INDUSTRIAL

DIESEL ENGINE
A-4JA1, A-4JB1
MODELS

WORKSHOP MANUAL

©2003 ISUZU MOTORS LIMITED

FOREWORD
This Workshop Manual is designed to help you perform necessary
maintenance, service, and repair procedures on applicable Isuzu
industrial engines.
Information contained in this Workshop Manual is the latest
available at the time of publication.
Isuzu reserves the right to make changes at any time without prior
notice.
This Workshop Manual is applicable to 1998 and later models.

NOTICE
Before using this Workshop Manual to assist you in
performing engine service and maintenance operations,
it is recommended that you carefully read and throughly
understand the information contained in Section - 1
under the headings “General Repair Instruction” and
“Notes on The Format of This Manual”

TABLE OF CONTENTS
SECTION 1.

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

SECTION 2.

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

SECTION 3.

ENGINE ASSEMBLY (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DISASSEMBLY)

29

SECTION 4.

ENGINE ASSEMBLY (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(INSPECTION AND REPAIR)

47

SECTION 5.

ENGINE ASSEMBLY (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(REASSEMBLY)

81

SECTION 6.

LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

SECTION 7.

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

SECTION 8.

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

SECTION 9.

ENGINE ELECTRICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

SECTION 10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
SECTION 11. SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
SECTION 12. REPAIR STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
SECTION 13. CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

GENERAL INFORMATION

SECTION 1

GENERAL INFORMATION
TABLE OF CONTENTS
ITEM

PAGE

General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Notes on the format of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Main data and specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Tightening torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1

GENERAL INFORMATION GENERAL REPAIR INSTRUCTIONS 1. 6. depending on their installation position. 10. 9. use a sealer on gaskets to prevent leakage. All parts should be carefully cleaned before inspection or reassembly. If necessary. 1. 5. Always keep disassembled parts neatly in groups. Always check and recheck your work. Where specified. Never reuse cotter pins. 3. 3. 11. Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions. Find the applicable section by referring to the Table of Contents at the beginning of the Manual. and tightening torques are included in the "General Information" section. and reassembly. 8. disconnect the grounding cable from the battery. 4. 7. This will ensure a smooth reassembly operation. Nut and bolt torque specifications should be carefully followed. No service operation is complete until you have done this. Discard them as you remove them. use the specially designed tool or tools. 2. inspection and repair. such engines have common parts and components as well as data and specifications. These parts vary in hardness and design. Replace them with new ones. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine or disconnecting pipes and hoses. Each section is divided into sub-sections dealing with disassembly. When more than two engine models are dealt in the manual. service specifications. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly. lock washers. This will reduce the chance of cable damage and burning due to short circuiting. O-rings. The section ENGINE ASSEMBLY is an exception. 2 . To not do so is extremely dangerous. This parts are divided in three sections to facilitates indexing. It is especially important to keep fastening parts separate. 2. gaskets. Always use the proper tool or tools for the job at hand. unless otherwise specified. Use genuine ISUZU parts. Before performing any service operation with the engine mounted. and self locking nuts. NOTES ON THE FORMAT OF THIS MANUAL This Workshop Manual is applicable to ISUZU industrial engine or engines which is or are stated in the title. Common technical data such as general maintenance items.

9 13 ★ 10 ★ Removal of unnumbered parts is unnecessary unless replacement is required. 5.2 1. v 7. the manual will direct you to the appropriate page. and their disassembly steps or reassembly steps are shown in the illustrations respectively. Idler gear shaft The removal or installation of parts marked with a triangle ( v ) is an important operation. 3. Idler gear “B” and shaft v 16. A brief explanation of the notation used follows. Inverted Engine 3 . v 9. self-explanatory removal and installation procedures are omitted. 6. For the sake of brevity. Cylinder head gasket v 11. Crankshaft damper pulley with dust seal 12. Timing gear case cover 13. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area. 14 ★ Repair kit 15 Disassembly Steps . 2. 6 ★ ★ 1 7 2 8 ★ 3 The number tells you the service operation sequence. Water by-pass hose Thermostat housing Water pump Injection nozzle holder Glow plug and glow plug connector Cylinder head cover Rocker arm shaft and rocker arm Push rod Cylinder head 10. More complex procedures are covered in detail. 17 The parts listed under "Disassembly Steps" or "Reassembly Steps" are in the service operation sequence. v 4.GENERAL INFORMATION 4. 5. 8. Detailed information is given in the text. 12 ★ 5 11 4 16 The "* Repair Kit" indicates that a repair kit is available. Parts marked with an asterisk (*) are included in the repair kit. Timing gear oil pipe 15. Timing gear cover 14. 6. Parts within a square frame are to be removed and installed as a single unit. Idler gear “A” 17. When the same servicing operation is applicable to several different units.

.8) 1 13. Flywheel Housing 8 6 10 5 1) Apply liquid gasket to the shaded area shown in the illustration.. 2) Use the oil seal installer to install the oil seal to the cylinder body.6±1. Measurement .ft/N·m) Letters and numbers contained in a circle refer to the illustration..8) 10.....8) 8.75 (0. 4.0±9...0 (40. .05) Bolt Service data and specifications are given in this table.2/107.07) Bolt 4 Special tools are identified by the tool name and/or number.ft/N·m) M10x1.47x0..5 ± 7.0 (79. Lubrication (grease) . 2 7 1 Flywheel Housing Bolt Torque The illustration shows how the special tool is to be used...2/103.0 ± 1.47x0. This is the item shown in the illustration.... Special tool use required or recommended(Isuzu tool or tools) ..8) M12x1. 2 Camshaft Timing Gear Bolt Torque kgf·m(lb.0 (71.. 11.5±7. Specified torque (tighten) .. Installation .2/ 54.. Oil Seal Installer: 5-8840-0141-0 14. 5...5±1. Adjustment .05) Bolt M12x1.....9±9..2/ 96...0±7.0±9. 9 3 2) Tighten the flywheel housing bolts to the specified torque a little at a time in the sequence shown in the illustration..GENERAL INFORMATION 7... 4 Removal Sealant application .8±1. Below is a sample of the text of the Workshop Manual.8 ± 9. 2) Apply engine oil to the bolt threads 2 . Inspection .. Disassembly .40x0. Reassembly . They tell you the type of service operation or step to perform... Directional indication . Crankshaft Rear Oil Seal 1) Apply engine oil to the oil seal lip circumference and the oil seal outer circumference. Cleaning ..0±7... Alignment (marks) .. 9.. Commercially available tool use required or recommended ..... Important operation requiring extra care .25 (0..... kgf·m(lb.. A detailed explanation of these symbols follows. Camshaft Timing Gear 1) Install the thrust plate 1 .25 (0. It is marked with a triangle (v) on the Major Components page. Symbols indicate the type of service operation or step to be performed. 3) Install the camshaft timing gear with the timing mark stamped side facing out. ... The following symbols appear throughout this Workshop Manual. Lubrication (oil) .0 (76.

5 . Components and parts are listed in the singular form throughout the Manual. 10. 11. The engine's direction of rotation is counterclockwise viewed from the flywheel. Measurement criteria are defined by the terms "standard" and "limit". Rear The flywheel side of the engine. Left The left hand side viewed from the same position. 1 and rear most cylinder is the final cylinder number of the engine. Directions used in this Manual are as follows: Front The cooling fan side of the engine viewed from the flywheel. "Limit" should be thought of as an absolute value. Cylinder numbers are counted from the front of the engine.GENERAL INFORMATION 9. Right The right hand side viewed from the same position. A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable. A measurement which is outside the "limit" indicates that the applicable part or parts must be either repaired or replaced. The front most cylinder is No.

) Fuel injection order degrees Specified fuel 14 In-line plunger.0 (3.0) 4.6 (4.GENERAL INFORMATION MAIN DATA AND SPECIFICATIONS Engine Model A-4JA1 A-4JB1 4JB1T Item Engine type Water cooled.2 805 x 625 x 729 739 x 625 x 746 578 x 771 x 577 Compression ratio (To 1) *Engine dimensions mm(in.4) 2.7 x 24.93.2 Specifications marked with an asterisk (*) will vary according to engine application. full flow Partial oil filter *Lubricating oil volume 31 (441/3.0 x 102.(qts) Water pump 5.4 x 22.771 (169.0) 18.6 (7.449 (152.62) 18.) 4 .7) *Engine weight (Dry) kg(lb. Bosch A type Governor rpm Injection nozzle 850 – 1.6 x 28.0157) 0. of cylinders .02) lit(cid) 2.000 Multi-hole type Injection starting pressure kgf/cm (psi/MPa) 2 Fuel filter type 185 (2630/18.9) – 6.8 x 30.7) Oil cooler (if so equipped) Water cooled built in oil filter Cooling method Pressurized forced circulation lit.0 (3.1) Cartridge papaer element Water sedimentor (if so equipped) Compression pressure Sediment/water level indicating type kgf/cm (psi/MPa) 2 Valve clearance (at cold) Intake Exhaust mm(in.2 18.Bore x Stroke mm(in.) Coolant volume 218 (480) .66 x 4.40 (0.1 x 24.6 x 29.7) (29.93.771 (169.0) 2.) Length x Width x Height (31. 6 Bosch distributor VE type Variable speed mechanical type *Low idle speed *Starter 245 (540) Diesel fuel Injection pump *Alternator 220 (486) 1 – 3– 4 – 2 *Fuel injection timing (B. in-line.93.0157) Pressurized circulation Oil pump Trochoid type Main oil filter type Cartridge paper element.66 x 4.D.40 (0.(qts) 5.0 x 102.0 (3.3) Belt driven impeller type Thermostat type Wax pellet type V-A 12 – 35 V-kW 12 – 2. overhead valve Combustion chamber type Direct injection Cylinder liner type Dry No.4 (6.T.8) 4.) Lubrication method Not equipped lit.9) – 6. four-cycle.4) (22.0 (5.5 (5.C.4 Total piston displacement 4 .04) mm(in.8) – 6.6 (4.02) 4 .) 0.0 x 92.3 (6.66 x 3.

3 (8.6 – 636.9/430.3/27.8 – 4.6 – 106.5 (36.6 (42.3) 2.8 (95.8) M 8 × 1.3/195.7/103.8 – 4.5 – 194.9 – 240.9 – 9.9 – 72.5 – 711.8 – 118.6) 6.2) 7.3 – 10.2/4.4) 43.2 – 2.9/75.6/205.9 – 544.0 (3.5 – 41.5 – 14.9 (143.4/16.3 – 34. 7 .4 (27.1 – 3.0 – 149.3) 7.5 21.7 – 83.3 – 10.4/424.3 (198.6/11.0 – 13.6 – 401.9/106.8 – 170.7 – 6.2 – 9.9 – 7.0 – 55.2) M20 × 1.7 – 16.6 (55.5 – 114.6) 19.1 – 166.8 – 229.3 – 24.4 – 23.7/269.0 (76.0/100.0 (264.0 – 7.8 – 44.8 – 8.2 – 139.5 – 345.3 – 64.8/358.3) 43.1) 13.8) M14 × 1.6 – 34.5 (15.0 – 73.8/316.6 – 23.8 – 22.5) M24 × 2.6 (20.6 – 350.3 – 33.3/60.3 – 131.3 – 204.9 – 5.9/88.1) 3.3) M18 × 1.6 – 55.3 – 62.4 (83.0 – 225.4 (14.5 (267.5 – 24.8 – 6.8 – 91.7 – 397.3 – 254.5 25.0 (33.6) M16 × 1.6 – 32.1 – 68.7 – 11.8/3.0 7.1 (26.5) An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such as casting.8 Refined Bolt Identification Bolt Diameter × pitch (mm) (7T) 9.6 – 17.0 36.2/251.1/36.8 – 67.8 (4T) 8.7 – 612.6/19.6 – 7.9 – 228.1 – 413.8 – 150.4 – 84.6 – 42.6) M22 × 1.3 – 22.1 – 96.9 – 539.4) 10.7 – 405.5 7.3) 11.3 (44.5 – 45.8 – 169.7 (408.5 10.2 – 305.3 – 59. STANDARD BOLT Strength Class kgf·m (lb.GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.25 5.2 (169.9 – 298.4/135.1 (12.4 – 35.9) *M14 × 2.8) 37.4 (65.9) *M16 × 2.5 – 46.0/27.8 – 475.9 – 125.6/554.6/78.9 – 159.7/93.5 – 1.2 (73.6 – 106.0 – 62.4 (112.8 (9T) Non-Refined No mark M 6 × 1.9 – 16.9 (52. Those shown in parentheses in the strength class indicate the classification by the old standard.9 – 84.0) 32.5 2.5 4.9 (52.0 – 31.6/45.0) 16.0/7.6 – 16.7 – 115.9 (313.2/49.3 – 48.2 – 25.6/113.9) 13.7 (20.8 – 78.4 – 0.2/129.8 – 17.8 – 20.8) *M12 × 1.8 – 110.25 2.8 (99.6) *M10 × 1.5 (233.8) 0.9) 9.0 0.0) 56.4) M10 × 1.2 – 469.6 – 7.4/151.6) 1.3/37.0 – 156.0 – 3.2) 15.9 – 177.0 (111.9 – 216.2 – 54.8) M12 × 1.7 – 3.4/362.7) 5.7 – 102.9 – 307.6 (151.5 – 46.5 (118.ft/N·m) 4.7 (56.5 – 84.4) 2.5 – 113.2 – 19.9 – 29.8 – 78.3 – 50.8 (5.5 – 143.8/71.8 – 11.7 – 30.7) 9.2 – 391.8 (2.8/71.2 (68.8 – 1.3/162.25 0.5 15.5 (317.3/20.6/229.2/56.1 – 830.2 – 15.8 – 13.2/159.7) 1.3) 23.0 10.1) 3.5 – 523.2 (185.9) 27.3 (78.

