front bearing
2. PTO gear
3. PTO shaft
2 4. Rear bearing
5. Oil thrower
1 6. O-ring
7. Bearing case
3
8. Oil seal
9. Flange
10. O-ring
11. Nut
Disassembly of the PTO idle gear assembly

1. Remove the bearing tightening nut to remove the
lock washer.
2. Use the press to pull the shaft out from the idle
gear assembly, then remove the tapered roller
bearing (front and rear).
MFW71LSH000901
3. Remove the outer races (front and rear) from the
Legend idle gear.
1. Baffle plate 4. Remove the inner spacer (shim) and the outer
2. Adaptor spacer (snap ring) from the idle gear.
3. Flywheel housing
4. Loosen the idle gear shaft bolt.

5. Remove with the shaft and idle gear assembly in
one piece.
Disassembly
Disassembly of the PTO gear assembly
1. Remove the O-ring from the bearing case.
2
3
4
5 6
7
8
MFW71LSH001001 MFW41LSH000201
Legend 2. Inspect the PTO gear.

1. Shaft • Inspect the gear tooth surfaces for damage and
2. Front bearing wear.
3. Inner spacer
3. Inspect the idle gear bearing.
4. Outer spacer
5. Rear bearing • Inspect the bearing for peeling, wear and
6. Idle gear abnormal sounds.
7. Lock washer • Inspect the entire circumference from between
8. Nut the roller and ball bearing cage to the inner race
for damage or peeling.
• Inspect the roller and ball bearing cage for any
Inspection abnormal looseness caused by wear.
1. Inspect the PTO bearing. • Rotate the bearing to manually inspect for
abnormal sounds, and check for any
• Inspect the bearing for peeling, wear and irregularities in movement.
abnormal sounds.
• Inspect the entire circumference from between
the roller and ball bearing cage to the inner race
for damage or peeling.
• Inspect the roller bearing cage for looseness
caused by wear.
• Rotate the bearing to manually inspect for
abnormal sounds, and check for any
irregularities (such as bumpiness) in
movement.
MFW41LSH000301
4. Inspect the idle gear.

• Inspect the gear tooth surface for wear and
damage, and the inner circumference for
damage.

NOTE:
There should be no gaps between the bearing end
surface and shaft surface.
3. Attach the O-ring to the bearing case and firmly fit

the rear bearing.
NOTE:
• Apply engine oil to the ball area before firmly fitting
the rear bearing.
• There should be no gaps between the bearing end
surface and case surface.
4. Firmly fit the PTO gear assembled at

Procedure 2. into the bearing case.
5. Press the oil thrower all the way in until it touches
the rear bearing.
MFW41LSH000501 6. Apply engine oil to the lip area of the oil seal, and
use oil seal installer (9-8522-1310-0) to fit it firmly
into the bearing case.
Reassembly 7. Insert and fasten the O-ring with a nut after
Reassembly of the PTO gear assembly assembling the flange to the PTO shaft.
Reassembly of the PTO idle gear
1
2 3
4
5
6 1
7
8 2
9
10 3
11 4
5 6
MFW71LSH000201
7
Legend 8
1. Front bearing
2. PTO gear MFW71LSH001001
3. PTO shaft
Legend
4. Rear bearing
1. Shaft
5. Oil thrower
2. Front bearing
6. O-ring
3. Inner spacer
7. Bearing case
4. Outer spacer
8. Oil seal
5. Rear bearing
9. Flange
6. Idle gear
10. O-ring
7. Lock washer
11. Nut
8. Nut
1. Firmly fit the PTO gear into the PTO shaft.
• Bake-fit at below 250 °C (482°F).
2. Firmly fit the front bearing into the PTO shaft.
• Firmly fit by pushing the inner race.

1. Use the snap ring pliers to insert the outer spacer a. Measure the gap in the idle gear bearing axis
(snap ring) into the idle gear. direction. Assemble the inner race of the idle
gear bearing without the inner spacer, and
measure the thickness (1) in the bearing axis
direction on a level block.
MFW41LSH000601
2. Fit the outer race of the tapered roller bearing

firmly into the outer space until they touch.
LNW71LSH001001
b. Next, assemble the inner spacer (2) and

measure the thickness (3) in the bearing axis
direction in the same way.
2
LNW71LSH000201
3. Select the inner spacer.
LNW71LSH001101
• Select spacers so that the measurements

above satisfy 0 mm (0 in) < (3) - (1) < 0.05
mm (0.002 in).
• Note that there are 21 spacer sizes in
increments of 0.07 mm (0.0028 in), ranging
from 6.05 mm (0.2382 in) to 7.45 mm
(0.2933 in).
4. Install the front side inner race to the shaft.
NOTE:
Apply engine oil to the bearing for the assembly.

