Mechanical Specification & Structure

Applicable Model Model Year 2001 2002 2003 Vehicle Model N*R 77 N*R 77 N*R 77 Emission Regulation Euro 3 Euro 3 Euro 3 / EPA 98


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MAIN CONSTRUCTION PARTS ------------------------------------------------------------------------------------PISTON, PISTON RING & CONNECTING ROD ------------------------------------------------------CRANKSHAFT ------------------------------------------------------------------------------------CYLINDER HEAD ------------------------------------------------------------------------------------VALVE MECHANISM ------------------------------------------------------------------------------------TIMING GEAR TRAIN ------------------------------------------------------------------------------------FLYWHEEL ------------------------------------------------------------------------------------EXHAUST SYSTEM ------------------------------------------------------------------------------------TURBOCHARGER ------------------------------------------------------------------------------------EGR SYSTEM ------------------------------------------------------------------------------------ENGINE LUBRICATION

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LUBRICATION SYSTEM ------------------------------------------------------------------------------------OIL PUMP ------------------------------------------------------------------------------------OIL FILTER & OIL COOLER --------------------------------------------------------------------------------

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------------------------------------------------------------------------------------------------------------------------------------------------------------------------THERMOSTAT ------------------------------------------------------------------------------------COOLING FAN & FAN CLUTCH --------------------------------------------------------------------------RADIATOR & RADIATOR CAP --------------------------------------------------------------------------RESERVOIR TANK ------------------------------------------------------------------------------------FUEL SYSTEM -------------------------------------------------------------------------------------

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FUEL INJECTION PUMP ------------------------------------------------------------------------------------FUEL INJECTION NOZZLE -------------------------------------------------------------------------------FUEL FILTER



------------------------------------------------------------------------------------------------------------------------------------------------------------------------PREHEATING SYSTEM ------------------------------------------------------------------------------------SPECIAL TOOLS
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N*R 4JH1-TC Engine-1









1. Engine Coolant Temperature (ECT) Sensor 2. Injection Pump 3. Check Hole (Scissors Gear) 4. Check Hole (Injection Pump Gear)

5. EGR Valve 6. EGR Cooler 7. Crankshaft Position (CKP) Sensor = Top Dead Center (TDC) Sensor

The 4JH1-TC engine is equipped with a water-cooled turbocharger. -Flywheel with crankshaft position (CKP) sensor timing slot -Timing gear train -Gear driven camshaft -Idler gear features a scissors gear -Exhaust gas re-circulation (EGR) system with cooler -Gear driven VP44 fuel injection pump . The mechanical features are follows. the exhaust emission regulations are described in the Euro 3 standards.N*R 4JH1-TC Engine-2 The four cycle direct injection 4JH1-TC engine features two valves per cylinder that are operated via a single camshaft fitted to the engine block. The crankshaft has been tufftrided to provide a longer service life. Chrome plated dry type cylinder liners provide the highest durability. Auto-thematic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold. a new high-pressure injection pump and an oil filter housing with cooler. And. The 4J series automotive diesel engine has special designed combustion chambers in the piston. Because the crankshaft is tufftrided. intercooler and EGR cooler. This design provides superior fuel economy over a wide range of driving conditions. The 4JH1-TC engine is equipped with the VP44 injection pump that is fully electrically controlled via the engine management system made by Bosch . it cannot be reground.

5 54.N*R 4JH1-TC Engine-3 ENGINE MAIN DATA & SPECIFICATION General Engine Model Engine Type Engine Dimension (mm) (Length x Width x Height) Engine Weight (Kg) (With Clutch Housing.Number of Cylinders Fuel Injection Order Bore x Stroke (mm) Total Displacement (cc) Bore Pitch (mm) Compression Ratio Combustion Camber Type Cylinder Liner Idle Speed (rpm) Fast Idle Speed (rpm) Full Load Maximum Engine Speed (rpm) No Load Maximum Engine Speed (rpm) Fuel System Injection Pump Type Injection Nozzle Type Number of Injection Hole Diameter of Injection Hole (mm) Designed Value of Injection Nozzle Operating Pressure (Mpa) Adjustment Value of Injection Nozzle Operating Pressure (Mpa) Fuel Filter Type Valve System Valve Layout Drive Type Intake Valve Open At BTDC (deg) Intake Valve Close At ABDC (deg) Exhaust Valve Open At BBDC (deg) Exhaust Valve Close At ATDC (deg) Intake Valve Clearance At Cold (mm) Exhaust Valve Clearance At Cold (mm) 4JH1-TC Diesel.35.4 0.0 18.3 .21 19.8 (2nd) 20.8 (2nd) Cartridge Paper Element and Water Separator Overhead Valve Gear Drive 24.4 .8L) Cylinder Layout .4 x 104.0 0. Coolant 5.0 (1st) 34.5 55. Fan Guide) Engine Weight (Kg) (With Engine Oil 7.0 26.0 .0L.9 2999 106.21.5 (1st) 33.3 Direct Injection Dry Type 700±25 750±25 3600±100 4200±100 BOSCH VP44 (Electronic Controlled) Two Spring Type (Hole Nozzle) 5 0. Four Cycle 767 x 589 x 707 Approximately 255 Approximately 269 Inline-Four Cylinders 1-3-4-2 95.

21 Wax Pellet With Jiggle Valve 82±2 Pressure Circulation Gear 6.60 / 12 .8.3 12 .0 .3 Centrifugal Impeller Type 1.2.N*R 4JH1-TC Engine-4 Cooling System Cooling Method Water Capacity (Litters) (Including Radiator) Water Pump Type Water Pump Pulley Ratio (Crank / Pump) Thermostat Type Thermostat Opening Temperature (deg.0 Cartridge Paper Element RHF5H Type (IHI) Equipped Dry Paper Element Equipped Water Cooled Assembled in Silencer Closed Type QOS 2 12 .80 IC 95D31R . C) Lubricating System Lubricating Method Oil Pump Type Oil Capacity (Litter) Oil Filter Type Intake System Turbocharger Intercooler Air Cleaner Type Intake Throttle & Exhaust Throttle Exhaust System EGR System Catalytic Converter Type PCV System Glow System Starting System Starter Motor Output (V-kW) Charge System Alternator Output (V-A) Regulator Type Battery Type Water Cooled 7.

the liner can be easily replaced. the wear is greatest near the top of piston ring at top dead center. liners can be divided into a dry type and a wet type according to the cooling method employed. With cylinder liners. The cylinder block is made of cast iron because it has to be strong enough to resist not only high temperatures.N*R 4JH1-TC Engine-5 MAIN CONSTRUCTION PARTS CYLINDER BLOCK Cylinder Block The cylinder block is a complex structure with cooling water and lubricating oil passages. The carbon generated by combustion absorbs the sulfuric acid. but also the high pressure gasses generated in the cylinders. The water cooled cylinder block can be divided into a one-piece cast type and a liner type. In the liner type liners are inserted into the cylinder portion of the block. side pressure. Cylinder Liner Grade Identification . it is necessary to measure the liners to make sure that the dimensions meet the requirement. The sulfur contained in light oil is burnt to form SO2. sulfuric acid is generated by the reaction (H2O + SO3 = H2SO4). When the water vapor in the burnt gas reaches the dew point. This is due to piston slapping. and thermal expansion. part of which is oxidized into SO3. and the wear decreases towards bottom dead center. With the dry liner type. and crankshaft supports in the lower part. because heat conduction decreases is the liners do not closely fit the cylinder block. Furthermore. When worn. thin sleeve is pressed into place inside the cylinder. When replacing liners. It also needs to have sufficient corrosion resistance to withstand these gasses. With dry liner type there is no possibility of cooling water leakage. and causes serious chemical corrosion.