31 – 127.75/54.63 – 27.57) 17.41/50.5 (57.85/83.3 – 10.89) 8.34 – 128.58 – 88.4 (26.14 – 86.6 – 24.35 – 28.9 (91.71 – 173. x pitch) 0.8 – 17.5 – 9.9 (57.1 – 12.06 – 180.7 (85.ft/N·m) Bolt head marking Nominal size (dia.9 – 3.5 – 0.8 (25.2 – 25.85 – 189.7 (124.19 – 196.3 – 7. 8 .64) M14 × 1.65 – 49.71 – 173.10 – 52.34) M10 × 1.1 – 6.61 – 6.6 – 11.55 – 37.95/34.18) 17.5 0. FLANGED HEAD BOLT kgf·m (lb.26) 3.25 1.99 – 76.02/115.2 – 16.2 (31.48 – 91.59/18.79 – 244.76) 11.1 – 26.5 (37.07/77.54) 11.5 *M14 × 2 M16 × 1.33 – 8.56 – 185.33 – 8.5 *M16 × 2 A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.53 – 38.69) 8.61/168.6 (80.80 – 78.02/115.71) 11.GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.7 (61.2 (58.9 (52.01/176.28 – 120.59) 12.24) 3.47 – 115.06/108.12/35.68) M12 × 1.9 (4.67/5.5 8.20/23.92 – 94.50 – 60.34) 7.16 – 70.6 – 1.79) 11.52 – 265.5 (125.03 – 44.76) M 8 × 1.93) 18.57) 11.0 (62.49) 7.8 – 17.07/42.6 – 6.18/40.5 – 5.24/79.79/109.87) 4.14 – 85.60) 2.3 – 3.88 – 11.88 – 11.77) 16.25 5.61) 1.32 – 56.01) M6 ×1 *M10 × 1.46/10.34/77.58 – 106.50/170.37) 7.83 – 163.6 – 8.13 – 136.30/114.9 (17.35 – 124.2 (4.43 – 119.4 (13.8 (16.1 – 16.9 (3.5 – 12.47 – 116.10/162.91 – 82.9 (120.1 – 2.6 (84.7 (85.78 – 19.0 (7.83/71.4 – 2.63 – 256.8 (29.0 – 27.02/85.62 – 127.67/5.00 – 120.20 – 66.50/4.31 – 41.61 – 56.73 – 172.95 – 14.34 – 128.6 – 18.70/123.1 (130.3 – 3.67 – 253.7 – 17.25 2.7 (81.40 – 186.6 – 8.4 (40.76) 1.48) *M12 × 1.63 – 33.85 – 162.75 3.9 – 11.30 – 59.82) 4.7 – 13.74 – 24.48/22.

1/78.0 – 9.7 – 36.8 – 13.8 (5.4 – 66.2 – 9.8) 1.0 – 11.0 8.0 – 2.4 – 49.2) (72.6) 1st Step 2nd Step New bolt 3. and Rocker Arm Shaft Bracket kgf·m(lb.0 – 6.0) (59.2 (21.9 – 65.1 – 107.0/7.0 10.4 – 90.8 – 17.8 – 19.1/29.0 (36.4 – 79.9) 9 .GENERAL INFORMATION SPECIAL PARTS FIXING NUTS AND BOLTS Cylinder Head Cover.ft.4/9.4/49. Cylinder Head.6) 5.4 – 88.2 – 14./N·m) 0.0 – 58.2) Reused bolt 8.2 – 43.0 (57.0 (7.5/80.8 – 1.6/98.0 – 5.

4 – 88.7 – 130.2) 10 .9 – 65.4/4.1 – 24.0 (115.2 – 90.3/13.4 – 2.5) 14 – 24 (1.6) 8.4 (10.1 – 17.4 (10.5 (83.4/112.4 – 2.3/13./N·m) 11.8 – 122.6 – 176. Connecting Rod Bearing Cap.GENERAL INFORMATION Crankshaft Bearing Cap.0 – 9.1 – 240.4 – 177. and Oil Pan kgf·m(lb.5 (145. Flywheel.5 – 12.1 – 17.4 – 2.1/78.7 – 23.3) 1.0 (57.2) 16.7 – 23.2/197.5) 20. Crankshaft Damper Pulley.4 – 7.0 – 18.ft.5) 1.2/159.

3/13./N·m) M10 x 1.1/86.4 – 2.4 – 2.7 – 23.1 – 113.0 (72.1 – 117.3/13.25 (0.7) 1.6 (69.7) M12 x 1.7 (48 – 63/66 – 85) 11 .7/45.4 (10.6 – 8.1 – 17.3 – 47.GENERAL INFORMATION Timing Gear Case.05) 4.7 – 23.4 – 2.9/94.07) 8.05) 9.7 – 23.4 – 86. and Timing Gear kgf·m(lb.1 – 64.6 – 11.3 – 105.8 (63.ft.8 – 10.8) M12 x 1.47 x 0.75 (0.5) 6.8/98.0 – 1.4 (10.7 – 23.5) 10.2 – 10.6 – 6.1 – 17.0 – 12. Camshaft.5) 1.4 (10.47 x 0.4 (10.7) 1.1 – 17.5) 1.7 – 78.39 x 0.3/13.9) 1. Flywheel Housing.9/9.5 (7.25 (0.8 – 14.6 (33.4 – 2.1 – 17.3/13.4 – 83.

4 – 2.1 – 17.3/13.1 – 17.4 (10.7 – 23.4 (10./N·m) 1.5) 12 .4 – 2.1 – 17.3/13.4 (10.7 – 23.5) 1.GENERAL INFORMATION Cooling and Lubricating System kgf·m(lb.7 – 23.4 – 2.4 (10.7 – 23.5) 1.5) 1.4 – 2.1 – 17.3/13.1 – 17.5) 1.7 – 23.3/13.3/13.4 (10.4 – 2.ft.

1 – 17.4 (10.7 – 23.4 (10.1 – 17.GENERAL INFORMATION Intake and Exhaust Manifold kgf·m(lb.5) 1.4 – 2.7 – 23.5) 13 ./N·m) 1.3/13.ft.3/13.4 – 2.

7 – 23.4 (10.6 – 4.8 – 78.6 – 24.5) 3.0 – 8.6 (26.4 – 18.4) 14 .3/13.9/58.4 – 2./N·m) 1.5 (14.0 – 2.3/35.ft.1/19.1) 6.0 – 33.GENERAL INFORMATION Engine Electrical kgf·m(lb.4 – 57.5) 2.0 (43.3 – 45.1 – 17.

2) 1.4 – 2.4 – 2.5) 15 .9/19.5) 1.5) 1.0 (14.7 – 23.4 (10.4 – 43.2) 3.4 – 2.7 – 23.4 – 2.4 – 2.3/13.3/13.5) 1.4 – 28.1 – 17.7 – 23.4 (10.GENERAL INFORMATION Fuel Injection System kgf·m(lb.1 – 17.3/13.7 – 23.1 – 17.2 – 4.3/13./N·m) 20 – 4.4 (10.4 (23.ft.4 (10.6 – 39.7 – 23.1 – 31.3/13.1 – 17.4 (10.5) 1.1 – 17.8/31.

MEMO 16 .

. . . . . . . . . . . . . . . . . . 18 Injection pump identification . . . . . . . . . . . . . . . 18 Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel system . . . . . . .MAINTENANCE SECTION 2 MAINTENANCE TABLE OF CONTENTS ITEM PAGE Model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 28 17 . . . . . . . . . . . . . . . . . 26 Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Compression pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Injection timing . . . . . . . . . . . 22 Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .

. Note: Always check the identification number before beginning a service operation. 3.. Loosen the used oil filter by turning it counterclockwise with a filter wrench..... Applicable service data will vary according to the identification number. (LICENCE BOSCH) A …Identification number In-line type Injection volume should be adjusted after referring to the adjustment data applicable to the injection pump installed..... .... Filter Wrench 18 .. Loosen the drain plug to drain the engine oil..... INJECTION PUMP IDENTIFICATION A Pump No.. 1 ZEXEL (Manufacturer of the injection pump) identification number 2 ISUZU Parts Number Distributor type LUBRICATING SYSTEM Main Oil Filter Replacement Procedure 1.... 2. The injection pump identification number (A) is stamped on the injection pump identifications plate... Use of the wrong service data will result in reduced engine performance and engine damage...MAINTENANCE MAINTENANCE Servicing refers to general maintenance procedures to be performed by qualified service personnel..... NP .. Wait a few minutes and then retighten the drain plug. Maintenance interval such as fuel or oil filter changes should be refered to “INSTRUCTION MANUAL”....PE . MODEL IDENTIFICATION Engine Serial Number The engine number is stamped on the rear left hand side of the cylinder body.

This will allow the new fuel filter to seat properly. Check the engine oil level and replenish to the specified level if required. 5.MAINTENANCE 4. Filter Wrench 2. 5. Clean the oil cooler fitting face. Turn in the new fuel filter until the filter O-ring is fitted against the sealing face. 6. Use a filter wrench to turn in the fuel filter an additional 1/3 to 2/3 of a turn. 6. Apply a light coat of engine oil to the O-ring. 7. 3. Supply fuel to the new fuel filter to facilitate bleeding. Be very careful to avoid fuel spillage. 4. 19 . Start the engine and check for oil leakage from the main oil filter. This will allow the new oil filter to seat properly. Use a filter wrench to turn in the filter an additional 1 and 1/4 of a turn. FUEL SYSTEM Fuel Filter Replacement Procedure 1. 9. Clean the upper cover fitting face. Apply a light coat of engine oil to the O-ring. Filter Wrench 8. Turn in the new oil filter until the filter O-ring is fitted against the sealing face. Loosen the used fuel filter by turning it counterclockwise with the filter wrench.

8 – 14.9/8.ft. 2) Operate the priming pump until fuel mixed with foam flows from the bleeder screw. 5) Loosen the bleeder bolt 3 while operating the injection pump priming pump to check that the air has been bled completely. For the engine equipped with in-line type injection pump 1) Loosen the priming pump cap 1 on the injection pump. 3) Operate the priming pump until there are no more bubbles visible in the fuel being discharged from the fuel return eye bolt on the fuel filter. 2) Loosen the fuel return eye bolt 2 on the fuel filter. 4) Operate the priming pump several times and check for fuel leakage.5 (6./N·m) 0. If the float 1 has reached level 2 . 4) Retighten the fuel return eye bolt on the fuel filter.5 – 10. loosen the drain plug 3 (at the bottom side of the water separator) to drain the water.9 – 1. 080ES004 20 . 6) Operate the priming pump several times to check for fuel leakage around the injection pump and the fuel filter. 2. 2 1 Drain Plug Torque 3 kgf·m(lb.7) Air Bleeding 1.MAINTENANCE Water Separator (Water Sedimentor) (Optional Equipment) Check the water separator float 1 level. Air bleeding screw For the engine equipped with distributor type injection pump 1) Loosen the bleeder screw on the injection pump overflow valve. 3) Tighten the bleeder screw.

ft.001) 40 (Reference) Removing or installing one shim will increase or decrease the nozzle opening pressure approximately 3. and adjusting shim 4. Injection Nozzle Opening Pressure kgf/cm2(psi/MPa) 185 (2. 1 5.1) 1 2 3 Spray Condition (1) Correct (2) Incorrect (Restrictions in orifice) (3) Incorrect (Dripping) Injection Nozzle Adjustment 1. If the injection nozzle does not open at the specified pressure.) 0. 4 3 2 Adjusting Shim Availability Range Increment Total No.2/39.630/18. WARNING: TEST FLUID FROM THE INJECTION NOZZLE TESTER WILL SPRAY OUT UNDER GREAT PRESSURE. install or remove the appropriate number of adjusting shims to adjust it./N·m) 4.77 kgf/cm2 (53.025 (0. Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure. Use a wrench to remove the injection nozzle retaining nut. Retaining Nut Torque kgf·m(lb. 3. If the opening pressure is above or below the specified value. 2. the injection nozzle must be replaced or reconditioned.0) 4.06) 0. KEEP YOUR HANDS AWAY FROM THE INJECTION NOZZLE TESTER AT ALL TIMES.9 – 36.2 – 49.0 – 5. the push rod 2 . Attach the injection nozzle holder to the injection nozzle tester.6 psi/370kPa). the spring 3 . of Shims mm(in.0 (28. Install the injection nozzle 1 .MAINTENANCE Injection Nozzle Injection Nozzle Inspection Use a nozzle tester to check the injection nozzle opening pressure and the spray condition. Clamp the injection nozzle in a vise. 21 .50 – 1. IT CAN EASILY PUNCTURE A PERSON’S SKIN.50 (0.02 – 0. If the spray condition is bad. the injection nozzle must be replaced or reconditioned.