5. Install the PTO idle gear.
MFW71LSH000801
MFW71LSH000601
8. Tighten the nut (2) via the lock washer (1).
6. Install the inner spacer (1).
Tightening torque 147 N⋅m (15 kg⋅m/108 lb⋅ft)
• After tightening the nut, measure the clearance
in the PTO idle gear axis direction.
- If the clearance is not within specified value,
replace the spacer and readjust it.
1
Clearance in the axis direction
0 - 0.05 mm (0- 0.002 in)
Friction starting torque

0.2 N⋅m (0.02 kg⋅m/1.7 lb⋅in)
NOTE:
• Apply engine oil to the bearing for assembly.
• The clearance value in the direction of the axis is
important. Make adjustments so that it always falls
within the specified range.
MFW71LSH000701 • After tightening, bend the lock washer to fasten the
7. Install the rear side inner spacer (1). nut.
NOTE:
Apply engine oil to the bearing for assembly.
MFW71LSH000301

Installation 2. Apply molybdenum disulfide to the bolt seat
surface and thread section, then tighten it at the
Installation of the PTO idle gear assembly
specified torque.
2 3 Tightening torque:
98 N⋅m (10.0 kg⋅m/72 lb⋅ft)
First time
Angle-controlled tightening
1 Second time
4 method 60 - 90°
• Confirm that the bolt is tightened at 157 N⋅m
5 (16 kg⋅m/116 lb⋅ft) or more in the tightening
direction.
3. Install the adaptor to the flywheel housing.
6 • Apply liquid gasket (Three Bond No. 1207C) to
the area (1) shown in the diagram below before
7
installation.
2
8
10
9
MFW71LMH000501
Legend 1
1. Idle gear A 3
2. Front bearing MFW81BSH000201
3. Idle gear Legend
4. Rear bearing 1. Liquid gasket
5. Lock washer 2. Flywheel housing
6. Shaft 3. Adaptor
7. Bolt
8. Nut
9. Inner spacer
10. Thrust collar
1. Install the idle gear assembly.

• The idle gear A and crank gear should be
aligned.
NOTE:
• The idle gear assembly should be securely installed
to the cylinder block installation section.
• Apply engine oil to the bearing just before
installation.
• Apply engine oil to the inner circumference of the
bush and the thrust contact surface of idle gear A.
• Take sufficient care to ensure that the thrust collar
does not come off.

• Apply liquid gasket (Three Bond No. 1207C) to NOTE:
the area (1) shown in the diagram below. After firmly fitting it in, do not hammer the cover section
(4).
1
2
MFW81BSH000301
Legend
1. Liquid gasket
2. Adaptor
4. Install the baffle plate.
3
4
MFW71LMH000301
MFW81BSH000401

Refer to "Timing Gear Train" in Section 1B, Engine
Mechanical.
6. Install the idle gear cover.
• Apply a thin layer of grease to the O-ring (1) to
install it.
• Apply liquid gasket (Three Bond No. 1207C) to
seven places on the flange surface (2) and the
bolt seat surface (3).
• Tighten the bolt at the specified torque.

Installation of the PTO crankshaft gear assembly
1. Install the spacer to the crankshaft gear.
2. Position the crankshaft gear to the crankshaft
knock pin, then tap with a rubber hammer to set it.
3. Install the oil seal retainer.
• When installing, apply Three Bond No. 1207C.
4. Install the slinger oil seal set to between the
crankshaft gear and oil seal retainer.
• Refer to "Crankshaft Rear Oil Seal" in Section
1B, Engine Mechanical.
• Refer to "Flywheel" in Section 1B, Engine
Mechanical.
6. Install the transmission.