021 .030 2 2-AX (For piston size AX) 2-CX (For piston size CX) 3 97. This information is important when cylinder liners need to be replaced.001 . The production line stamped cylinder liner grade on the top of cylinder body.020 Liner Set Grade (Including Piston) 1 Liner Grade (Without Piston) 1-AX (For piston size AX) 1-CX (For piston size CX) 2 97.040mm .020 97.97. Service Standard: 97.021 . Marks are made on top of the cylinder block to indicate the cylinder liner diameter.97.97. Calculate the average value of the four measurements.97.3 and 4 . you will select service parts grade for cylinder liner "1-AX" grade and for piston "AX" grade.1.041 .050 4 4-AX (For piston size AX) 4-CX (For piston size CX) The 4JH1-TC engine employs chrome plated dry type cylinder liner. 2 . Inspection Item Cylinder Body Bore Measurement Required Tool: Cylinder Indicator Measure the point "A" across 1 . 2.N*R 4JH1-TC Engine-6 Production Line Use Liner Outside Grade 1 Measurement in Service Cylinder Body Bore Diam eter Average (mm) 97. 3 .97. If you find cylinder liner outside diameter grade "1" on the cylinder body and piston outside diameter "B" on the piston top or result of measurement of each parts.011 .97.97.001 .4.97.031 .040 3 3-AX (For piston size AX) 3-CX (For piston size CX) 4 97.011 . the cylinder liner outside diameter grade 1.040 97.97.031 .010 Service Parts Liner Outside Diameter (mm) 97. 3 and 4.030 97.2.

03mm .0.40mm Service Limit: 95.48mm Cylinder Body Upper Face Warpage Required Tool: Straight Edge. Feeler Gauge Service Standard: 0 .2 and 3 .N*R 4JH1-TC Engine-7 Cylinder Liner Bore Measurement Required Tool: Cylinder Indicator Measure the point "1" (20mm) across 2 . Service Standard: 95.05mm or less Service Limit: 0.1mm Service Limit: Between any two adjacent cylinders must not exceed 0. Calculate the average value of the two measurements. Feeler Gauge Service Standard: 0.3.20mm Cylinder Liner Projection Required Tool: Straight Edge.

. The gas pressure is conveyed to the crankshaft. various factors. Therefore. and reduce the gas sealing performance. Piston Pin Snap Ring 4. Piston Ring Carrier When the piston temperature rises. Piston The 4JH1-TC engine accommodates the 4 pistons made of aluminum alloy. Connecting Rod Bearing 2. The pistons are exposed to high temperature and high pressure gas during the explosion stroke. and at the same time maintain combustion pressure in the combustion chambers. and dimensions. piston expansion will increase and this causes piston seizure or ring sticking. Then ring groove wear will increase. particularly. PISTON RING & CONNECTING ROD 1. the piston pin center is offset a certain amount to the thrust side of the bore to reduce side forces on the piston and this marks for reduced piston slapping noise.N*R 4JH1-TC Engine-8 PISTON. Thus. thermal expansion. 1 1. During operation. Piston Pin 5. Piston Ring 3. With the offset piston. and most of the heat received is released to the cooling water via the cylinder walls. shape. the pistons must undergo continuous reciprocating motion at high speed along the cylinder walls under side pressure. such as piston weight. Connecting Rod 6. a special cast iron ring carrier is cast into the top ring groove which is exposed to a great heat load and this improves wear resistance of the ring groove. in the case of aluminum alloy pistons. must be taken into account in designing the pistons.

384 95.374 CX 95.394 Service Grade AX Service Piston Diameter (mm) 95.390 The piston diameter is essential information in case an engine is overhauled.355 . Front Mark Size Mark A B C D Outside Diameter (mm) 95.95.374 95.359 .365 .375 .385 .364 95.95. A.95. . B.95. Note: The cylinder liner installation procedure may result in slight decreases in cylinder liner clearances.N*R 4JH1-TC Engine-9 1. These marks can be found at the top of the piston. Always measure the cylinder liner clearance after installation to be sure that it is correct. The tolerance between the piston and the cylinder liner is important to assemble the engine. Size Mark Identification 2.95. Using the above diagram you can order the correct piston.95. C and D are the marks used to identify the piston diameter.374 .

and those used for scraping off excess oil. Oil rings are tapered or grooved on their sliding surface to increase unit pressure so that a close fit with the cylinder walls can be maintained by their own tension. Two piston rings guarantee a fast build up of air pressure and one oil ring prevents oil from the sump entering the combustion chamber.N*R 4JH1-TC Engine-10 1. and prevent excess oil from entering the combustion chambers. Oil Ring 2. This is the only time they move ahead of the pistons. During the explosion stroke the high pressure gas pushes down the rings. The compression rings alternately hit the top and bottom of the ring grooves as the pistons run up and down. The compression rings also increase combustion pressure as the high pressure gas pushes the rings towards the cylinder walls from behind the rings. First Compression Ring The aluminum alloy pistons of 4JH1-TC engine have an integrated toroidal shaped combustion chamber with centrally arranged swirl chambers. To meet demands for oil rings with greater unit pressure suitable for high speed engine. They also conduct the heat received by the pistons to the cylinder walls. The piston rings scrap off the oil sprayed on the cylinder walls to leave the minimum required oil film to lubricate the pistons and piston rings. . The piston rings are fitted into the ring grooves around the pistons to keep the combustion chamber airtight between the piston and cylinder. Second Compression Ring 3. are known as oil rings. oil ring with expander have come into general use. The rings used mainly to maintain combustion pressure are called compression rings.

and transmits explosion forces imposed on the piston. One end of the connecting rod is connected to the piston with a piston pin. The piston bottom is special shaped to guide the oil along the entire surface to ensure a sufficient cooling. directly from the oil pump. however the big end is divided into two pieces. and they are tightened to the crankshaft with bolts. and is called the "small end".N*R 4JH1-TC Engine-11 Piston Cooling Jet Four oil jets are placed under the pistons to cool the piston bottom. While the other end is called "big end" generally a bushing is press-fitted to the small end. tension and bending forces. . to the crankshaft. The connecting rod is made of forging metal to resist compression. The jets are supplied with oil. 1. Piston Front Mark 2. Connecting Rod Front Mark The connecting rod is a rod which connects a piston to the crankshaft.

075mm Piston Ring & Ring Groove Clearance Required Tool: Feeler Gauge Service Standard: Service Limit: 30.N*R 4JH1-TC Engine-12 Inspection Item Piston Diameter & Piston Clearance Measurement Required Tool: Micrometer Measurement Point: 70mm Service Grade: AX 95.390mm Cylinder Liner & Piston Clearance: 0.5mm (1st & 2nd) / 0.10mm / 2.05 .0.374mm / CX 95.31.97mm .150mm Piston Ring Gap Required Tool: Feeler Gauge Measurement Point: 1.95.3 .120mm Service Standard: 0.25 .0.09 .13mm (1st) / 0.995 .375 .07mm (Oil) Service Limit: 0.5mm Piston Pin Diameter Required Tool: Micrometer Service Standard: 30.03 .0.057 .0.45mm (Oil) Service Limit: 1.359 .09 (2nd) 0.0.

08mm or Less (Bend) / 0.0.35mm Piston Pin & Connecting Rod Small End Bushing Clearance Required Tool: Caliper Calibrator.008 .15mm (Twist) Connecting Rod Thrust Clearance Required Tool: Feeler Gauge Service Standard: 0.N*R 4JH1-TC Engine-13 Connecting Rod Alignment Required Tool: Connecting Rod Aligner.23mm Service Limit: 0. Feeler Gauge Service Standard: 0.020mm Service Limit: 0.05mm or Less (Twist) Service Limit: 0. Dial Indicator Service Standard: 0.050mm .20mm (Bend) / 0.

Therefore. Crankshaft Bearing Cap The crankshaft is the main shaft of the engine which takes the pressure of burnt gas generated during engine operation at the crankshaft pins via the connecting rods. Crankshaft Upper Bearing 3. The crankshaft balance relative to its axial center is maintained by adjusting the balance weights.N*R 4JH1-TC Engine-14 CRANKSHAFT 1. Crankshaft 2. Crankshaft Lower Bearing 4. tufftriding (nitrizing treatment) has been applied. Because of this. . and transmits it to the outside. specially by drilling holes in them. Crankshaft Thrust Bearing 5. converts the power into rotary motion. under size bearing are not available. it is not possible to regrind the crankshaft surfaces. Note: To increase crankshaft strength.