Check the thermostat initial opening temperature. Drive Belt Deflection mm(in. 1 3.0 (0.) . Heat the water. A Crankshaft damper pulley B Alternator pulley A C Cooling fan drive pulley D Depress the drive belt mid-portion with a 10 kgf (22 lb/98 N) force.0 (0.39) Thermostat Operating Test 1. Check the thermostat full opening temperature. Completely submerge the thermostat in water. Thermostat Full Opening Temperature 95 (203) 3 Valve Lift at Fully Open Position 8.MAINTENANCE COOLING SYSTEM D Cooling Fan Drive Belt C B Fan belt tension is adjusted by moving the alternator.315) 1 Thermostat 2 Agitating Rod 3 Wooden Piece 22 °C(°F) mm(in. 2.) 10. Thermostat Initial Opening Temperature 2 °C(°F) 82 (180) 4. Stir the water constantly to avoid direct heat being applied to the thermostat.

the No.40 (0. 4 piston is at TDC on the compression stroke. If the No. If the No. 4 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft damper pulley TDC line is aligned with the timing pointer.0 – 6.2 – 43. Rocker Arm Shaft Bracket Bolt Torque 3 1 2 4 TDC kgf·m(lb. 3. Adjust the No. 1 piston is at TDC on the compression stroke.MAINTENANCE VALVE CLEARANCE ADJUSTMENT 1. 1 or the No. (At TDC on the compression stroke of the No.016) Loosen each valve clearance adjusting screw as shown in the illustration. the No. Tighten the lock nut securely. Turn the valve clearance adjusting screw until a slight drag can be felt on the feeler gauge.) 0. 23 .8) 2. 1 intake and exhaust valve push rods. 4. Valve Clearance mm(in.0 – 58. 1 cylinder or the No. 5. 4 cylinder valve clearances while their respective cylinders are at TDC on the compression stroke.4/49. Retighten the rocker arm shaft bracket bolts in sequence as shown in the illustration.0 (36. 1 cylinder) Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end.ft/N·m) 5. 1 cylinder intake and exhaust valve push rods have play. Bring the piston in either the No. 1 cylinder intake and exhaust valve push rods are depressed. Check for play in the No.

Realign the crankshaft damper pulley TDC line with the timing pointer.5/39. 4 stroke) INJECTION TIMING Injection Timing Confirmation Procedure 1. 1 fuel injection pipe.1) 5) Operate the injection pump priming pump while slowly rotating the crankshaft until fuel stops flowing from the delivery valve holder. and the delivery valve holder 3 . (At TDC on the compression stroke of the No.0 (14. 2) Remove the No. the delivery valve spring 2 .0 – 4. Adjust the clearances for the remaining valves as shown in the illustration.9/19.2) 11) Operation to air breeding.ft/N·m) 4. 1 3) Remove the delivery valve holder 1 . TDC 17 6) Conform that the crankshaft damper pulley notched line is aligned with the timing gear case cover pointer. 9) Tighten the delivery valve holder to the specified torque. 24 . In-line type injection pump 1) Rotate the crankshaft clockwise to align the camshaft gear timing mark “O” with the timing gear case cover pointer. Fuel Injection Pipe Torque kgf·m(lb. 2 4) Tighten the delivery valve holder to the specified torque.ft/N·m) 2.0 – 4. Injection Timing (Static BTDC) 14° 7) Remove the delivery valve holder.6 – 39.2 – 44. The No. 3 2 1 8) Install the delivery valve 1 .9 – 32.5 (28. the delivery valve spring 2 . 1 cylinder will now be at the point where nearly injection timing. 10) Install the fuel injection pipes and tighten them to the specified torque. 3 Delivery Valve Holder Torque kgf·m(lb.MAINTENANCE Rotate the crankshaft 360°.4 – 28. and the delivery valve 3 .

The No.7/18. 080ES003 Pump Fixing Bolt kgf·m(lb. continue with the following steps.ft/N·m) 1. 1 cylinder will now be at the point where nearly injection timing. 5) Set dial gauge in the “0” position. • If injection timing will be advanced.5 (0. • If injection timing will be retarded.9 (13. 3) Fit a dial gauge and set lift to 1 mm (0.7 (12.) 0. move the injection pump toward the engine. adjust bolt and pump distribution head plug to the specified torque.3/16. 10) Adjust the injection pump setting angle. Starting Timing mm(in.MAINTENANCE 2.02) 080ES002 8) If the injection timing is outside the specified range.6) Injection Pump Distributor Head Plug kgf·m(lb. 2) Remove injector pump distributor head plug.ft/N·m) 1. Tighten the pump fixing nut. 7) Turn the crankshaft in the normal direction and read the measuring device’s indication at TDC.039 in). move the injection pump away from the engine.7) 25 . 4) Set crankshaft damper pulley Top Dead Center mark about 45° before Top Dead Center from the pointer. Distributor type injection pump 1) Rotate the crankshaft clockwise to align the camshaft gear timing mark “O” with the timing gear case cover pointer. Measuring device: 5-8840-0145-0 6) Turn the crankshaft a little rightwise and leftwise and see if the pointer is stable in the “0” position. 9) Loosen the injection pump fixing nuts and bracket bolts.

1 cylinder glow plug hole. Remove all of the glow plugs from the engine.157) . 5. 3. Turn the engine over with the starter motor and take the compression gauge reading. Set a compression gauge to the No. 2. Compression Pressure kgf/cm2(psi/MPa) at 200 rpm Standard 31 (441/3. Compression Gauge :5-8840-2675-0 Adapter :5-8840-9029-0 4. Start the engine and allow it to run for several minutes to warm it up.MAINTENANCE COMPRESSION PRESSURE MEASUREMENT 1. Stop the engine and cut the fuel supply.04) 26 Limit 22 (313/2.

........................ ............................... ......MAINTENANCE RECOMMENDED LUBRICANTS ENGINE TYPE TYPES OF LUBRICANTS Without turbocharger Diesel engine oil CC or CD grade With turbocharger Diesel engine oil CD grade ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE [Single grade] ................................................................................................... ... SAE 40 .................... .................................................................................................................... ................................ ........................................................... ................................ ............ ..................................................................................... 20W–40 ....................................... .......................................... ....... .......... ............... .......................................... ................................................................................................................. ...................... SAE 10W SAE 30 ....................................................... SAE 15W–40.............. Ambient Temperature –30°C (–22°F) –15°C (5°F) –0°C (32°F) 15°C (59°F) 25°C 30°C (77°F) (86°F) [Multi grade] .............. .... .................................................. 20W .......................................... ........................................................ 27 ......................................................................... .................................................................................................. SAE 10W–30 .................................................................................................................... SAE 20.........................................

20. 3. 12. 15.MAINTENANCE ENGINE REPAIR KIT All of the numbered parts listed below are included in the Engine Repair Kit. 9. 6. 14. 18. Cylinder head gasket Cylinder head cover gasket Head cover cap nut gasket Drain cock gasket Crankshaft rear oil seal Gear case gasket Gear case cover gasket Oil pan drain plug gasket Oil pan gasket Oil filter gasket * * * * * 11. 20 3 19 2 17 18 14 15 13 19 10 5 11 12 1 6 19 4 7 9 8 16 * * * 28 1. 19. 16. The gaskets marked with an asterisk (*) are also included in the Top Overhaul Kit. 8. 7. Water pump gasket Water outlet pipe gasket Thermostat housing gasket Intake manifold gasket Exhaust manifold gasket Crankshaft front oil seal Nozzle holder O-ring Nozzle holder gasket Joint bolt gasket Vacuum pump pipe gasket . 5. 10. 13. 17. 2. 4.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE ASSEMBLY ( 1 ) SECTION 3 ENGINE ASSEMBLY ( 1 ) TABLE OF CONTENTS ITEM PAGE General description . . . . . . . . . . . . . 30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 29 . . . . . . . . . . . . . . . . .

Chrome plated dry type cylinder liners provide the highest durability. These bearings are especially sensitive to foreign material such as metal scraps. Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold. Because it is tufftrided. This type of gasket eliminates cylinder head bolt retightening.ENGINE ASSEMBLY ( 1 ) ENGINE ASSEMBLY GENERAL DESCRIPTION This illustration is based on the A-4JA1 engine. it cannot be reground. It is very important that the oil ports and other related parts be kept clean and free of foreign material. This design provides superior fuel economy for a wide range. The crankshaft main bearings and the connecting rod bearings are aluminum plated. 30 . The laminated steel sheet cylinder head gasket is very durable. The tufftrided crankshaft has a long service life. The A-4J Series of industrial engines features the unique ISUZU troidal square combustion chamber.

Cooling fan and spacer Cooling fan drive belt Cooling fan drive pulley Alternator and adjusting plate Fuel pipe (Fuel filter to injection pump) Fuel pipe (Fuel filter to feed pump) Fuel pipe (Fuel filter leak off) Fuel filter Oil pipe (Injection pump to cylinder body) Rear engine hanger 11. 18. 5.ENGINE ASSEMBLY ( 1 ) DISASSEMBLY These disassembly steps are based on the A-4JA1 engine. 16. 21 20 18 3 7 8 5 13 14 12 11 10 16 17 19 4 2 1 6 9 15 Disassembly Steps . 17. 8. 10. 3. Intake manifold Starter Oil filter Oil pressure switch Cooling water rubber hose Cooling water intake pipe Front engine hanger Exhaust manifold 31 . 15. 19. 6. Fuel leak off pipe v 12. 20. 9. v 21. 2. Injection pump 14. Fuel injection pipe with clip v 13. 7.1 1. 4.

3) Pull the injection pump with the injection pump timing gear free from the rear. Exhaust Manifold 4 3 32 8 7 5 Loosen the exhaust manifold bolts a little at a time in the numerical order shown in the illustration. 21. Do not apply excessive force to the injection pipes. 3) Remove the injection pipes. Injection Pump 1) Remove the six injection pump bracket bolts from the cylinder body timing gear case. 2) Remove the injection pump rear bracket bolts from the rear bracket. 2) Loosen the injection pipe clips. 13. Note: Plug the injection pump delivery holder ports with the shipping caps (or the equivalent) to prevent the entry of foreign material.1) 12. Fuel Injection Pipe with Clip 1) Loosen the injection pipe sleeve nuts at the delivery valve side. 1 6 2 .ENGINE ASSEMBLY ( 1 ) Important Operations (Disassembly Steps .

15. Crankshaft damper pulley with 12.ENGINE ASSEMBLY ( 1 ) 6 ★ ★ 1 7 2 8 ★ 3 9 13 ★ 10 ★ 12 ★ 5 11 4 16 17 14 ★ Repair kit 15 Disassembly Steps . 6. 13. 17. 2. 3. v 7. 8. 14. v 9. Cylinder head gasket v 11. Water by-pass hose Thermostat housing Water pump Injection nozzle holder Glow plug and glow plug connector Cylinder head cover Rocker arm shaft and rocker arm Push rod Cylinder head 10. v 16. v 4. dust seal Timing gear case cover Timing gear cover Timing gear oil pipe Idler gear “B” and shaft Idler gear “A” Idler gear shaft Inverted Engine 33 . 5.2 1.

3 1. Timing gear case v 8. 3a. Crankshaft bearing cap with lower bearing 11. 4. Tappet 15. 5. 2. Oil pan Oil pan (If so crankcase equipped) Crankcase (If so equipped) Flywheel Rear flywheel (If so equipped) Flywheel housing Oil pump with oil pipe Camshaft with camshaft timing gear and thrust plate 7.ENGINE ASSEMBLY ( 1 ) 16 ★ 15 7 6 14 4 3 11 13 12 3a 9 8 10 2 5 ★ 1a 1 ★ Repair kit Disassembly Steps . 1a. v 3. Crankshaft with crankshaft timing gear v 13. Crankshaft thrust bearing 12. Crankshaft rear oil seal 16. Cylinder body . Connecting rod cap with lower bearing 34 v 9. Piston and connecting rod with upper bearing v 10. v 6. Crankshaft upper bearing v 14.

Nozzle Holder Remover: 5-8840-2034-0 Sliding Humme: 5-8840-0019-0 7.2) 4. 8 35 . Cylinder Head 14 6 10 2 1 15 5 9 11 13 17 16 Loosen the cylinder head bolts in numerical order a little at a time. Injection Nozzle Holder 1) Remove the nozzle holder bracket nuts. 7 3 12 4 Note: Failure to loosen the cylinder head bolts in numerical order a little at a time will adversely effect the cylinder head lower surface. 2 9. Note: 1 3 4 Failure to loosen the rocker arm shaft bracket bolts in numerical order a little at a time will adversely effect the rocker arm shaft.ENGINE ASSEMBLY ( 1 ) Important Operations (Disassembly Steps . 2) Use the nozzle holder remover and the sliding hammer to remove the nozzle holder together with the holder bracket. Rocker Arm Shaft and Rocker Arm Loosen the rocker arm shaft bracket bolts in numerical order a little at a time.