Installation of the PTO assembly
2
3
4
5
6
7
8
9
1 10
11
21
20
19 18
17
16
15 14
13
12
MFW71LLF000601
Legend
1. Flywheel housing 12. Idle gear cover
2. Front bearing 13. Bolt
3. PTO gear assembly 14. Nut
4. Rear bearing 15. Lock washer
5. Oil thrower 16. Idle gear
6. O-ring 17. Rear bearing
7. Bearing case 18. Outer spacer
8. Oil seal 19. Inner spacer
9. Flange 20. Front bearing
10. O-ring 21. Shaft
11. Nut
1. Apply a thin layer of oil to the O-ring and install to 3. Install the PTO assembly to the flywheel housing
the bearing case. and tighten the bearing case at the specified
2. Firmly fit the front bearing outer into the gear case. torque.
• Apply engine oil to the ball part of the bearing Tightening torque: 47 N⋅m (4.8 kg⋅m/35 lb⋅ft)
before firmly fitting it in.

4. Install PTO oil pipe brackets (1) and (2).
MFW71LMH000401
5. Install the oil pipe of the PTO gear unit.

• Install the clip.

e d
MFW71LLF000301
(a) 47 N⋅m (4.8 kg⋅m/35 lb⋅ft)

(b) 480 N⋅m (48.9 kg⋅m/354 lb⋅ft)
(c) 98 N⋅m (10.0 kg⋅m/72 lb⋅ft) → Angle-controlled tightening method 60 - 90°
(d) 147N⋅m (15.0 kg⋅m/108 lb⋅ft)
(e) 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
MG4HK-WE-0871_69197奥付 2011.5.7 5:15 PM ページ 1
Published: May, 2011 All rights reserved.

Seventh Edition
WORKSHOP MANUAL
ENGINE
(4HK1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
MG4HK-WE-0871_69197奥付 2011.5.7 5:15 PM ページ 2
2008-2011MY
2008-2011MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4HK1 model)

ENGINE
(4HK1 model)
No.MG4HK-WE-0871

01 Engine MG4HK-WE-0871 7th

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

01 Engine MG4HK-WE-0871 7th

Uploaded by

Copyright:

Available Formats

TOP

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 Clearance Between the

Engine Mechanical (4HK1) 1B-5

1B-6 Engine Mechanical (4HK1)

Engine Mechanical (4HK1) 1B-7

1B-8 Engine Mechanical (4HK1)

Engine Mechanical (4HK1) 1B-9

Euro4 specification only

1B-10 Engine Mechanical (4HK1)

Euro3 specification only

Engine Mechanical (4HK1) 1B-11

Euro2 specification only

1B-12 Engine Mechanical (4HK1)

Euro4 specification only

Engine Mechanical (4HK1) 1B-13

1B-14 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-15

Valve clearance mm (in)

• When the 1st cylinder is at the compression top

a. Completely loosen each adjust screw of the

1B-16 Engine Mechanical (4HK1)

4. Install the battery negative terminal.

6. Install the compression gauge adaptor and the

Compression pressure inspection

Engine Mechanical (4HK1) 1B-17

Compression pressure MPa (kg/cm2/psi) / r/min

• Sequentially measure each cylinder.

8. Remove the compression gauge.

Determining the overhaul period

Increasing the fuel consumption rate

Abnormal noises in engine

1B-18 Engine Mechanical (4HK1)

Engine Mechanical (4HK1) 1B-19

Condition Possible Cause Correction

1B-20 Engine Mechanical (4HK1)

Condition Possible Cause Correction

Engine Mechanical (4HK1) 1B-21

Condition Possible Cause Correction

1B-22 Engine Mechanical (4HK1)

Condition Possible Cause Correction

Engine Mechanical (4HK1) 1B-23

Condition Possible Cause Correction

1B-24 Engine Mechanical (4HK1)

Condition Possible Cause Correction

Engine Mechanical (4HK1) 1B-25

Condition Possible Cause Correction

1B-26 Engine Mechanical (4HK1)

Engine Mechanical (4HK1) 1B-27

1B-28 Engine Mechanical (4HK1)

Illustration Tool Number/ Description Illustration Tool Number/ Description

Engine Mechanical (4HK1) 1B-29

1 5. Remove the transmission.

6. Remove the engine harness.

3. Remove the oil level gauge.

1B-30 Engine Mechanical (4HK1)