983 – 73.992 1 or 2 or 3 or 3 73.061 0.922 69.044 .060 2 73.059 0.0.922 .0.066 0.69.922 .932 69.045 .917 . .69.74.975 – 73.0.050 .N*R 4JH1-TC Engine-15 Crankshaft Bearing Grade Mark Identification Crankshaft Journal Grade Identification Main Bering Bore Diameter (mm) Grade Main Bearing Bore Diameter (mm) 73.927 .0.068 0.037 .061 0.992 .063 0.042 .927 .983 1 or 2 or 3 or .927 69.055 0.039 .927 .044 .922 69.0.917 .053 0.0.932 69.0.917 .69.000 Crankshaft Main Journal Diameter (mm) Size Mark 1 or 2 or 3 or Outside Diameter Crankshaft Bering Size Oil Clearance (mm) 1 69.927 69.927 69.69.052 .69.0.922 .69.922 4 4 5 2 3 4 1 2 2 0.932 69.0.

915 .N*R 4JH1-TC Engine-16 Inspection Item Crankshaft Run-out Required Tool: Dial Indicator Service Standard: 0.917 .110mm Crankpin & Connecting Rod Bearing Clearance Required Tool: Cylinder Indicator Service Standard: 0.08mm Crankshaft & Crank Pin Diameter Required Tool: Micrometer Measure the point 3.2.1 and 2 .930mm (Crank Pin) 0. Service Standard: 69.100mm .08mm (Uneven Wear) Crankshaft Journal & Bearing Clearance Required Tool: Cylinder Indicator Service Standard: 0.029 .91mm (Crankshaft Journal) 52.90mm (Crank Pin) 0.0.037 .69.068mm Service Limit: 0. 4 across 1 .52.932mm (Crankshaft Journal) 52.083mm Service Limit: 0.05mm or Less Service Limit: 0.0.05mm or Less (Uneven Wear) Service Limit: 69.

have complex water cooling passages to cool them uniformly since they are heated to high temperatures. therefore. It is exposed to burnt gas at high temperatures. problems such as burnt gas leakage and gasket damage can result. Water By-pass Hose 2. Rocker Arm Shaft & Rocker Arm 6. Injection Nozzle & Nozzle Holder 5. Cylinder Head 8. The cylinder head is mounted on the cylinder block with a gasket between them. The cylinder head is made of cast iron having great heat resistance and strength. and therefore must be airtight against compression and explosion pressures. in particular. Cylinder Head Cover 4. it can in some cases become distorted over a long period. It is necessary. Cylinder Head Gasket The cylinder head is a vital component which forms the combustion chamber together with the cylinder block and piston. . It is fitted with a valve mechanism and injection nozzles.N*R 4JH1-TC Engine-17 CYLINDER HEAD 1. Unless the mounting bolts are tightened evenly in the proper order. Because the cylinder head is a casting. The exhaust valves and injection nozzles. Thermostat Housing 3. to check the flatness of its seating surface whether it is removed or installed. Push Rod 7.

215 – 0.315 – 0.265 Gasket Thickness 1.30 0.N*R 4JH1-TC Engine-18 Loosening Order Cylinder Head Bolts Torque 1st Step: 49Nm 2nd Step: 60 degree . Gasket Grade Mark Piston Projection 0.75 degree Tightening Order Loosen the cylinder head bolts in numerical order a little at a time. The thickness of the cylinder head gasket can be retrieved from three different marks that are located under the intake manifold.35 0. . The cylinder head gasket is of a metal 4 layer type of which the thickness can be identified even when the cylinder head is assembled to the engine. lubricant oil and cooling water at the same time. The cylinder head bolts are tightened according to the torque tightening method in numerical order. In case of an overhaul of the engine the thickness of the cylinder head gasket can be determined by measuring the piston projection.365 1.265 – 0.315 1.40 A cylinder gasket has to seal the combustion gases. They need to be checked for cracks and damages when dismantled.75 degree 3rd Step: 60 degree .

40mm Exhaust Manifold Warpage Required Tool: Straight Edge.05mm or Less Service Limit: 0. Feeler Gauge Service Standard: 0.05mm or Less Service Limit: 0.55mm Manifold Fitting Face Warpage Required Tool: Straight Edge. Feeler Gauge Service Standard: 0.05mm or Less Service Limit: 0. Feeler Gauge Service Standard: 0.N*R 4JH1-TC Engine-19 Inspection Item Cylinder Head Lower Face Warpage Required Tool: Straight Edge.20mm .20mm Cylinder Head Height Required Tool: Height Gauge Service Standard: 92.00mm Service Limit: 91.20mm Maximum Grinding Allowance: 0.

Spring 6. The rocker arm is a lever moving about the rocker arm shaft. it will seriously affect engine performance.N*R 4JH1-TC Engine-20 VALVE MECHANISM 1. The purpose of the camshaft and rocker arms is to open and close the intake and exhaust valves to control the combustion timing. tappets. If these parts are worn or damaged. Rocker Arm Shaft Bracket 4. Camshaft Thrust Plate 3. camshaft gear. Camshaft Timing Gear 2. depends particularly on the cams. idler gear. Rocker Arm 3. valves and valve springs. The camshaft has intake and exhaust cams for every cylinder. Camshaft 1. involving valve opening and closing timing and firing order. Rocker Arm 5. Engine performance. camshaft. Rocker Arm Shaft The valve mechanism opens and closes the intake and exhaust valves at the correct moment to raise intake and exhaust efficiency and assure satisfactory delivery of engine performance. push rods. Snap Ring 7. and conveys the motion of the push rod driven by the cam to open and close the valve. The crankshaft indirectly of engine performance. It consists of a crank gear. The crankshaft indirectly drives the camshaft through a gear. rocker arms. Snap Ring 2. .

.5 degree 26. Air keeps flowing into the cylinder as long as there is a negative pressure.0 degree 55.N*R 4JH1-TC Engine-21 Valve Lift Ex-Valve In-Valve TDC BDC TDC BDC TDC 54. This is to discharge the remaining burnt gas by the intake of a fresh charge of air. as the combustion chamber pressure is high. the bottom surfaces of the tappet is machined to a spherical surface to prevent the cam and tappet from deviating wear. so the intake valve is closed after the piston begins to rise from bottom dead center. tappets are made of special cast iron. This condition is known as valve overlap. There is some delay due to the fact that the intake air has a moment of inertia and that the intake air passage area does not instantaneously increase. and can be expressed by the crankshaft rotary angle. Furthermore. Tappet Tappets operate to convey the cam action to the valves through push rod and rocker arms. To put is other way. It follows. Therefore. more air can be drawn into the cylinder by opening the valve slightly before top dead center. The timing is controlled by the camshaft. each cam and tappet are offset to turn the tappet during operation and this makes for even contact with each other. Tappets have to withstand large forces these are the pressure of burnt gas. and to improve the contact condition.0 degree 24. The valves do not open and close exactly at top dead center and bottom dead center because the intake air would not flow in immediately upon the opening of the intake valve. and closed after top dead center. therefore. It is known from the above description that there is a overlap period where both the intake and exhaust valves are open near top dead center. and the surface in contact with the cam is hardened by a suitable heat treatment.5degree Valve timing means the valve opening and closing operation peculiar to an engine. The exhaust valve is opened before bottom dead center to assure smooth discharge of exhaust gas. the tensile force of valve springs and inertia force of moving parts.

The valve face is machined to angle of 45 degree to seal the gas and convey heat to the valve seat when the valve is closed.2mm Rocker Arm Shaft Outside Diameter Required Tool: Micrometer Service Standard: 18. Inspection Item Rocker Arm Shaft Run-out Required Tool: Dial Indicator. Valve springs hold the working parts of the intake and exhaust valve mechanism to the cams by spring tension while the valves are in motion. Further.N*R 4JH1-TC Engine-22 Valve & Valve Spring The purpose of the intake and exhaust valves is to assist passage of as much air and discharge gas as possible in the very short time of a single cycle of this piston. V-Block Service Limit: 0. The valves supported by valve guides.90mm . they have to withstand operation over an extended period. operate only in the vertical plane. The valve spring holds the valve to the valve seat while it is closed to keep the combustion chamber airtight.98 . The valves are made of heat resistant steel because the intake valves have to withstand temperatures up to about 400 degree centigrade and the exhaust valves operate in a temperature from 500 degree centigrade to 800 degree centigrade. In addition the valves prevent high pressure gas leaking while in the are the closed position being able to open and close correctly despite exposure to high temperature burnt gas.00mm Service Limit: 18.19. thereby correctly opening and closing the valve according to the cam profile.