2) Use the damper pulley remover to remove the damper pulley.012) Idler Gear “A” End Play Measurement Insert a feeler gauge between the idler gear and the thrust collar to measure the gap and determine the idler gear end play.) Standard 0. the crankshaft timing gear backlash.0039–0.07 (0. Damper Pulley Remover 16. Timing Gear Backlash mm(in. Idler Gear “A” Measure the camshaft timing gear backlash.0028) 36 Limit 0. If the measured value exceeds the specified limit. the thrust collar must be replaced.) Standard Limit 0. If the measured value exceeds the specified limit. Crankshaft Damper Pulley with Dust Seal 1) Block the flywheel with a piece of wood to prevent it from turning. the timing gear must be replaced. Idler Gear End Play mm(in.30 (0.ENGINE ASSEMBLY ( 1 ) 11.012) . and the idler gear “A” end play before removing the idler gear “A” and shaft.17 (0. Timing Gear Backlash Measurement 1) Set a dial indicator to the timing gear to be measured. 2) Move the gear to be checked as far as possible to both the right and the left.10–0.30 (0.0067) 0. Take the dial indicator reading. Hold both the gear to be checked and the adjoining gear stationary.

and the camshaft during the disassembly procedure. If the connecting rod upper bearings are to be reinstalled. the cam. mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. Flywheel 1) 1 4 5 3 2 Block the flywheel with a piece of wood to prevent it from turning. 2) Pull the camshaft free along with the camshaft timing gear and the thrust plate.3) 3. Connecting Rod Cap with Lower Bearing If the connecting rod lower bearings are to be reinstalled. mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.ENGINE ASSEMBLY ( 1 ) Important Operations (Disassembly Steps . 2) Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration. Camshaft with Camshaft Timing Gear and Thrust Plate 1) Remove the thrust plate bolts. Piston and Connecting Rod with Upper Bearing 1) Remove carbon deposits from the upper portion of the cylinder wall with a scraper before removing the piston and connecting rod. 2) Move the piston to the top of the cylinder and tap it with a hammer grip or similar object from the connecting rod lower side to drive it out. 6 6. 9. Note: Be careful not to damage the camshaft journal. 37 . 8.

Oil Seal Remover: 5-8840-2360-0 38 . 13.ENGINE ASSEMBLY ( 1 ) 10. If the measured value exceeds the specified limit. If the crankshaft bearings are to be reinstalled. install the special tool as shown in the illustration and remove the oil seal.0039) 2) 3 4 10 7 8 9 6 5 2 1 Limit 0. mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. With the oil seal pushed in deep.0118) Loosen the crankshaft bearing cap bolts in numerical order a little at a time. Crankshaft Bearing Cap with Lower Bearing 1) Measure the crankshaft end play at the center journal of the crankshaft. the crankshaft thrust bearing must be replaced.10 (0. mark their fitting positions by tagging each tappet with the cylinder number from which it was removed. Crankshaft Upper Bearing If the crankshaft upper bearings are to be reinstalled. Crankshaft Rear Oil Seal (Axial Type) Remove the flywheel housing. mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. 15. 14. Do this before removing the crankshaft bearing caps. Tappet If the tappets are to be reinstalled.30 (0.) Standard 0. Crankshaft End Play mm(in.

Rocker arm v 3. Rocker arm shaft snap ring 7. Rocker arm 39 . Rocker arm shaft bracket 5. Rocker arm shaft snap ring v 2. Rocker arm shaft spring 6.ENGINE ASSEMBLY ( 1 ) DISASSEMBLY SINGLE UNIT ROCKER ARM SHAFT AND ROCKER ARM 6 2 7 5 1 4 3 Disassembly Steps v 1. Rocker arm shaft 4.

ENGINE ASSEMBLY ( 1 ) Important Operations 1. 3) Remove the rocker arm shaft bracket. If the rocker arms and rocker arm shaft brackets are to be reinstalled. 40 . 2) Remove the rocker arms. Rocker Arm Shaft Snap Ring 2. Rocker Arm 3. mark their installation positions by tagging each rocker arm and rocker arm shaft bracket with the cylinder number from which it was removed. Rocker Arm Shaft Bracket 1) Use a pair of snap ring pliers to remove the snap rings.

Cylinder head 41 . Valve spring v 4. Valve spring lower washer 7. Split collar 2. Valve spring upper seat 3.ENGINE ASSEMBLY ( 1 ) CYLINDER HEAD 1 2 3 5 6 7 4 Disassembly Steps v 1. Valve stem oil seal 6. Intake and exhaust valves 5.

Spring Compressor: 9-8523-1423-0 4. Never replace only one or the other. 42 . the valve guide must be replaced. Intake and Exhaust Valve If the intake and exhaust valves are to be reinstalled. Note: If there is excessive valve guide wear or damage. The valve and the valve guides must be replaced as a set. Refer to Page 50 of “Inspection and Repair” for the valve and valve seat insert procedure. Refer to Page 49 of “Inspection and Repair” for the valve guide replacement procedure. If there is excessive valve wear or damage. Split Collar 1) Place the cylinder head on a flat wooden surface. the valve must be replaced.ENGINE ASSEMBLY ( 1 ) Important Operations 1. mark their installation positions by tagging each valve with the cylinder number from which it was removed. Do not allow the valve to fall from the cylinder head. 2) Use the spring compressor to remove the split collar.

Piston pin snap ring 7. 4. 2.ENGINE ASSEMBLY ( 1 ) PISTON AND CONNECTING ROD 2 6 7 4 3 5 1 Disassembly Steps v v v v 1. Connecting rod 6. Piston 43 . Connecting rod bearing Piston ring Piston pin snap ring Piston pin v v 5. 3.

3. mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. Piston Ring 1) Clamp the connecting rod in a vise. Piston Pin Snap Ring Use a pair of snap ring pliers to remove the piston pin snap rings. Take care not to damage the connecting rod. Piston Ring Replacer Do not attempt to use some other tool to remove the piston rings. Piston Tap the piston pin out with a hammer and a brass bar. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled.ENGINE ASSEMBLY ( 1 ) Important Operations 1. Piston ring stretching will result in reduced piston ring tension. 2. 44 . Piston Pin 7. mark their installation positions by tagging each piston with the cylinder number from which it was removed. Piston Pin Snap Ring 4. 2) Use a piston pin replacer to remove the piston rings. 5. If the pistons are to be reinstalled.

Camshaft 45 . Thrust plate 3. CAMSHAFT TIMING GEAR. Camshaft timing gear v 2. AND THRUST PLATE 4 3 2 1 Disassembly Steps v 1. Feather key 4.ENGINE ASSEMBLY ( 1 ) CAMSHAFT.

Use the universal puller 1 to pull out the camshaft timing gear 2 . Camshaft Timing Gear 2. Thrust Plate 1) 3 2) 2 Clamp the camshaft in a vise. Take care not to damage the camshaft. .ENGINE ASSEMBLY ( 1 ) Important Operations 1. Universal Puller: 5-8840-0086-0 3) 1 46 Remove the thrust plate 3 .

. . . . . . . . 48 47 . . . . . . . . . . . . .ENGINE ASSEMBLY ( 2 ) SECTION 4 ENGINE ASSEMBLY ( 2 ) TABLE OF CONTENTS ITEM PAGE Inspection and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

624) 91.2 (0.620) – 92. the cylinder head must be replaced. H Cylinder Head Lower Face Warpage mm(in) Standard A E C D F Limit Maximum Grinding Allwance 0. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face.05 (0. Exhaust Manifold Fitting Face Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage. and part replacements if excessive wear or damage is discovered during inspection.60) Note: If the cylinder head lower face is reground. the cylinder head must be replaced. repairs.3 (0.002) or less 0. 2.05 (3.95 (3. 48 . CYLINDER HEAD Cylinder Head Lower Face Warpage 1. Regrind the manifold cylinder head fitting faces if the measured values are greater than the specified limit but less than the maximum grinding allowance.008) 0. If the measured values exceed the maximum grinding allowance.65 (3.012) B Cylinder Head Height (Reference) mm(in) Standard Limit 91. valve depression must be checked. Regrind the cylinder head lower face if the measured values are greater than the specified limit but less than the maximum grinding allowance.ENGINE ASSEMBLY ( 2 ) INSPECTION AND REPAIR Make the necessary adjustments. If the measured values exceed the maximum grinding allowance.

Valve Guide Replacer: 9-8523-1212-0 49 .002) or less 0. set the dial indicator needle to “0”. With the valve stem inserted in the valve guide. If the measured values exceed the specified limit. Measure the valve stem outside diameter. Move the valve head from side to side. 2.0098) Measuring Method . Note the highest dial indication.039 – 0. 2.064 – 0. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter. the valve and the valve guide must be replaced as a set.008) Exhaust Valve 0.25 (0.016) VALVE GUIDE Valve Stem and Valve Guide Clearance Measuring Method .096 (0.008) 0.4 (0.2 (0.069 (0.0025 – 0. Valve Guide Replacement Valve Guide Removal Use a hammer and the valve guide replacer to drive out the valve guide from the cylinder head lower face.II 1. Valve Stem Clearance mm(in) Standard Limit Intake Valve 0.I 1. Refer to the Item “Valve Stem Outside Diameter”.20 (0.0038) 0. Read the dial indicator.ENGINE ASSEMBLY ( 2 ) Manifold Fitting Face Warpage mm (in) Standard Limit Maximum Grinding Allwance 0.0027) 0.05 (0.0015 – 0.

3102) Valve Thickness Measure the valve thickness. If the measured value is less than the specified limit.3124) 7.0 (0. Valve Guide Replacer: 9-8523-1212-0 4. Use a hammer to drive the valve guide into position from the cylinder head upper face.936 (0. Valve Guide Upper End Height (H) (Reference) mm(in) 13. Measure the height of the valve guide upper end from the upper face of the cylinder head.3134) 7.88 (0.512) H Note: If the valve guide has been removed. both the valve and the valve guide must be replaced as a set. Attach the valve guide replacer to the valve guide.8 (0. 3.961 (0. 2.5 (0. VALVE AND VALVE SEAT INSERT Valve Stem Outside Diameter Measure the valve stem diameter at three points. Valve Stem Outside Diameter mm(in) Standard Limit Intake Valve 7.921 – 7.88 (0.059) . the valve and the valve guide must be replaced as a set.3129 – 0.3118 – 0. Intake and Exhaust Valve Thickness mm(in) Standard 1.ENGINE ASSEMBLY ( 2 ) Valve Guide Installation 1. If the measured value is less than the specified limit.949 – 7.071) 50 Limit 1.3102) Exhaust Valve 7. Apply engine oil to the valve guide outer circumference. the valve and the valve guide must be replaced as a set.

20 (0.047) Valve Contact Width 1. Measure the valve contact width.5 (0. Make smooth the valve contact surfaces. Valve Contact Width mm(in) Standard Limit Intake 1. the valve seat insert must be replaced.067) 2.73 (0. the valve seat insert must be replaced.28 (0. 2. Check the valve contact faces for roughness and unevenness. Arc weld the entire inside circumference 1 of the valve seat insert 2.079) 2. If the measured value exceeds the specified limit. 1 Valve Depression mm(in) Standard Limit Intake 0.087) Exhaust 2.050) Exhaust 0.2 (0.098) Valve Seat Insert Replacement 2 3 Valve Seat Insert Removal 1.7 (0. 1 51 . If the measured value exceeds the specified limit.70 (0. 2. Install the valve 1 to the cylinder head 2 .ENGINE ASSEMBLY ( 2 ) Valve Depression 2 1. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface.029) 1. 4 This will invite contraction and make removal of the valve seat insert easier. 2.0 (0.028) 1. Allow the valve seat insert to cool for a few minutes.

2. Valve Seat Angle 45° Note: Use an adjustable valve cutter pilot. Carefully place the attachment 1 (having a smaller outside diameter than the valve seat insert) on the valve seat insert 2 . Note: 2 The smooth side of the attachment must contact the valve seat insert. Remove only the scratches and rough areas. Carefully remove carbon and other foreign material from the cylinder head insert bore. Use a bench press 3 to gradually apply pressure to the attachment and press the valve seat insert into place. Valve Seat Insert Installation 3 1 1. 52 . This will bring the contact width back to the standard value. Use a valve cutter (15°. Note: Do not apply an excessive amount of pressure with the bench press. and 75° blades) to minimize scratches and other rough areas. 45°. Damage to the valve seat insert will result. 150˚ 90˚ 30˚ Valve Seat Insert Correction 1.ENGINE ASSEMBLY ( 2 ) 3. 2. 4. Do not cut away too much. Take care not to damage the cylinder head 4 . Use a screwdriver 3 to pry the valve seat insert free. Take care not to cut away unblemished areas of the valve seat surface. Remove the carbon from the valve seat insert surface. Do not allow the valve cutter pilot to wobble inside the valve guide.

0 (63.6) 29. If the measured value exceeds the specified limit. VALVE SPRING Valve Spring Free Height Use a vernier caliper to measure the valve spring free height.53 in) 32.9 mm (1. If the measured value is less than the specified limit. 6.2 (1.7 (1. Valve Spring Inclination mm(in) Standard Square Limit 1. Check that the valve contact width is correct. Check that the valve seat insert surface is in contact with the entire circumference of the valve. Insert the valve into the valve guide. the valve spring must be replaced.6 (71.96) 48. 4. Apply abrasive compound to the valve seat insert surface.5 (0. 7. Valve Spring Free Height mm(in) Standard Limit 49. Turn the valve while tapping it to fit the valve seat insert. the valve spring must be replace. If the measured value is less than the specified limit.098) Valve Spring Tension Use a spring tester to measure the valve spring tension. Valve Spring Tension kgf(lb/N) Compressed Height Standard Limit 38.06) or less 2.ENGINE ASSEMBLY ( 2 ) 3.9/319.4) 53 . the valve spring must be replaced. 5.90) Valve Spring Inclination Use a surface plate and a square to measure the valve spring inclination.5 (0.9/284.

742) Rocker Arm Shaft and Rocker Arm Clearance 1.750) 2.748) 18.00 (0.2 (0. If the measured value is less than the specified limit.85 (0. The rocker arm must be at cold condition.008) .748 – 0. Rocker Arm Shaft Outside Diameter mm(in) Standard Limit 18.01 – 0. Rocker Arm and Rocker Arm Shaft Clearance mm(in) Standard 0. the rocker arm shaft must be replaced.ENGINE ASSEMBLY ( 2 ) ROCKER ARM SHAFT AND ROCKER ARM Rocker Arm Shaft Run-Out 1.002) 54 Limit 0.03 (0. Place the rocker arm shaft on a V-block.024) Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm fitting portion outside diameter. 2. If the measured value exceeds the specified limit.0004 – 0. Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter.05 (0. If the measured rocker arm shaft run-out exceeds the specified limit.6 (0. Measure the rocker arm shaft outside diameter.05 (0.01 – 19. Rocker Arm Bushing Inside Diameter mm(in) Standard Limit 19.749) 19. correct the rocker arm shaft run-out with a bench press. Rocker Arm Shaft Run-Out mm(in) Standard Limit 0. If the run-out is very slight.008) 0. Use a dial indicator to measure the rocker arm shaft central portion run-out.2 (0.747 – 0.98 – 19. the rocker arm shaft must be replaced. replace either the rocker arm or the rocker arm shaft.

Remove the cylinder body dowel. 1 2 Cylinder Body Upper Face Warpage mm(in) Standard 0.008) If the measured value is more than the limit. A E Limit D F B 55 . Remove the cylinder liner.002) or less C 0. Refer to “Cylinder Liner Replacement”.ENGINE ASSEMBLY ( 2 ) 3. 3. Use a straight edge 1 and a feeler gauge 2 to measure the four sides and the two diagonals of the cylinder body upper face.05 (0. CYLINDER BODY Cylinder Body Upper Face Warpage 1.2 (0. they may be honed with an oil stone. the cylinder body must be replaced. If necessary. Rocker Arm Correction 2 Inspect the rocker arm valve stem contact surfaces for step wear 1 and scoring 2 . Check that the rocker arm oil port is free of obstructions. the rocker arm must be replaced. use compressed air to clean the rocker arm oil port. 2. 1 If the step wear or scoring is severe. If the contact surfaces have light step wear or scoring.

Cylinder Liner Bore mm(in) Standard Limit 93.59 in)] If the measured value exceeds the specified limit.945 – 248.105 (9.663) 93.021 – 93.0012 in).43 – 0. Refer to “Cylinder Body Bore Measurement”. Hold a straight edge 1 along the top edge of the cylinder liner to be measured.ENGINE ASSEMBLY ( 2 ) Cylinder Body Height (Reference) mm(in) Standard 247. Reinstall the cylinder liner. 2.03 mm (0.7679) 4. Cylinder Liner Projection Inspection 1 1.662 – 3. It cannot be rebored or honed.0039) The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0. Cylinder Liner Projection mm(in) Standard 2 0 – 0. If the inside of the cylinder liner is scored or scorched.060 (3. Reinstall the cylinder body dowel. 56 . Measuring Point 1 : Maximum wear portion [11 – 15 mm (0. the cylinder liner must be replaced. 5.10 (0 – 0.665) Note: The inside of the dry type cylinder liner is chrome plated. Use a feeler gauge 2 to measure each cylinder liner projection. the cylinder liner must be replaced. X Y Y X 1 Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder bore at measuring point 1 in the thrust X – X and axial Y – Y directions of the crankshaft.10 (3.7616 – 9.

If the cylinder liner fitting interference is too large. Note: Take care not to damage the cylinder body upper face during the cylinder liner removal procedure.74059 – 3. 3.021 – 95. Discard the cylinder liner.74019 – 3.031 – 95.001 – 95. A-4JB1) 1 2. 4.00075) If the cylinder liner fitting interference is too small.74133) 3 95. Cylinder Liner Remover: 5-8840-2039-0 (A-4JA1.020 (3.74173) 4 57 .030 (3.00004 – 0.040 (3.74055) φ 95 Cylinder Body Bore Diameter 1 95.ENGINE ASSEMBLY ( 2 ) Cylinder Liner Replacement 2 Cylinder Liner Removal 1. Refer to “Cylinder Body Upper Face Warapage”.011 – 95.001 – 0.74138 – 3.019 (0. Calculate the average value of the four measurements to determine the correct cylinder grade. Cylinder Liner Grade Selection Measure the cylinder body inside diameter and select the proper cylinder liner grade number corresponding to the cylinder body inside diameter. (Y – Y) and (Z – Z). Standard Fitting Interference (Reference) mm(in) 0.86 in) 2. Take measurements at measuring point 1 across positions (“W – W”). Cylinder Body Bore Measurement X W 1.74094) 2 95. it will be difficult to insert the cylinder liner into the cylinder body. Measure the cylinder body upper face warpage. engine cooling efficiency will be adversely affected.010 (3. (“X – X”). Z Y Y Z X W Measuring Point 1 : 98 mm (3. Cylinder Liner Grade Nominal Dimension Liner Grade 95.74098 – 3. Insert the cylinder liner remover 1 into the cylinder body (from the lower side of the cylinder body) unit it makes firm contact with the cylinder liner. Use a bench press 2 to slowly force the cylinder liner from the cylinder body.

Cylinder Liner Installation Using Dry Ice If the cylinder liner is a chrome plated dry type. thus making installation easier. Cooling the cylinder liner with dry ice will cause the cylinder liner to contact. 1) Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores.102.ENGINE ASSEMBLY ( 2 ) Cylinder Liner Installation 1.900 N) to the cylinder liner. 8) After installing the cylinder liner.5 lb/24. Cylinder Liner Installer: 5-8840-2040-0 5) Position the cylinder body so that the installer center 3 is directly beneath the bench press shaft center 4. measure the cylinder liner projection. 7) Apply a force of 2. 58 . 3 1 2 3 4 4) Set the cylinder liner installer 3 to the top of the cylinder liner.512. 2) Use compressed air to blow-dry the cylinder liner and bore surfaces. Refer to “Cylinder Liner Projection Inspection”.5 lb/4. Cylinder Liner Installation Using The Special Tool. Note: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation. it is advisable to use dry ice during the installation procedure.500 kgf (5.500 N) to fully seat the cylinder liner. 2. Note: Check that the cylinder liner is set perpendicular to the bench press and that there is no wobble. Note: It is important that the cylinder liner be inserted to the cylinder body immediately after it has been cooled. 3) Insert the cylinder liner 1 into the cylinder body 2 from the top of the cylinder body. 6) Use the bench press to apply a seating force of 500 kgf (1.

CARELESS HANDLING OF DRY ICE CAN RESULT IN SEVERE FROSTBITE.ENGINE ASSEMBLY ( 2 ) WARNING: DRY ICE MUST BE USED WITH GREAT CARE. Grade of cylinder inside diameter Grade of piston Combination AX AX OK CX CX OK AX CX NG CX AX NG 59 . Piston Selection Select the same grade number as the one for the cylinder liner inside diameter.

Failure to select the correct piston grade will result in engine failure. X – X.004 (3.055 (0. the cylinder liner installation procedure may result in slight decreases in cylinder liner clearances. 60 .76 in) Piston Grade Grade mm(in) Piston Outside Diameter 4JA1 4JB1 AX 92.6611) 92. Always measure the cylinder liner clearance after installation to be sure that it is correct.979 – 92.6622) 1 Cylinder Liner and Piston Clearance mm(in) 0.0007 – 0. 1.51 in) for A-4JA1 160 mm (6. However.6612 – 3.0022) Note: :Cylinder liner kit clearances are preset. and Z – Z) at both measuring points. Measure the cylinder liner bore in four different direction (W – W. Then select the appropriate piston grade for the installed cylinder liner.060 (3. Measuring Points 1 : 20 mm (0.663) 93.ENGINE ASSEMBLY ( 2 ) W Piston Grade Selection X Z Y Z Y W X 1 Measure the cylinder liner bore.10 (3.6610 – 3. Measure the piston outside diameter.6606 – 3.662 – 3.020 (3.995 – 93. Measure the cylinder liner bore.005 – 93. There are two measuring points ( 1 and 2 ). 2.021 – 93.6615) CX 92.79 in) for all A-4J models 2 : 140 mm (5.017 – 0.665) Note: It is most important that the correct piston grade be used. Piston Measuring Point 1 : 70 mm (2.6618) 93.010 (3. 2 Calculate the average value of the eight measurements to determine the correct cylinder liner bore.30 in) for A-4JB1 Cylinder Liner Bore mm(in) Standard Limit 93.6616 – 3.989 – 93.994 (3.

the tappet must be replaced.5114) 12.ENGINE ASSEMBLY ( 2 ) TAPPET AND PUSH ROD 1 2 3 Visually inspect the tappet camshaft contact surfaces for pitting. it must be replaced. If the measured value is less than the specified limit.99 (0.5098) 61 . If the tappet is damaged. 4 5 1 2 3 4 5 Pitting Cracking Normal contact Irregular contact Irregular contact Note: The tappet surfaces are spherical. cracking.5106 – 0. Refer to the illustration at the left.95 (0. Do not attempt to grind them with an oil stone or similar tool in an effort to repair the tappet. The tappet must be replaced if any of these conditions are present. and other abnormal conditions.97 – 12. Tappet Outside Diameter Measure the tappet outside diameter with a micrometer. Tappet Outside Diameter mm(in) Standard Limit 12.

012) 3. The camshaft and the camshaft bearings must be replaced if these conditions are discovered during inspection.945 – 49. 2. the oil pump drive gear. If the measured value exceeds the specified limit. Push Rod Curvature mm(in) Limit 0.ENGINE ASSEMBLY ( 2 ) Tappet and Cylinder Body Clearance mm(in) Standard Limit 0.9663 – 1.1 (0.975 (1. Visually inspect both ends of the push rod for excessive wear and damage. the camshaft must be replaced.03 (0. CAMSHAFT Visually inspect the journals.0039) Push Rod Curvature 1.953) .9675) 62 Limit 49.3 (0. Lay the push rod on a surface plate. the cams.60 (1. Camshaft Journal Diameter mm(in) Standard 49. Camshaft Journal Diameter X Y Y X Use a micrometer to measure each camshaft journal diameter in two directions ((X – X) and (Y – Y)).0012) 0. and the camshaft bearings for excessive wear and damage. the push rod must be replaced. If the measured value is less than the specified limit. The push rod must be replaced if these conditions are discovered during inspection. Roll the push rod along the surface plate and measure the push rod curvature with a thickness gauge.

Camshaft Run-Out mm(in) Standard Limit 0.65 (1.005) Camshaft Bearing Replacement Camshaft Bearing Removal 1. the camshaft must be replaced.002) 0. Measure the run-out with a dial indicator.08 (1.05 (0.9716) If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit.004) Camshaft and Camshaft Bearing Use an inside dial indicator to measure the camshaft bearing inside diameter.64) Camshaft Run-Out 1. Use the camshaft bearing replacer to remove the camshaft bearing. H Cam Height H mm(in) Standard Limit 42. Camshaft Bearing Clearance mm(in) Standard Limit 0. If the measured value is less than the specified limit.9685 – 1. the camshaft must be replaced. the camshaft bearing must be replaced.9697) 50. Camshaft Bearing Inside Diameter mm(in) Standard Limit 50. If the measured value exceeds the specified limit. Mount the camshaft on V-blocks.02 (0. Remove the cylinder body plug plate. Bearing Replacer: 5-8840-2038-0 63 . 2.12 (0.0 – 50.ENGINE ASSEMBLY ( 2 ) Cam Height Measure the cam height (H) with a micrometer. 2.03 (1.10 (0.65) 41.0008) 0.08 (1.