2 Service Standard: 49.20mm Camshaft Run-out Required Tool: Dial Indicator.100mm 0.010 .030mm 0.02mm Service Limit: 41.10mm (Clearance) Camshaft Thrust Clearance Required Tool: Dial Indicator Service Standard: 0.975mm Service Limit: 49.0.06 .60mm Cam Height Required Tool: Micrometer Service Standard: 42.65mm .02mm or Less Service Limit: 0.19. Dial Indicator Service Standard: 19. V-Block Service Standard: 0.08mm (Clearance) Service Limit: 19.08mm Service Limit: 0.N*R 4JH1-TC Engine-23 Rocker Arm Inside Diameter Required Tool: Caliper Calibrator.10mm Camshaft Journal Diameter Required Tool: Micrometer Measure the point across 1 .1 & 2 .945 .49.

4mm (In & Ex) .99mm Service Limit: 12.0.4mm or Less Valve Clearance Required Tool: Feeler Gauge Service Standard: 0.08mm 0.00 .N*R 4JH1-TC Engine-24 Camshaft Bearing Inside Diameter Required Tool: Cylinder Indicator Service Standard: 50.085mm (Camshaft Bearing Clearance) Service Limit: 0.025 .97 .95mm Tappet & Cylinder Body Clearance Required Tool: Cylinder Indicator Service Standard: 0.12mm (Camshaft Bearing Clearance) Tappet Outside Diameter Required Tool: Micrometer Service Standard: 12.03mm Service Limit: 0.10mm Push Rod Curvature Required Tool: Feeler Gauge Service Limit: 0.

2mm (In) / 2.0.064 .200mm (In) / 0.093mm (Ex) Service Limit: 0.38mm (Ex) Service Limit: 1.7.1mm (In & Ex) Service Limit: 1.069mm (In) / 0. Depth Gauge Service Standard: 1.N*R 4JH1-TC Engine-25 Valve Stem & Valve Guide Clearance Required Tool: Dial Indicator with Stand Service Standard: 0.41mm (In) / 1.250mm (Ex) Valve Stem Outside Diameter Required Tool: Micrometer Service Standard: 7.0mm (Ex) Service Limit: 2.921 .5mm (Ex) .7mm (In) / 2.961mm (In) / 7.0.6mm (In & Ex) Valve Contact Width Required Tool: Vernier Caliper Service Standard: 1.946 .7.850mm (Ex) Valve Thickness Required Tool: Vernier Caliper Service Standard: 1.880mm (In) / 7.936mm (Ex) Service Limit: 7.039 .1mm Valve Depression Required Tool: Straight Edge.

1mm Valve Spring Squareness Required Tool: Steel Square Service Limit: 1.0mm Service Limit: 47.N*R 4JH1-TC Engine-26 Valve Spring Free Height Required Tool: Vernier Caliper Service Standard: 48.9mm Service Standard: 296.2N Service Limit: 257.9N .7mm Valve Spring Tension Required Tool: Spring Tester Compressed Height: 38.

Idle Gear A 3. Idle Gear B (Scissors Gear) 4. Fuel Pump Gear 5. where one idler gear is equipped with "scissors gear". :" & Idle Gear A ". -Stiff and compact construction -Maintenance free -Direct power drive The gear train consists of five gears. :" 4. Timing Mark Idle Gear B ". 1." & Idle Gear A ". Benefits of a gear type timing system are. Crankshaft Gear 2. Timing Mark Camshaft Gear ":" & Idle Gear A ":" 3.N*R 4JH1-TC Engine-27 TIMING GEAR TRAIN 1." 2. . Camshaft Gear The 4JH1-TC engine used a gear type timing system. Timing Mark Crankshaft Gear ". eliminates play in the gear train and reduces engine noise. Timing Mark Idle Gear B ". ." & Fuel Pump Gear". This special gear." .

:" which corresponded to timing mark on the idler gear B. :" which corresponded to timing marks on the idler gear A. It has timing marks ". Align Mark for Pump Gear 6. . The number of teeth of the idler gear A is 42 teeth. It has timing mark ":" which correspond to timing mark on the camshaft gear. installed onto a shaft. Main Gear The idler gear B is a scissors gear type. and ". Align Mark for Idle Gear 5." that corresponds with a timing mark on the idler gear A. Bushing 11. .N*R 4JH1-TC Engine-28 Crankshaft Gear 1. Pin (Sub Gear Side) 4. Pin 8. and ". Sub Gear 10. The bearing is supplied with oil via the hollow shaft. Locking Bolt 3. Idler Gear A The idler gear A is a gear that transfers the rotating force to the idler gear B and camshaft gear. and ". Front 9. Crankshaft Gear Timing Mark The crankshaft gear (30 teeth) has a timing mark ". Special about this idler gear B is that it is equipped with two scissors gears. Idler Gear B 1. Pin (Main Gear Side) 2. Spring 7." which corresponded to timing mark on the crankshaft gear." which corresponded to the fuel pump gear. The one at the back eliminates that backlash of idle gear A and the pump gear. The number of teeth of the idler gear B is 52 teeth.

The idler gear A and idler gear B must be fixed with a bolt. Spring 1. and the elliptical spring is set between those pins. Main Gear 7. Under this condition. When installing the scissors gear. Rear Gear 6. The pins are fixed on the main gear and the sub gear. Bearing 8. Rotation Direction 6. Front Gear 9. Snap Ring 2. Spring Force 5. pins and an elliptical spring. After installing the scissors gear. Drive Gear 2. Spring 3. the bolt is removed to release the spring. The cam gear must be fixed with a bolt and is positioned by a key. Sub Gear 4. sub gear. Lock Bolt The scissors gear comprises a main gear. . Snap Ring 5. the main gear and sub gear must be fixed with the spring compressed.N*R 4JH1-TC Engine-29 Structure & Action of Scissors Gear 1. Main Gear 3. Spring 4. the main gear and sub gear are opened by the tensile force of the spring between the mate gears to reduce the backlash to zero.

Under normal circumstances. Please take in account that when timing gears are aligned using the timing gear marks shown in the picture above. inspection holes are available in the timing case. a cover seals these inspection holes. Top dead center can be identified by the marks on the crankshaft pulley and the timing gear case. . In case the gear case is removed. When the covers are removed. To inspect or set the aligning of the timing gear. two or three different timing marks are visible on the gears.N*R 4JH1-TC Engine-30 Fuel Pump Gear The fuel pump gear is fixed to the fuel pump with a center bolt and positioned by a key to the fuel pump shaft. the second mark of the gear becomes visible. The fuel pump gear has 60 teeth. . The fuel pump pulley has a timing mark ". These marks are used for aligning timing related parts that do not require disassembling of the timing case." which corresponds to timing marks on idler gear B. that you have to rotate the crankshaft to top dead center to check the timing through the inspection holes.

Crankshaft Position (CKP) Sensor 2. . Clutch Cover The flywheel is added crankshaft position (CKP) sensor pulsar function. This signal is required by the ECM to identify the crankshaft position and the engine speed. The CKP sensor located at the flywheel housing uses these slots to generate an inductive signal. The sensor reads the four slots that are incorporated in the flywheel.N*R 4JH1-TC Engine-31 FLYWHEEL 1 2 3 1. Flywheel with Sensor Slot 3.

Rhodium (Rh) or Palladium (Pd). . The catalytic converter exists of a ceramic carrier that has a thin active layer that consists of small quantities of noble metals.N*R 4JH1-TC Engine-32 EXHAUST SYSTEM 1. Exhaust Brake Unit 2. Inspection Item Exhaust Brake Unit Required Tool: Vacuum Gauge Check to see if the exhaust valve opens and closes smoothly when the power chamber is applied with a negative pressure (400 mmHg 700mmHg) by the vacuum pump. The conversion rate is very dependent on the temperature of the ceramic material. The following metals can be used Barium (Ba). Please note that the ceramic material can be damaged if subject to excessive shocking. This oxidation catalytic converter is capable of decreasing Hydro Carbon (HC) and Carbon monoxide (CO) by utilizing excess air present in the exhaust gasses of a diesel engine. Platinum (Pt). The normal operating temperature of an oxidation catalytic converter is 600-800 degree centigrade. Exhaust Silencer With Catalytic Converter The oxidation catalytic converter is housed inside the silencer just after the engine brake valve.