002 – 0.4 – 86. Install the thrust plate.050 – 0.8/98.2 (0.0 – 12. Apply engine oil to the bolt setting face and the bolt threads.1 – 117. 2. Remove the thrust plate 3 . Install the camshaft gear.7) 64 . Before removing the camshaft gear 1.0045) 3 Limit 0. 3. Universal Puller: 5-8840-0086-0 2.0 (72. 1 3 2 2. Align the bearing oil holes with the cylinder body oil holes. 1 Thrust Plate Installation 1. Camshaft Gear Torque kgf·m(lb. If the measured value exceeds the specified limit. Camshaft End Play mm(in) Standard 0. 2.008) Thrust Plate Replacement 2 Thrust Plate Removal 1. Use the universal puller 1 to remove the camshaft timing gear 2 . Use a feeler gauge to measure the clearance between the thrust plate and the camshaft journal.ft/N·m) 10. the thrust plate must be replaced. Use the camshaft bearing replacer installer to install the camshaft bearing.ENGINE ASSEMBLY ( 2 ) Camshaft Bearing Installation 1. Bearing Replacer: 5-8840-2038-0 Camshaft End Play 1. push the thrust plate 2 as far as it will go toward the camshaft gear 3.114 (0.

Hold the surface to be inspected perfectly horizontal to prevent the solution from running. tufftriding (Nitrizing Treatment) has been applied. Inspect the oil ports for obstructions. Judgment 1. Approximately 10mm 1. The sliding surface of the pin or journal. Steam clean the crankshaft surface immediately after completing the test. If there is no discoloration after thirty or forty seconds. the crankshaft must be replaced. the crankshaft is usable. There must be no traces of oil on the surfaces to be inspected. it is not possible to regrind the crankshaft surfaces. If discoloration appears (the surface being tested will become the color of copper).ENGINE ASSEMBLY ( 2 ) CRANKSHAFT AND BEARING Inspect the surface of the crankshaft journals and crankpins for excessive wear and damage. Test liquid should not be applied to the area around the oil port. 2. 3. Use a syringe to apply the solution to the surface to be inspected. Use an organic cleaner to thoroughly clean the crankshaft. 2. Because of this. Note: Do not allow the solution to come in contact with the oil ports and their surrounding area. Prepare a 5 – 10% solution of ammonium cuprous chloride (dissolved in distilled water). Crankshaft Tufftriding Inspection The portion to be tested shall be held horizontally so as not to let the test solution flow. 65 . Wait for thirty to forty seconds. Inspect the oil seal fitting surfaces for excessive wear and damage. Note: To increase crankshaft strength.

05 (0. If the measured values are less than the limit. If the measured value exceeds the specified limit. Use a micrometer to measure the crankshaft journal diameter across points (“1 – 1”) and (“2 – 2”). Gently turn the crankshaft in the normal direction of rotation. Use the micrometer to measure the crankshaft journal diameter at the two points ( 3 and 4 ). Read the dial indicator as you turn the crankshaft. the crankshaft must be replaced.08 (0. 3. 2. Crankshaft Run-Out mm(in) Standard Limit 0. Set a dial indicator to the center of the crankshaft journal. Crankshaft Journal and Crankpin Diameter 3 4 1 2 2 1 1. so that a good finger pressure is needed to fit the bearing into position.0031) Bearing Tension Check to see if the bearing has enough tension. 66 .ENGINE ASSEMBLY ( 2 ) Note: The ammonium cuprous chloride solution is highly corrosive. the crankshaft must be replaced. Because of this. Repeat Steps 1 and 2 to measure the crankpin diameter. Crankshaft Run-Out 1.002) or less 0. it is imperative that the surfaces being tested be cleaned immediately after completing the test. 2.

7524) Crankpin Diameter mm(in) Standard Limit 52.ft/N·m) 8.2) 3.0031) 0.0839) 52.0043) Connecting Rod Bearing Inside Diameter 1.05 (0.080 (0. 2.4 – 88.930 (2.932 (2.9 – 65.1/78. Tighten the bearing cap to the specified torque.906 (2. Use a inside dial indicator to measure the connecting rod bearing inside diameter.0829) Crankshaft Journal and Crankpin Uneven Wear mm(in) Standard Limit 0.0 – 9.3589 – 2.3587) A-4JB1 69.0 (115.0 – 18. Install the bearing to the connecting rod big end.08 (0.0031) Crankshaft Journal and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankshaft journal diameter exceeds the specified limit.3595) 59.910 (2./N·m) 16. the bearing and/or the crankshaft must be replaced.917 – 69. 67 .910 (2.0833 – 2.5) Crankshaft brg’ cap Bolt Torque Crankshaft Journal and Bearing Clearance mm(in) Standard Limit 0.7531) 69. Crankshaft Bearing Cap Bolt Torque kgf·m(lb.932 (2.ENGINE ASSEMBLY ( 2 ) Crankshaft Journal Diameter mm(in) Standard Limit A-4JA1 59. Connecting Rod Bearing Cap Bolt Torque kgf·m(lb.035 – 0.002) or less 0.7526 – 2.9 – 176.0014 – 0.11 (0.915 – 52.ft.0 (57.917 – 59.7 – 130.2/156.

Install the bearing caps with the bearing. Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing. Rotate the crankshaft approximately 30° to seat the bearing. and the bearings.0026) 0. Crankshaft Bearing Cap Bolt Torque kgf·m(lb.0 – 18.0 (115.9 – 176.066 (0. 6. 7.0039) Clearance Measurements (With Plastigage) Crankshaft Journal and Bearing Clearance 1. 8. 3.029 – 0. 4. 5.2/156. Remove the bearing cap.ENGINE ASSEMBLY ( 2 ) Crankpin and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit.5) Do not allow the crankshaft to turn during bearing cap installation and tightening. 68 . Carefully place the crankshaft on the bearings. the bearing and/or the crankshaft must be replaced.7 – 130.0011 – 0. Install the bearings to the cylinder body. Crankpin and Bearing Clearance mm(in) Standard Limit 0. the journal bearing fitting surface. 2. Tighten the bearing caps to the specified torque. Clean the cylinder body. the bearing caps.10 (0.ft/N·m) 16.

0043) Crankpin and Bearing Clearance 1.0036) mm(in) 0. If the measured value exceeds the limit.11 (0. the connecting rod. Apply engine oil to the Plastigage to keep it from falling.ENGINE ASSEMBLY ( 2 ) 9. Crankshaft Journal and Bearing Clearance Standard Limit 0. Do not allow the crankshaft to move when installing the bearing cap.0014 – 0. and the bearings. 2) Use an inside dial indicator to measure the bearing inside diameter. Attach the Plastigage to the crankpin. 2. the crankshaft and/or the bearing must be replaced. If the crankshaft journal and bearing clearance exceeds the limit. the bearing cap.035 – 0. perform the following additional steps. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. 69 . Clean the crankshaft. 3. Install the bearing to the connecting rod and the bearing cap. 1) Use a micrometer to measure the crankshaft outside diameter. 4. Prevent the connecting rod from moving.080 (0.

0026) 0. 2) Use an inside dial indicator to measure the bearing inside diameter. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. 1 2 70 The crankshaft gear timing mark (“X – X”) must be facing outward.ft/N·m) 8. Crankshaft Gear Installer: 9-8522-0020-0 .0 – 9. Use the crankshaft gear installer 1 to install the crankshaft gear 2 .0 (57.4 – 88. Crankshaft Timing Gear Remover: 9-8840-2057-0 2 Crankshaft Timing Gear Installation 1. the crankshaft and/or the bearing must be replaced. Remove the bearing cap.029 – 0. Crankpin and Bearing Clearance mm(in) Standard Limit 0. Remove the crankshaft feather key.066 (0.10 (0. 7.1/78. 1) Use a micrometer to measure the crankpin outside diameter. Do not allow the connecting rod to move when installing and tightening the bearing cap. 2.9 – 65. If the crankpin and bearing clearance exceeds the specified limit. Install the bearing cap and tighten it to the specified torque.2) 6.ENGINE ASSEMBLY ( 2 ) 5. Use the crankshaft gear remover 1 to remove the crankshaft gear 2 .0011 – 0. perform the following additional steps. If the measured value exceeds the specified limit. Install the crankshaft gear. Connecting Rod Bearing Cap Bolt Torque kgf·m(lb. 2.0039) Crankshaft Timing Gear Replacement Crankshaft Timing Gear Removal 1 1.

Bearing damage and reduced bearing service life will result. 71 . 2. Place the crankshaft pilot bearing horizontally across the crankshaft bearing installation hole. Do not strike the bearing inner races. Crankshaft Pilot Bearing Replacement Crankshaft Pilot Bearing Removal Use the pilot bearing remover to remove the pilot bearing. Tap around the edges of the crankshaft pilot bearing outer races with a brass hammer to drive the bearing into the crankshaft bearing installation hole. Pilot Bearing Remover: 5-8840-2000-0 Sliding Hammer: 5-8840-0019-0 Crankshaft Pilot Bearing Installation 1. Pilot Bearing Installer: 5-8522-0024-0 Note: Strike only the crankshaft pilot bearing outer races with the hammer.ENGINE ASSEMBLY ( 2 ) CRANKSHAFT PILOT BEARING Check the crankshaft pilot bearing for excessive wear and damage and replace it if necessary.

2. There will be a ridge on the flywheel surface area.0 (0. do not measure the friction surface wear amount at the non-ridge area but be sure to measure it at the rear-friction surface which is shown in the illustration by shaded area. the ring gear must be replaced.ENGINE ASSEMBLY ( 2 ) FLYWHEEL AND RING GEAR 1 Flywheel 1. 72 . Measure the flywheel friction surface wear amount (depth) The flywheel friction surface area actually making contact with the clutch driven plate (the shaded area in the illustration) will be smaller than the original machined surface area. If the measured value is between the standard and the specified limit. Ring Gear Replacement Ring Gear Removal Strike around the edges of the ring gear with a hammer and diesel to remove it. the flywheel must be replaced. If the ring gear teeth are broken or excessively worn. Ring Gear Inspect the ring gear.04) or more Note: Because a ridge is produced at the flywheel friction surface as illustrated. Flywheel Friction Surface Depth 1 mm(in) Limit 1. Be sure to measure the surface wear in the area inside the ridge. If the measured value exceeds the specified limit. the flywheel may be reground. Inspect the flywheel friction surface for excessive wear and heat cracks.

2 1 Measuring Point 1 : 10 mm (0. The ring gear must be installed with the chamfer facing the clutch. PISTON Piston Grade Selection and Cylinder Liner Bore Measurement Refer to the Section “CYLINDER BODY”. Insert the piston ring horizontally into the cylinder liner.39 in) Measuring Point 2 : 120 mm (4. 2. 73 . and then light the rag. Do not allow the temperature of the gas burner to exceed 200°C (390°F). Heat the ring gear evenly with a gas burner to invite thermal expansion. Use a feeler gauge to measure the piston ring gap. Use a piston inserted upside down to push the piston ring into the cylinder liner until it reaches either measuring point 1 or measuring point 2. wrap the diesel fuel soaked rag around the rim of the ring gear. Item “Cylinder Liner Bore Measurement” for details on piston grade selection and cylinder or liner bore measurement. PISTON RING Piston Ring Gap 1. the piston ring must be replaced. 3.72 in) or If the piston ring gap exceeds the specified limit. It must be perfectly horizontal. Note: Another method of heating the ring gear to invite thermal expansion is to soak a rag in diesel fuel. Cylinder liner diameter is the smallest at these two points. Do not allow the piston ring to slant to one side or the other. 2. Install the ring gear when it is sufficiently heated.ENGINE ASSEMBLY ( 2 ) Ring Gear Installation 1.

002 – 0.090 – 0.070 (0.ENGINE ASSEMBLY ( 2 ) Piston Ring Gap mm(in) Standard 1 s t Compression Ring 2nd Compression Ring Oil Ring 0. If a piston ring groove is damaged or distorted.004 – 0.0035 – 0.0012 – 0.40 (0.5 (0.016) 0. 74 .006) 0.10 – 0.012) Limit 1.075 (0.125 (0. the piston must be replaced.008 – 0.30 (0.0049) 2nd Compression Ring mm(in) Oil Ring 0.050 – 0.003) Limit 0. the piston ring must be replaced. If the clearance between the piston ring and the piston ring groove exceeds the specified limit.0028) Visually inspect the piston.20 – 0.059) Piston Ring and Piston Ring Groove Clearance Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston. Piston Ring and Piston Ring Groove Clearance Standard 1 s t Compression Ring 0.15 (0.030 – 0.

replace the piston pin and/or the connecting rod bushing. Connecting Rod Bushing Replacer 75 . Use the connecting rod bushing remover to remove the connecting rod bushing.97 (1.002) Connecting Rod Bushing Replacement Connecting Rod Bushing Removal 1.0006) Piston Pin and Connecting Rod Small End Bushing Clearance Use a caliper calibrator and a dial indicator to measure the piston pin and connecting rod small end bushing clearance. Piston Pin Hole mm(in) Standard 29.0003 – 0. If the clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit. Piston Pin and Connecting Rod Small End Bushing Clearance mm(in) Standard Limit 0. If the measured value is less than the specified limit.008 – 0.ENGINE ASSEMBLY ( 2 ) PISTON PIN Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points. Piston Pin Diameter mm(in) Standard Limit 31.220) 30.219) Piston Pin and Piston Clearance Use an inside dial indicator to measure the piston pin hole (in the piston).0 (1.002 – 29.00008 – 0.007 Piston Pin and Piston Pin Hole Clearance mm(in) 0.015 (0.0008) 0.05 (0. Clamp the connecting rod in a vise.002 – 0.020 (0. the piston pin must be replaced. 2.