These parts are supported by the bearing housing. with floating bearings. The turbocharger increases air intake efficiency. This results in increased engine power. trouble with the turbocharger is indicated..N*R 4JH1-TC Engine-33 TURBOCHARGER Turbo Spec. If reduced performance is noted. 1 2 3 1. made by Ishikawajima-Harima Heavy Ind. Isuzu Parts Number Serial No. If there is no apparent engine damage or wear. A water-cooled turbocharger. The turbocharger internal mechanism consists of the turbine wheel. Production Serial Number 3. check the engine for damage or wear. Part materials have been carefully selected and machined to extremely high precision. Ltd. and the radial bearings. the compressor wheel. The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing air exhaust port. RHF5H Parts No. . Co. (IHI RHF5) is used. and minimal engine noise. Turbocharger Specification Number 2. The turbocharger operates at very high speeds and temperatures. reduced fuel consumption. Turbocharger servicing requires great care and expertise.

Oil Feed Pipe 3.8KPa (862 .2 .08mm Service Limit: 0.0. Exhaust Manifold 1.124. Turbocharger Assembly 2.09mm .02 . Turbocharger Assembly 2.N*R 4JH1-TC Engine-34 1.934mmHg) when the rod is moved to 2mm Wheel Shaft End Play Required Tool: Dial Indicator Service Standard: 0. Water Pipe Inspection Item Waste Gate Operating Pressure Required Tool: Pressure Gauge Service Standard: 115. Adapter 3.

Exhaust Manifold 6. Turbocharger The 4JH1-TC engine is equipped with the EGR cooler. This results in reducing nitrogen oxide (Nox) emissions. The amount of EGR is controlled by EVRV (electrical vacuum regulating valve) via the engine control module (ECM) command signal depends on the engine speed. operating of the accelerator pedal and engine coolant temperature. Fresh Air 8. EGR Cooler 3. Intercooler 4.16mm EGR SYSTEM 1. Intake Manifold 5.07 . EGR Valve 2.0.N*R 4JH1-TC Engine-35 Wheel Shaft & Bearing Clearance Required Tool: Dial Indicator Service Standard: 0. The EGR cooler reduces the temperature of the air being drawn into the engine and the combustion temperature.12mm Service Limit: 0. Waste Gate 7. Exhaust Gas 9. The EVRV is shaped to control vacuum applied to the diaphragm chamber of the EGR valve based on control signal sent from the ECM. .

EGR Valve 3.-21. make sure that the valve is smoothly actuated. EGR Cooler 2. Service Standard: -15.N*R 4JH1-TC Engine-36 1. Intake Manifold 4. Turbocharger Assembly Inspection Item EGR Valve Operating Pressure Test Required Tool: Vacuum Gauge With negative pressure applied to the diaphragm chamber.99 . Exhaust Manifold 5.-160mmHg) when the shaft is moved EVRV Resistance Required Tool: Circuit Tester Service Standard: Approximately 14 ohms at 20 degree centigrade .32KPa (-120 .

370Kpa) 4. Oil Pressure Switch Operating Pressure: 0.5kg/cm 2 (29.7kg/cm 2 (310 . The engine has many sliding and rotating parts. Oil Cooler Relief Valve Opening Pressure: 3.8 . oil filter.N*R 4JH1-TC Engine-37 ENGINE LUBRICATION LUBRICATION SYSTEM 5: Oil Press. The forced circulation lubrication system consists of an oil pan. Regulating Valve: 1.4 . The entire oil supply route is called a lubricating system.1. It is then delivered to the vital parts of the engine from the cylinder body oil gallery. Oil Filter Relief Valve Opening Pressure: 0.120Kpa) 5. which acts a frictional resistance. Oil not only reduces friction between moving parts but cools.3 .8kg/cm 2 (608 . Regulating Valve Operating Pressure: 5.8 .3.630Kpa) 3. seals.0Kpa) 6.0. Oil Pump Relief Valve Operating Pressure: 6.49.216Kpa) Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and oil filter. converting their friction into fluid friction.7.4kg/cm 2 (570 . cleans. These parts constantly generate friction. The process of forming an oil film to prevent direct contact of these friction-causing parts.6.764Kpa) 2. oil cooler. SW Warning Lamp Cylinder Body Oil Gallery Oil Filter & Cooler Assembly 6: Regulating Valve Oil Filter 4: Relief Valve Idler Gear Shaft Oil Cooler Piston Cooling Jet 3: Relief Valve 2: Regulating Valve Timing Gear 1: Relief Valve Oil Pump Rocker Arm Oil Strainer Rocker Arm Shaft Connecting Rod Bearing Camshaft Bearing Vacuum Pump Crankshaft Bearing Turbocharger Oil Pan 1. . and thus minimizing frictional resistance is called lubrication. and keeps dust out.2kg/cm 2 (80 . A forced circulation system which pressure-feeds oil from an oil pump is generally used.2 .2 . and oil gallery in the cylinder block. prevents rusting.2kg/cm 2 (176 . oil pump.2.8 .

The drawn oil is discharged along the housing (to B). The oil pump driven gear turns along the inner surface of the housing together with the pump gear which is driven by the camshaft. rpm and oil viscosity. Drive Gear (driven by the camshaft) 2. oil pipe resistance. Driven Gear B The gear type oil pump is adopted to the 4JH1-TC engine. The geared pump is structured as shown in the picture. Pump Cover 4. . a negative pressure is created between the gears and the housing which draws the oil out of the oil pan through a strainer (from A). and it is driven by the gear on the camshaft to conduct oil in the oil pan to the parts to be lubricated. Driven Gear 5. Drive Gear 6. Pinion Gear 6. oil feed pressure. Oil Pipe 2. Relief Valve Assembly 7. The efficiency of the geared pump varies with the clearance between the gears and housing. Oil Strainer 3.N*R 4JH1-TC Engine-38 OIL PUMP 1. and pressure-fed to the oil gallery. A 1 2 1. Oil Pump Body The oil pump is installed on the cylinder body by means of two bolts. As a result.

or a partial-flow type. Oil Cooler & Filter Body 4. Regulating Valve Engine oil will slowly become contaminated by metal fragments produced by the friction of the working and sliding parts of the engine. which allows only part of the oil to pass through. Oil Cooler 2. the oil can be directly fed to the oil gallery without going through the element. while particles in suspension will be fed with the oil to engine parts. It is for these reason that an oil filter is installed in the oil passage to remove such foreign particles.N*R 4JH1-TC Engine-39 Inspection Item Gear Teeth & Body Inner Wall Clearance Required Tool: Feeler Gauge Service Standard: 0. Steel Square Service Standard: 0. which allows all the oil to pass through it.15mm OIL FILTER & OIL COOLER 1. The full-flow type is used for 4JH1-TC engine. and by carbon and sludge generated by fuel combustion.14mm Service Limit: 0. The filter is either a full-flow type. In case of filter element become clogged. . A bypass valve is built into the oil filter. possibly causing accelerated wear and seizure.20mm Gear & Body Clearance Required Tool: Feeler Gauge. Oil Filter 3. Thus safe lubrication of the system is assumed.06mm Service Limit: 0. Oil Cooler Relief Valve 5. Heavy sediment will settle to the bottom of the oil pan.

suddenly drops. the by-pass valve should be fully open. If the engine operates at high speed. Apply compressed air (200Kpa /2kg/cm 2 ) If air bubbles rise to the surface. 2) Check the oil temperature in the oil gallery If the oil cooler element is clogged up. vehicles operated under severe conditions. Inspection to determine if any clogging up of the oil cooler elements has occurred. pour oil or light oil into the oil cooler element through the inlet port. that is. Submerge the oil cooler water passage. A visual check of by-pass valve movement is too difficult and it can only be confirmed by a slap sound which occurred when the valve opens and close. Therefore. 1) Check oil gallery pressure at idling speed If the oil cooler element is clogged up. . 3) Check the operation of the oil cooler by-pass valve If the oil cooler element is clogged up. under extreme load at high speed for extended periods.200 Kpa) over the normal figure.N*R 4JH1-TC Engine-40 Lubricating oil for the most part often acts as a coolant for surfaces that are subject to severe friction. When the temperature of lubricating oil exceeds 125 . As a result. the oil gallery pressure reading will be increased 1 to 2 kg/cm2 (100 . However if the oil cooler unit is attached to the engine. and check to see that it flows away from the outlet port. rotating and sliding parts may begin to stick. stable up to this temperature. The by-pass valve opens when the pressure difference between the element inlet and outlet port exceeds a certain figure. Inspection Item Water Leakage 1. the following procedure is recommended.130 degree centigrade. 2. its lubricating performance. and it becomes difficult to maintain the oil film. are equipped with an oil cooler to prevent the lubricating oil from overheating. the oil temperature in the oil gallery will be higher than normal. there is water leakage. The plate tube type oil cooler allows lubricating oil to pass through the tube whose outer surfaces are cooled by engine coolant. when the oil cooler unit is detached from the engine. the oil temperature will increase rapidly. or is heavily loaded. This increased pressure is due to an oil pressure loss in the oil cooler element.

The circulating coolant cools the lubricating oil in the heat exchanger and the turbocharger. To quickly increase cold engine coolant temperature for smooth engine operation. the water pump. or causing abnormal wear and seizure. When the coolant temperature reaches specified value. It can also accelerate cylinder liner wear as the sulfur dioxide generated in the combustion stroke is combined with the water in the gas to form a corrosive substance. Reservoir Tank 4. The engine cooling system consists of the radiator. Oil Cooler 7. Car Heater 9. Radiator 2. altering oil properties. The heat generated by fuel combustion in the cylinder heats the component parts around the combustion chambers of the engine. Turbocharger 11. can lower thermal efficiency and deteriorate combustion. a radiator and an EGR cooler. the thermostat will begin to open and a gradually increasing amount of coolant will circulate through the radiator. the coolant is circulated by the water pump and through the by-pass hose and back to the cylinder body. possibly reducing lubrication performance. the cooling fan. Radiator Cap 3. . All of the coolant is now circulating through the radiator for effective engine cooling. If these parts are not properly cooled. Cylinder Head 6. Water Pump 10. on the other hand. and maintain engine operation at an appropriate temperature. Overcooling. It also adversely affects the lubricating oil supplied to the moving parts of the engine. a cooling fan.N*R 4JH1-TC Engine-41 ENGINE COOLING COOLING SYSTEM 1. a thermostat. thus reducing output power. The cooling system is designed to prevent engine overheating and overcooling. which consists of a coolant pump. the inside engine temperature rises sharply and overheats. The thermostat will be fully open when the coolant temperature reaches specified value. thermostat assembly. Thermostat 5. and the thermostat. Cooling Fan The cooling system is a pressurized coolant forced circulation type. The coolant does not circulate through the radiator. EGR Cooler 8.

N*R 4JH1-TC Engine-42 WATER PUMP Water Pump Assembly The water pump is a centrifugal impeller type and is driven by V type drive belt. the water runs through the water outlet pipe to the radiator. After cooling the cylinder head. The water pump draws the coolant from the radiator. feeds it through the oil cooler into the cylinder block to cool the outer surfaces of the cylinders. The water in the cylinder head is directed by a water jacket to cool the outer surfaces of the nozzle holders and around the valve seats. If the cooling water temperature is below the valve operating temperature. and then into the cylinder head. . The water outlet pipe has a thermostat to regulate the engine cooling water temperature. the cooling water is fed back through the water pump by-pass into the engine without returning to the radiator.

A complete cut off of the cooling water to the radiator when the thermostat is fully closed will shorten engine warm up time. This thermostat has wax sealed inside its casing. thereby preventing the cooling water from flowing out. The jiggle valve releases the air while cooling water is being added.95 degree centigrade. Agitating Rod Initial Opening Temperature: 82 degree centigrade Full Opening Temperature: 95 degree centigrade Valve Lift: 9. The full opening valve lift is more than 9. and the valve opens or closes when the wax expands or contracts. the water passage valve is automatically closed. When the water temperature rises. When the cooling water is cold immediately after starting the engine. Inspection Item Thermostat Operating Temperature Required Tool: Thermometer. and closes when even the slightest water pressure is applied as the engine start running. The thermostat opens and closes the water outlet pipe and radiator water passage according to the cooling water temperature to control it and prevent the engine from overheating or overcooling.5 mm. and the cooling water keeps circulating through the by-pass circuit without going through the radiator. to open the valve.N*R 4JH1-TC Engine-43 THERMOSTAT 1. thus permitting speedy engine warm up. but the system cannot be filled with cooling water because air will remain trapped inside the engine. the valve opens to connect the water passage to the radiator and the by-pass circuit is closed so that the engine temperature may be kept at an appropriate level. the wax is solid and contracted so that the valve is closed under the pressure of the spring. moving a spring. Jiggle Valve The thermostat is a wax pellet type with a jiggle valve and has an opening temperature of 82 . If the engine becomes overcooled during operation. Therefore. the wax liquefies and expands to push the spring and valve down.5mm . When the cooling water temperature is low. the thermostat is generally fitted with a small air vent. the water passage is closed by the valve. As the water temperature rises.

The engine cooling capacity is designed to prevent engine overheating even at a high ambient temperature. Bimetal The cooling fan consists of seven plastic blades and is fitted with a fan clutch of the fluid coupling type filled with silicon oil. Thus.N*R 4JH1-TC Engine-44 COOLING FAN & FAN CLUTCH 1. High speed operation of the fan increases noise and causes a marked power loss. Fluid Coupling 2. it is un-necessary for the fan to run fast when the engine is running fast at a low ambient temperature. The fan clutch senses and drop in the ambient temperature and controls the fan speed. .

If the fan clutch rotates more readily.N*R 4JH1-TC Engine-45 Inspection Item Thermostat Operating Temperature Required Tool: Thermistor. Service Standard: 8 . Heat Gun Warm up the bimetal up to 80 degree centigrade. Cooling Fan Drive Belt Deflection Required Tool: Ruler Apply a force of 98Nm (10kg) to the drive belt mid-portion.10mm . silicone grease is leaking internally.

.N*R 4JH1-TC Engine-46 RADIATOR & RADIATOR CAP 1. thereby protecting the radiator from collapse. because of the corrugated fin has a great radiation area. The corrugated fin type also consists of a series of long tubes extending from the top to bottom of the radiator. and air passes through the other. The radiator is a tube type with corrugated fins. Radiation efficiency is great in sprite of the same volume of the radiator. Furthermore the louver on the corrugated fin increases air speed and this makes for increased radiation efficiency. which is used to maintain the pressure in the radiator at required level. The radiator cap has a pressure valve. The radiator core is divided into two separate and intricate compartments. While fins are placed between the tubes and have a corrugation shape. Radiator 2. water passes through one. There is also a vacuum valve to take fresh air from the out side if the radiator pressure is reduced when the engine cools off. Intercooler The radiator is a device for a large volume of water in close contact with a large volume of air so that heat will transfer from the water to the air. Radiator Cap 3. and thus increases the capacity and cooling efficiency of the water pump.

and to control the internal pressure of the radiator tank. is forced out of the radiator. the coolant volume expands by about 5% when the temperature exceeds 90 degree centigrade.25kg/cm 2 ) RESERVOIR TANK Reservoir Tank The reservoir tank is employed to prevent coolant loss. the radiator has a suitable sized upper tank which corresponds to the increase in the volume of coolant. Therefore. This prevents coolant loss to a large degree.0 . and expanded volume of coolant overflows from the radiator. namely to ensure cooling efficiency.95 . and the period between topping up the radiator is greatly increased. Vapor. Generally.123KPa (0. on the other hand. for example when the engine is stopped. the internal pressure in the radiator becomes negative which causes the coolant to be drawn back into the radiator.5kg/cm 2 ) Radiator Cap Pressure Proof Required Tool: Radiator Cap Tester Testing Pressure: 93.1. When the coolant temperature in the radiator falls. .N*R 4JH1-TC Engine-47 Inspection Item Radiator Pressure Proof Required Tool: Radiator Cap Tester Testing Pressure: 147KPa (1. Thus coolant loss is prevented.