008) 0. Connecting Rod Bushing Replacer: 3.ENGINE ASSEMBLY ( 2 ) Connecting Rod Bushing Installation 1. Clamp the connecting rod in a vice. Use the connecting rod bushing installer to install the connecting rod bushing. Connecting Rod Alignment Per Length of 100 mm (3. the connecting rod must be replaced.20 (0. If either the measured distortion or parallelism exceed the specified limit. Use a piston pin hole grinder 1 fitted with a reamer 2 to ream the piston pin hole.15 (0.006) .94 in) Standard Distortion Parallelism 76 0.002) mm(in) Limit 0.05 or Less (0. 2. 1 2 CONNECTING ROD Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole.

014) IDLER GEAR SHAFT AND IDLER GEAR Idler Gear Shaft Outside Diameter Use a micrometer to measure the idler gear shaft outside diameter.770 – 1.ENGINE ASSEMBLY ( 2 ) Connecting Rod Side Face Clearance 1.009) 0. the connecting rod must be replaced. If the measured value exceeds the specified limit.771) 44.35 (0.95 – 44. If the measured value is less than the specified limit.98 (1.90 (1. 2. Connecting Rod and Crankpin Side Face Clearance mm(in) Standard Limit 0. Install the connecting rod to the crankpin. Use a feeler gauge to measure the clearance between the connecting rod big end side face and the crankpin side face.767) 77 . the idler gear must be replaced. Idler Gear Shaft Outside Diameter mm(in) Standard Limit 44.23 (0.

Use an inside dial indic ator to measure the idler gear Idler Gear Inside Diameter mm(in) Standard Limit 45.0010 – 0.933 – 0.2 (0.7728) 45.025 – 0. Crankshaft Front Oil Seal Replacement Oil Seal Removal Use a plastic hammer and a screwdriver to tap around the oil seal to free it from the gear case.008) Idler Gear “B” Bearing replacement Use a suitable bar and a bench press or hammer. Take care not to damage the oil seal fitting surfaces.0 (0.ENGINE ASSEMBLY ( 2 ) Idler Gear “A” Inside Diameter 1.6 (0.7756) If the clearance between the idler gear shaft outside diameter and the idler gear inside diameter exceeds the limit.0033) 0. Idler Gear Shaft and Idler Gear Clearance mm(in) Standard Limit 0.03 (1.4 – 0. mm(in) Projection 1 0.945) TIMING GEAR CASE COVER Replace the crankshaft front oil seal if it is excessively worn or damaged.024) Height 2 23. 78 .085 (0. 1 2 Bearing projection amount should be within the specified height. the idler gear must be replaced.0 – 45.7 – 24.016 – 0.7717 – 1.10 (1.

Use the oil seal installer and the installer grip to insert the oil seal 1 mm (0. Oil Seal Installer: 5-8840-2061-0 79 . 2. Apply a coat of engine oil to the oil seal lip circumference.ENGINE ASSEMBLY ( 2 ) Oil Seal Installation 1.039 in) into the front portion of the timing gear case.

MEMO 80 .

. . . . . . . . . . . . . . . . . .ENGINE ASSEMBLY ( 3 ) SECTION 5 ENGINE ASSEMBLY ( 3 ) TABLE OF CONTENTS ITEM PAGE Reassembly . . . . . . . . . . . . . . . . . . . . . . . 82 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker arm shaft snap ring 3. Rocker arm shaft bracket 82 5.ENGINE ASSEMBLY ( 3 ) REASSEMBLY SINGLE UNIT ROCKER ARM SHAFT AND ROCKER ARM 3 2 4 5 6 1 7 Reassembly Steps v 1. Rocker arm shaft spring 7. Rocker arm 6. Rocker arm shaft snap ring . Rocker arm shaft 2. Rocker arm 4.

2) Install the rocker arm shaft together with the rocker arm.157 in)) facing the front of the engine.ENGINE ASSEMBLY ( 3 ) Important Operations 1. 4 mm (0. the rocker arm shaft bracket. Rocker Arm Shaft 1) Position the rocker arm shaft with the large oil hole (Dia. and the spring. 83 .

v 4. Valve spring 6. 2. Split collar . 84 Cylinder head Valve spring lower washer Valve stem oil seal Intake and exhaust valve v v 5. Valve spring upper seat 7. v 3.ENGINE ASSEMBLY ( 3 ) CYLINDER HEAD 7 6 5 3 2 1 4 Reassembly Steps 1.

2) Install the intake and exhaust valves. Split Collar 1) Use the spring compressor to push the valve spring into position. Spring Compressor: 9-8523-1423-0 2) Install the split collar to the valve stem. Valve Spring 1) Turn the cylinder head up to install the valve springs.ENGINE ASSEMBLY ( 3 ) Important Operations 3. Intake and Exhaust Valve 1) Apply a coat of engine oil to valve stem. 3) Set the split collar by tapping around the bead of the collar with a rubber hammer. 85 . 7. Valve Stem Oil Seal 1) Apply a coat engine oil to the oil seal inner face. Take care not to allow the installed valves to fall free. 5. 2) Install the valve springs with the fine pitched end (painted pink) facing down. 2) Use an oil seal installer to install the oil seal to the valve guide. Oil Seal Installer: 5-8840-2033-0 4. 3) Turn the cylinder head up to install the valve springs. Take care not to allow the installed valves to fall free.

Connecting rod bearing . 2. 3. Piston ring 7. Piston Piston pin snap ring Connecting rod Piston pin v v 5.ENGINE ASSEMBLY ( 3 ) PISTON AND CONNECTING ROD 6 2 1 4 5 3 7 Reassembly Steps v v v v 86 1. Piston pin snap ring 6. 4.

4) Check that the connecting rod moves smoothly on the piston pin. 2) Use a pair of snap ring pliers to install the piston pin snap ring to the piston. Piston pin snap ring 3. 2) Use your fingers to force the piston pin into the piston until it makes contact with the snap ring. Piston pin 1) Apply a coat of engine oil to the piston pin and the piston pin hole. Piston 2. 3) Install the piston to the connecting rod. Connecting rod 1) Clamp the connecting rod in a vise. 87 . 3) Use your fingers to force the piston pin snap ring into the piston snap ring groove. Take care not to damage the connecting rod.ENGINE ASSEMBLY ( 3 ) Important Operations 1. 2 4. 1 The piston head front mark 1 and the connecting rod “ISUZU” casting mark 2 must be facing the same direction.

3) Check that the piston rings rotate smoothly in the piston ring grooves.ENGINE ASSEMBLY ( 3 ) 6. Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil before installing the oil ring. 88 . Piston Ring 3 1) Use a piston ring replacer to install the three piston rings. Piston Ring Replacer: 2 Install the piston rings in the order shown in the illustration. 1 1 Oil ring (Coil expander type) 2 2nd compression ring (Taper undercut type) 3 1st compression ring (Barrel face type) Note: Install the compression rings with the stamped side facing up. 7. Connecting Rod Bearing Carefully wipe any oil or other foreign material from the connecting rod bearing back face and the connecting rod bearing fitting surface. 2) Apply engine oil to the piston ring surfaces.

ENGINE ASSEMBLY ( 3 )

CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE

1
2
3
4

Reassembly Steps
1. Camshaft
2. Feather key

v

3. Thrust plate
4. Camshaft timing gear

89

ENGINE ASSEMBLY ( 3 )

Important Operations

4. Camshaft Timing Gear
1) Install the thrust plate 1 .
2) Apply engine oil to the bolt threads 2 .
3) Install the camshaft timing gear with the timing
mark stamped side facing out.

2

Camshaft Timing Gear Bolt Torque

kgf·m(lb.ft/N·m)

10.0 – 12.0 (72.4 – 86.8/98.1 – 117.7)
1

90

ENGINE ASSEMBLY ( 3 )

MEMO

91

ENGINE ASSEMBLY ( 3 )

REASSEMBLY

1

13

7
8

2
14
15
5
3

4

15a

9

10

6

11

12

16a

16

★ Repair kit

Reassembly Steps – 1
v
v
v
v
v
v

Cylinder body
Tappet
Crankshaft upper bearing
Crankshaft with crankshaft timing gear
Crankshaft thrust bearing
Crankshaft bearing cap with lower
bearing
v 7. Timing gear case
v 8. Camshaft with camshaft timing gear
and thrust plate
v 9. Piston and connecting rod with upper
bearing

92

1.
2.
3.
4.
5.
6.

v
v
v
v
v
v

10.
11.
12.
13.
14.
15.
15a
v 16.
16a

Connecting rod cap with lower bearing
Crankcase (If so equipped)
Oil pump with oil pipe
Crankshaft rear oil seal
Flywheel housing
Flywheel
Rear flywheel (If so equipped)
Oil pan
Oil pan (If so crankcase equipped)

Inverted Engine

Crankshaft damper pulley with dust seal v 8. Cylinder head gasket v 9.ENGINE ASSEMBLY ( 3 ) 17 ★ ★ 14 11 13 10 ★ 12 9 5 ★ 8 ★ 6 ★ 15 7 16 2 1 4 ★ Repair kit 3 Reassembly Steps – 2 v 1. Timing gear oil pipe v 5. Cylinder head 10. Timing gear case cover v 7. Timing case cover 6. Thermostat housing 14. Water by-pass hose v 15. Cylinder head cover 93 . Rocker arm shaft and rocker arm v 12. Idler gear “B” 4. Water pump v 13. Injection nozzle holder 17. Idler gear “A” v 3. Idler gear shaft v 2. Glow plug and glow plug connector seal v 16. Push rod v 11.

Note: Do not apply engine oil to the bearing back faces and the cylinder body bearing fitting surfaces. 94 . Cylinder Body Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder body. 2) Locate the position mark applied at disassembly if the removed crankshaft upper bearings are to be reused. 4. Crankshaft Upper Bearing The crankshaft upper bearings have an oil hole and an oil groove. and the water jackets. 1 2) Locate the position mark applied at disassembly (if the tappet is to be reused). Crankshaft with Crankshaft Timing Gear Apply an ample coat of engine oil to the crankshaft journals and the crankshaft bearing surfaces before installing the crankshaft. 1) Carefully wipe any foreign material from the crankshaft upper bearing and the crankshaft upper bearing fitting surfaces. 2. 2 3. The lower bearings do not.ENGINE ASSEMBLY ( 3 ) Important Operations (Reassembly Steps-1) 1. the oil holes. Note: The tappet must be installed before the camshaft. Tappet 1) Apply a coat of engine oil to the tappet 1 and the cylinder body tappet insert holes 2 .

4 (10. The arrow mark journal number must correspond to the journal to which the bearing cap is installed.9 – 176. 2) Install the bearing caps.2/156. 7. The crankshaft thrust bearing oil groove must be facing the sliding face.1 – 17. 5 Nile 3) Apply a coat of engine oil to the bearing cap bolts. Timing Gear Case 1) Tighten the timing gear case with timing gear case gasket to the specified torque.4 – 2. The bearing cap arrow marks must be facing the front of the engine.0 – 18. 5 bearing cap fitting surface at the points shown in the illustration.3/13. 4) Tighten the crankshaft bearing cap bolts to the specified torque a little at a time in the sequence shown in the illustration. Note: 1 2 3 The No.0 (115. Crankshaft Thrust Bearing 1) Apply an ample coat of engine oil to the crankshaft thrust bearings. 4 journal bearing cap does not have a number stamped on it.7 – 23.5) 3 7 2 6 10 5) Check to see that the crankshaft turns smoothly by rotating it manually. Timing Gear Case Bolt Torque kgf·m(lb.7 – 130. 8 1 4 5 9 Crankshaft Bearing Cap Torque kgf·m(lb.5) 2) Cut away any excessive flash from the timing gear gasket. Note: Be sure that the bearing cap fitting surface is completely free of oil before applying the silicon adhesive.ENGINE ASSEMBLY ( 3 ) 5. 6.ft/N·m) 16. 95 . Do not allow the silicon adhesive to obstruct the cylinder thread holes and bearings. 2) Install the crankshaft thrust bearings to the crankshaft center journal.ft/N·m) 1. Crankshaft Bearing Cap with Lower Bearing 1) Apply silicon adhesive to the cylinder body No.

ENGINE ASSEMBLY ( 3 ) 8. 3) Tighten the thrust plate to the specified torque. 1 4) Apply a coat of engine oil to the upper bearing surfaces. 3 This will facilitate smooth break-in when the engine is first started after reassembly. 5) Apply a coat of engine oil to the cylinder wall. 9. Thrust Plate Bolt Torque kgf·m(lb.7 – 23.ft/N·m) 1. Camshaft with Camshaft Timing Gear and Thrust Plate 1) Apply a coat of engine oil to the camshaft and the camshaft bearings.5) 4) Check to see that the camshaft turns smoothly by rotating it manually. 96 .4 – 2. 2) Install the camshaft to the cylinder body.4 (10. Take care not to damage the camshaft bearings. Note: Do not apply engine oil to the bearing back faces and the connecting rod bearing fitting surfaces. Connecting Rod Bearing Cap with Lower Bearing 1) Apply a coat of engine oil to the circumference of each piston ring and piston. 2 1 2) Position the piston ring gaps as shown in the illustration.3/13. Piston and Connecting Rod with Upper Bearing 3 10.1 – 17. 2 1 1st compression ring 2 2nd compression ring 3 Oil ring 3) Apply a coat of molybdenum disulfide grease to the two piston skirts.