there is always an excess of fuel from the feed pump. Therefore. Fuel Filter With Water Separator 6. where water and dust are removed from the fuel before fed to the injection pump. and not in direct proportion to engine speed. diesel fuel is supplied at pressures of up to 100 Mpa to the injection nozzle. the fuel filter with water separator. The feed pump increase the fuel feed rate in direct proportion to the engine speed. The fuel in the fuel tank of a diesel engine is pumped up into a fuel filter by a feed pump. and the injection nozzle. but the amount of fuel required to be injected into the cylinders varies with vehicle running conditions. the fuel return pipes run from the nozzles and injection pump to the fuel tank via fuel filter to return the excess fuel to the fuel tank. and injects it into the combustion chambers of the engine through injection nozzles. the injection pump. Injection Pump Control Unit (PSG) *PSG=Pumpen Steuer Great (German) 3. After being pressurized by the VP44 fuel injection pump. Injection Nozzle 5. Thus. . Fuel Tank The fuel system consists of the fuel tank. Engine Control Unit (ECM) 4. VP44 Fuel Injection Pump 2.N*R 4JH1-TC Engine-48 FUEL SYSTEM 1.

The VP44 fuel injection pump has a pump control unit (PSG) fitted on top it. Depending on the characteristic of each pumps such as manufacturing dispersion. The Bosch engine management features a fully electronic controlled VP44 fuel injection pump. Injection Pump Gear Check Hole Cover 2. The ECM calculates the desired fuel quantity and fuel injection timing and sends this information to the pump control unit (PSG). Scissors Gear Check Hole Cover 3. This pump control unit (PSG) then actuates the internal actuators accordingly. Note: This VP44 fuel injection pump is not allowed to disassembly repair even though any pump failures. that exchanges information with the engine control module (ECM) via a CAN-bus. Injection Pump Bracket 4. The pump is only allowed to replace some gaskets of external parts such as feed pipe gaskets in case of the fuel leaks. VP44 Fuel Injection Pump The biggest and most significant changes on the 4JH1-TC engine in comparison to the previous 4J series engine can be found on the engine management system.N*R 4JH1-TC Engine-49 FUEL INJECTION PUMP 1. the pump control unit (PSG) memorizes a peculiar data for the specified engine performance which is differed from pump to pump. because the pump is specially calibrated by special pump tester in the manufacturing process. .

Leak-off Pipe 5.5MPa (1st Stage) / 33. Nozzle Body The fuel is injected inside the combustion chamber by means of two stage injectors with five holes. The two stage injectors feature two springs that each can be adjusted separately in order to achieve the following injector opening pressures. Gasket Nozzle Holder 2.8MPa (2nd Stage) 1.21 mm. Gasket Injection Nozzle 3.35. These holes have a diameter of 0. 1st Spring 7.3 .0 .N*R 4JH1-TC Engine-50 FUEL INJECTION NOZZLE 1. Push Rod 4. 2nd Spring 8. 1st Opening Pressure Adjustment Shim 2.21. Nozzle Needle Valve 9. -Designed Operating Pressure: 19.8MPa (2nd Stage) -Adjusting Operating Pressure: 20. Copper Gaskets .0MPa (1st Stage) / 34. Injection Pipes 7. 2nd Opening Pressure Adjustment Shim 3. Clamp Nozzle Holder 4. Injection Nozzle Assembly 6. Speacer 5. Injection Cavity 6.

It is used during the water draining and air bleeding procedure. When the float reaches the specified level. Float 7. If the operating pressure is incorrect. because the nozzle is specially tightened in the manufacturing process. Copper gaskets provide a seal between the nozzle leak-off pipe and the injection nozzles. The nozzle is only allowed to check the 1st operating pressure. Filter Cartridge 5. A diaphragm type priming pump is installed at the top of the water separator. fuel leaks and splay conditions. Air Bleeder Plug 4. Level Sensor Assembly The fuel filter assembly equipped with a water separator is adopted for the 4JH1-TC engine. FUEL FILTER 1. the fuel must be perfectly clean. On top of it. air bleeding plug is provided. a warning light comes on to inform the driver to drain the water from the water separator. the nozzle must be replaced to new one. fuel leaks from the nozzle or bad splay conditions.N*R 4JH1-TC Engine-51 The injection nozzles are attached to the cylinder head by means of a clamp and seal off in the cylinder head by means of a gasket nozzle holder and gasket injection nozzle. Filter Element 6. The water separator has an internal float. Drain Plug 8. . As the inside of the injection pump is lubricated by the fuel which it is pumping. The fuel filter and the water separator removes water particles and other foreign material from the fuel before it reaches the injection pump. Note: This injection nozzle is not allowed to disassembly repair even though any nozzle failures. Priming Pump 2. Body Assembly 3.

4. Turn the ignition switch to the "ON" position. wait 1 minute. If the fuel injection pump has been replaced. Loosen the air bleeder plug and operate the priming pump until strong resistance is felt (about 15 cycles). 1. Depress the accelerator pedal and clutch pedal to the floor and hold them down. 2. And. Allow the engine to idle for 5 minuets. 8.N*R 4JH1-TC Engine-52 Note: The air bleeding procedure for fuel system has been modified for the 4JH1-TC engine. 3. Loosen the air bleeder plug and operate the priming pump until strong resistance is felt (about 10 cycles). the fuel has been exhausted or the fuel filter has been replaced. Stop pumping and tighten the air bleeder plug. Stop pumping and tighten the air bleeder plug. wait 1 minute. 6. Loosen the air bleeder plug and operate the priming pump until strong resistance is felt (about 5 cycles). If the engine does not start. . turn the ignition switch to the "START" position and crank the engine until it starts. Wait until the glow indicator lamp turns off. repeat Step 5 . And. 5. 7. And then. Stop pumping and tighten the air bleeder plug. the following air bleeding procedure will require.7. 9.

.3 kW made by Hitach. the contacts of magnetic switch are closed. the plunger is attracted. On the 4JH1-TC engine has an output of 2. and the armature rotates. the ring gear runs to start the engine. Then.N*R 4JH1-TC Engine-53 ELECTRICAL PARTS STARTER MOTOR Starter Assembly Connecting Diagram The starting system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft. When the starter switch is turned on. At the same time. and the pinion is pushed forward by the shift lever to mesh with ring gear.

Armature 20. Pinion Assembly 11. Magnetic Switch Assembly 2. Plunger 5. Bearing Retainer 17. Adjusting Shims 4. Screw 24.N*R 4JH1-TC Engine-54 1. Pinion Shaft 13. Gear Case 8. Shift Lever 7. Bolt 10. Return Spring 14. Brush Holder 22. Clutch 12. Torsion Spring 6. Motor Assembly 19. Screw 18. Lead Wire . Pinion Stopper 15. Dust Cover 9. Rear Cover 23. Through Bolt 25. Pinion Stopper Clip 16. Yoke 21. Magnetic Switch 3.

2 Repeat Step 1 at different segments of the armature core.7 . the armature is grounded.2mm Commutator Outside Diameter Required Tool: Vernier Caliper Service Standard: 35mm Service Limit: 34mm Armature Grounding Test Required Tool: Circuit Tester Hold one probe of the circuit tester against the commutator segment.02mm Service Limit: 0. There should be continuity between all segments of the armature core.05mm Commutator Mica Segments Wear Required Tool: Vernier Caliper Service Standard: 0.9mm Service Limit: 0. . If the circuit tester indicates continuity. And. Armature Continuity Test Required Tool: Circuit Tester 1 Hold the circuit tester probes against two armature core segments.0. hold the other circuit tester probe against the armature core.N*R 4JH1-TC Engine-55 Inspection Item Commutator Run-out Required Tool: Dial Indicator. V-Block Service Standard: 0.

N*R 4JH1-TC Engine-56

Yoke Field Winding Ground Test

Required Tool: Circuit Tester Hold one circuit tester probe against the field winding end or brush. Hold the other circuit tester probe against the bare surface of the yoke body. If there is continuity, the field coil is grounded.

Yoke Field Winding Continuity Test

Required Tool: Circuit Tester Hold one circuit tester probe against the “C” terminal lead wire. Hold the other circuit tester probe against the field winding brush. There should be continuity.

Brush Length

Required Tool: Vernier Caliper Service Standard: 14.5mm Service Limit: 9.5mm

Brush Holder Insulation Test

Required Tool: Circuit Tester Touch one probe to the holder plate and the other probe to the positive brush holder. There should be no continuity.

Overrunning Clutch

Inspect the overrunning clutch gear teeth for excessive wear and damage. Rotate the pinion clockwise. It should turn smoothly. Try to rotate the pinion in the opposite direction. The pinion should lock.

N*R 4JH1-TC Engine-57


Generator Assembly

Connecting Diagram

The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown in connecting diagram. The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame. On the 4JH1-TC engine, two type of outputs (60A or 80A) can be used depends on vehicle specification.

N*R 4JH1-TC Engine-58

1. Vacuum Pump 2. Cover 3. Brush 4. Through Bolt 5. Pulley Assembly 6. Pulley Nut 7. Pulley 8. Fan 9. Rotor Assembly 10. Speacer 11. Ball Bearing 12 Rotor 13. Front Cover Assembly 14. Front Cover 15. Ball Bearing 16. Bearing Retainer 17. Screw 18. Terminal Bolt & Nut 19. Condenser 20. Rear Cover 21. Stator 22. Diode 23. Holder Plate 24. Brush Holder 25. IC Regulator Assembly 26. Lead Wire 27. Mold Terminal 28. IC Regulator

Inspection Item Rotor Slip Ring Wear

Required Tool: Vernier Caliper Check the rotor slip ring surfaces for contamination and roughness. If rough, polish with #500-600 sandpaper. Service Standard: 34.6mm Service Limit: 33.6mm

Rotor Slip Ring Continuity Test

Required Tool: Circuit Tester Check for continuity between slip rings. There should be continuity.

Brush Length Required Tool: Vernier Caliper Service Standard: 20mm Service Limit: 6mm Diode Insulation Test Required Tool: Circuit Tester Check for continuity between the battery and each of the three stator coil lead terminals.N*R 4JH1-TC Engine-59 Rotor Slip Ring Insulation Test Required Tool: Circuit Tester Check for continuity between the slip rings and the rotor core or shaft. Reverse the polarity of the test probes. Stator Coil Continuity Test Required Tool: Circuit Tester Check for continuity across the stator coils. If there is continuity. There should be no continuity. Stator Coil Insulation Test Required Tool: Circuit Tester Check for continuity between each stator coils and the stator core. the diode is normal. the diode is normal. There should be continuity. If there is no continuity. There should be no continuity. .

When the lamp extinguishes the engine can be started. PREHEATING SYSTEM 1. Glow Fuse 50A 5. Glow Relay 7.5 kg/cm 2 onto "A" side of valve and check if there is air leak. Battery Voltage 3. Gauge Back Fuse 10A 6. Apply compressed air 1 . This does not imply that the glow plugs are no longer activated. Engine Control Unit (ECM) The 4JH1-TC engine is adopted with the quick on system 2 (QOS 2) preheating system which is controlled by engine control module (ECM). ECM Main Relay 2. The voltage on the coil of the relay glow plug is supplied by the relay engine control module (ECM) main. In the after glow phase the lamp is not illuminated but the glow plugs remain active for a certain period depending on engine coolant temperature. Glow Plug 9. The function of the glow time indicator lamp is to inform the driver whether the glow system is activated.N*R 4JH1-TC Engine-60 Vacuum Pump Check Valve Test Apply a light pressure onto the "B" side of valve with a screw driver and check that valve operates smoothly. . The ECM switches glow relay to operate glow plug depends on the coolant temperature. Ignition Switch 4. Glow Indicator Lamp 8.

) 5 4 3 2 1 0 -30 -20 -10 0 10 20 Coolant Temperature (degree centigrade) 30 40 50 After Glow Setting Curve 35 30 Time (Sec.N*R 4JH1-TC Engine-61 Pre Glow Setting Curve 8 7 6 Time (Sec.) 25 20 15 10 5 0 -30 -20 -10 0 10 20 Coolant Temperature (degree centigrade) 30 40 50 Inspection Item Glow Plug Continuity Required Tool: Circuit Tester Service Standard: 0.9 ohm .

5 in) 9-8523-1423-0 Valve Spring Compressor 5-8840-2033-0 Oil Seal Installer 5-8840-9018-0 Piston Ring Compressor 5-8840-2093-0 Tacho Meter 9-8523-1212-0 Valve Guide Replacer 5-8840-2036-0 Front Oil Seal Installer .0mm / 3.N*R 4JH1-TC Engine-62 SPECIAL TOOLS 5-8840-0200-0 Oil Filter Wrench (89.

N*R 4JH1-TC Engine-63 5-8840-2675-0 Compression Gauge 5-8531-7001-0 Gauge Adapter 5-8531-7002-0 Gauge Adapter 5-8840-0266-0 Angle Gauge 5-8840-2038-0 Camshaft Bering Replacer 5-8673-9149-0 Base 5-8673-9150-0 Lever Scissors Gear Setting Tool 5-8840-2360-0 Rear Oil Seal Remover .

N*R 4JH1-TC Engine-64 5-8840-2359-0 Rear Oil Seal Installer 5-8840-2313-0 Cylinder Liner Installer 5-8840-2304-0 Cylinder Liner Remover 5-8840-2000-0 Pilot Bearing Remover 5-8840-0019-0 Sliding Hammer 5-8522-0024-0 Pilot Bearing Installer 5-8521-0002-0 Universal Puller .

N*R 4JH1-TC Engine-65 5-8840-0075-0 Pressure Gauge 5-8840-0279-0 Vacuum Pump With Gauge .

dd.Other trouble ( ).Engine stall ( ): After stalling. 1. No warning light ( ) Customer’s complaint: Please enter “x” between brackets ( ) & Please enter phenomenon between underlined bracket ( ).Engine hard to start ( ): After some time. 4.yy) Km or Pump part number: Pump serial number: Diagnostic Trouble Code (DTC) Set :( ) DTC Present or Not Present :( ) Engine warning light: Lit ( ) Flashing ( ). When the trouble occurred: 1) 2) 3) From when the vehicle was purchased ( ) Km. miles) From ( or Other ( ).VP44 CHECK SHEET Issuer: OEM Distributor name: VIN Number: Date of issue: Customers name: Vehicle retail date: Vehicle trouble Mileage: (mm. gear position 5) During engine starting – after warm-up ( ) or engine still cold ( ) 6) From stationary acceleration ( ) 7) During braking ( ) 8) Other ( ) Condition of additional devices when the trouble occurs: 1) Air-conditioning is “ON” ( ) 2) Power steering operating ( ) 3) Position of A/T gear selector ( range) Additional parts replaced other than the injection pump: Injector Nozzle 1) Spray Pattern 2) Injection Pressure # 1 Cylinder Good or Bad Mpa # 2 Cylinder Good or Bad Mpa # 3 Cylinder Good or Bad Mpa # 4 Cylinder Good or Bad Mpa . are there any abnormal conditions? ( ) 3. 2. Excessive white smoke ( ) 8. 7.dd.Excessive black smoke ( ). Where the trouble occurs: 1) On the highway ( ) 4) Driving downhill ( ) 2) On city roads ( ) 5) In traffic jam ( ) 3) Driving uphill ( ) 6) Other ( ) Vehicle condition when the trouble occurs: 1) During acceleration ( ) 2) Slowing down ( ) 3) Stopping ( ) or range) 4) Constant speed ( ) – ( Km/hr.Hunting ( ): Engine speed is ( rpm) – ( rpm). 6. engine would restart ( ) or would not restart ( ).After starting the engine.Lack of engine power ( ). 5.yy) Mile date: (mm. engine would start ( ) or would not start ( ).