7 – 23. At the same time. 2) Apply sealant to the crankcase cylinder body fitting area.3/13. 5 1 6 8 4 3) Tighten the crankcase bolts to the specified torque a little at a time in the sequence shown in the illustration. rotate the crankshaft until the crankpin is at BDC. 11) Tighten the connecting rod caps to the specified torque.4 (10. Piston Ring Compressor 8) Use a hammer grip to push the piston in until the connecting rod makes contact with the crankpin.9 – 65. and the timing gear case arches at the positions shown in the illustration.2) 11. 5 bearing cap arches.0 (57.1/78. Note: It is absolutely essential that the bearing caps be installed in the correct direction.1 – 17. 9) Install the connecting rod bearing caps.5) 3 97 . Reversing the bearing cap direction will result in serious engine damage. 10) Apply a coat of engine oil to the threads and setting faces of each connecting rod cap bolt. the bearing grooves. The bearing cap number (at the side of the bearing cap) and the connecting rod number must be the same.4 – 2. Connecting Rod Cap Bolt Torque kgf·m(lb.ENGINE ASSEMBLY ( 3 ) 6) Position the piston head front mark so that it is facing the front of the cylinder body.ft/N·m) 8. Crankcase Bolt Torque 2 7 kgf·m(lb. The bearing cap front marks must be facing the front of the engine. Crankcase (if so equipped) 1) Apply sealant to the No.ft/N·m) 1. 7) Use a piston ring compressor to compress the piston rings.0 – 9.4 – 88.

5±0. 2) Insert the oil seal into the peripheral section of adapter.492 ± 0.3/13.4 – 2.ft/N·m) M10x1.3 – 105.7) M12x1.47x0. Standard Dimension = 12.6 (33.1 – 64.07) 4 8.6 – 11.3 mm (0. Crankshaft Rear Oil Seal 1) Apply engine oil to the oil seal lip circumference and the oil seal outer circumference. 4) Remove the adapter and the sleeve.25 (0. 3) Insert the sleeve into the adapter section. Oil Seal Installer: 5-8840-0141-0 13.012 in) Oil Seal Installer: 5-8840-9057-0 14. Oil Pump with Oil Pipe Install the oil pump with the oil pipe and tighten the bolts to the specified torque.47x0. 2) Use the oil seal installer to install the oil seal to the cylinder body.ft/N·m) 1.3 1) Tighten the adapter to the crankshaft rear and section with 2 bolts. 9 3 2) Tighten the flywheel housing bolts to the specified torque a little at a time in the sequence shown in the illustration.5) Note: Take care not to damage the O-rings when tightening the oil pipe bolts. Flywheel Housing 6 8 10 5 1) Apply sealant to the shaded area shown in the illustration. 5) With the seal pressed in.6 – 6.39x0.1 – 113. Crankshaft Rear Oil Seal (Axial Type) 12. check the dimension of the oil seal section. and 1) tighten it with a bolt (M12 x 1. 2 7 1 Flywheel Housing Bolt Torque kgf·m(lb. 13.9) .8 – 10.05) 9.1/86.1 – 17.75 (0.ENGINE ASSEMBLY ( 3 ) 12.05) 98 4.7 – 78.4 – 83.3 – 47.75L = 70) until the adapter section hits the sleeve.5 ± 0.6 (69.9/94.25 (0. Oil Pump Bolt Torque kgf·m(lb.7 – 23.8) M12x1.7/45.4 (10.8 (63.

3) Tighten the oil pan bolts to the specified torque a little at a time in the sequence shown in the illustration. 5 bearing cap arches.5 (83.ENGINE ASSEMBLY ( 3 ) 15.2 – 90.6) 16. Be absolutely sure that the lipped portion is fitted snugly in the groove.4(10. 8 2 Flywheel Bolt Torque kgf·m(lb. 5 bearing cap groove.4 – 2.4/112.5) 4 2 7 3 99 . 1 7 2) Apply a coat of engine oil to the threads of the flywheel bolts.3/13. 5 1 6 8 Oil Pan Bolt Torque kgf·m(lb.5 – 12.7 – 23. Flywheel 1) Block the flywheel with a piece of wood to prevent it from turning. and the timing gear case arches at the positions shown in the illustration. 2) Fit the gasket rear lipped portion into the No. Oil Pan 1) Apply sealant to the No. the bearing grooves.8 – 122.ft/N·m) 1.1 – 17.ft/N·m) 11. 6 3 4 5 3) Tighten the flywheel bolts in the numerical order shown in the illustration.

3/13.7 (48 – 63/66 – 85) kgf·m(lb.ft/N·m) .6 – 8. Idler Gear “A” 1) Apply engine oil to the idler gear 1 and the idler gear shaft 2 . 3) Align the idler gear “X” setting mark with the crankshaft timing gear 3 “X – X” setting mark. Idler Gear “B” Bolt Torque “Z” 100 6.ENGINE ASSEMBLY ( 3 ) Important Operations (Reassembly Steps-2) 1. 2 1 2) Position the idler gear setting marks “X” and “Y” so that they are facing the front of the engine. Idler Gear “A” Bolt Torque kgf·m(lb. 5 2) Align the idler gear 5 “Z” setting mark with the idler gear 1 “Z” setting mark.5) “X” 3 3.4 (10. “Y” 4) Align the idler gear “Y” setting mark with the camshaft timing gear 4 “Y – Y” setting mark. Idler Gear “B” 1 1) Apply engine oil to the idler gear and the idler gear shaft.7 – 23. Idler Gear Shaft The idler gear shaft oil hole must be facing up.4 – 2.1 – 17. 2. 1 4 5) Tighten the idler gear bolt to the specified torque.ft/N·m) 1.

0 – 21.1 – 17.ENGINE ASSEMBLY ( 3 ) 5.3/13. Timing Case Cover 1) Before installing the timing gear case.9/65. Crankshaft Damper Pulley with Dust Seal 1) Block the flywheel ring gear with a piece of wood to prevent it from turning. Cylinder Head Gasket The cylinder gasket “TOP” mark must be facing up.4 (10.7 – 8. Crankshaft Damper Pulley Bolt Torque kgf·m(lb.5 – 62.05) Bolt 6.20 in) strip of liquid gasket to the portion of the feather key indicated by the arrow in the illustration.7 (48. 3) Tighten the timing case cover bolts to the specified torque.12 in x 0. apply a 3 mm x 5 mm (0.7 – 85. 2) Tighten the crankshaft damper pulley to the specified torque.05) Bolt 1.4 – 2.7 – 205.25 (0. Timing Case Cover Bolt Torque kgf·m(lb.ft/N·m) 17.7 – 23.9/166.ft/N·m) M 8x1.9) Take care not to damage the crankshaft damper pulley boss.0(123.47x0. Front 101 .5) M12x1.3) 7.0 – 151.31x0.25 (0. 2) Check that the timing case cover O-ring is firmly inserted into the gear case groove. 8.

4 (10.0 – 9.4 (10.3/13.4–66. Rocker Arm Shaft Bracket Bolt Torque kgf·m(lb. Carefully set the cylinder head to the cylinder head gasket.ft/N·m) 1.ft/N.9) 11.0 – 58.5) 102 .1 – 17.4–79. Cylinder Head 1) Align the cylinder body dowels and the cylinder head dowel holes.5/80.0 10.2 – 9.2) (72.0 – 5. Water Pump Bolt Torque kgf·m(lb.2) 8. Thermostat Housing Bolt Torque kgf.6/98.0) (59.ft/N·m) 5. 2) Apply engine oil to the cylinder head fixing bolt threads and setting faces.4 – 2.7 – 23.0 – 11.2 (21. 2) Tighten the thermostat housing bolts to the specified torque.8) 12. Rocker Arm Shaft and Rocker Arm Tighten the rocker arm shaft bracket bolts in the numerical order shown in the illustration. 2) Tighten the other water pump bolts to the specified torque.4/49. Thermostat Housing 1) Install the thermostat housing.9–65.4–88.0 Reused Bolt (57. 12 8 16 Cylinder Head Bolt Torque 1st Step 18 14 2 6 15 7 10 3 11 New Bolt kgf·m(lb.ft/N·m) 2nd Step 3.5) 13. Water Pump 1) Temporarily tighten the water pump bolt marked with an arrow in the illustration.7 – 23.4–90. This bolt will be tightened to the specified to torque when the alternator adjusting plate is installed.ENGINE ASSEMBLY ( 3 ) 9.m) 1.m(lb. 13 4 5 17 1 9 3) Tighten the cylinder head bolts to the specified torque in two steps following the numerical order shown in the illustration.1/29.1/78.3/13.4 – 2.1 – 17.7–36.2 – 43.0 (36.1–107.4–49.0 8.0 – 6.

1 – 31. Injection Nozzle Holder 3 5 4 2 1 1) Install the injection nozzle gasket 1 and the Oring 2 to the injection nozzle holder 3 .6 – 24. 16. Glow Plug and Glow Plug Connector 1) Tighten the glow plugs to the specified torque. 3) Tighten the holder nuts with washer 5 to the specified torque. Injection Nozzle Holder Nut Torque kgf·m(lb.2) 103 . Glow Plug Torque kgf·m(lb.4 – 43.0 – 2. 2) Install the nozzle holder 3 together with the nozzle holder bracket 4 to the cylinder head.ft/N·m) 2.5) 2) Install the glow plug connectors.4 (23.4 – 18.1/19.ft/N·m) 3.ENGINE ASSEMBLY ( 3 ) 15.8 –/31.2 – 4.5 (14.

Fuel pipe (Fuel filter to feed pump) 9. Rear engine hanger 104 v 11. Injection pump v 3. Exhaust manifold 13. 17. v 15. Starter v 12.ENGINE ASSEMBLY ( 3 ) 12 18 14 19 7 6 9 2 1 3 4 10 16 17 13 15 20 21 8 5 11 Reassembly Steps – 3 v 1. Oil pipe (Injection pump to cylinder body) 6. 20. Fuel injection pump with clip 4. Cooling water intake pipe Cooling water rubber hose Alternator and adjusting plate Oil filter Oil pressure switch Front engine hanger Cooling fan drive pulley Cooling fan drive belt Cooling fan and spacer . Fuel pipe (Fuel filter to leak off) 8. 19. 21. Fuel leak off pipe 5. 18. Fuel filter 7. Intake manifold v 2. v 16. Fuel pipe (Fuel filter to injection pump) 10. 14.

4 –2.4 –2.7 – 23.3/13.5) 105 . 2.3/13. 3) Temporarily tighten the injection pump bracket bolt 5 . 3 Align the injection pump timing check hole pointer 3 with the timing gear “O” mark 4 . 4 4) Tighten the injection pump rear bracket bolts to the specified torque 6 . 1 2 2) Install the injection pump to the timing gear case. Injection Pump Rear Bracket Bolt Torque kgf·m(lb.ENGINE ASSEMBLY ( 3 ) Important Operations (Reassembly Steps-3) 1.7 – 23.5) 6 5) Tighten the injection pump bracket bolt 5 to the specified torque.ft/N·m) 1. Injection Pump 1) Turn the crankshaft slowly clockwise to align the camshaft timing check hole pointer 1 with the camshaft timing gear “O” mark 2 .4 (10. Injection Pump Bracket Bolt Torque 5 6 kgf·m(lb.1 – 17. This bolt will be finally tightened after the injection pump rear bracket bolts 6 .4 (10. Intake Manifold Install the intake manifold gasket with the end having the sharp corners facing the front of the engine.ft/N·m) 1.1 – 17.

4 – 28.0 – 4.ENGINE ASSEMBLY ( 3 ) 3.3/13.4) 12. 8 Exhaust Manifold Bolt Torque kgf.5) 6 106 2 3 7 .0 (43.4 – 2.ft/N·m) 6.2) 11. Note: Make absolutely sure that the clip is correctly positioned.m(lb·ft/N·m) 1. Starter Bolt Torque kgf·m(lb.9/58. An improperly positioned clip will result in injection pipe breakage and fuel pulsing noise.9/19.1 – 17.8 – 78.6 – 39.4 – 57.0(14.ft/N·m) 2. 3) Tighten the injection pipe sleeve nut to the specified torque. Fuel Injection Pipe with Clip 1) Temporarily tighten the injection pipe sleeve nut.0 – 8.7 – 23. 2) Set the clip in the prescribed position. Injection Pipe Sleeve Nut Torque kgf·m(lb. Starter Tighten the starter bolts to the specified torque. Exhaust Manifold 5 1 4 Tighten the exhaust manifold bolts to the specified torque a little at a time in the numerical order shown in the illustration.4(10.

Oil Filter Bolt Torque kgf·m(lb.ft/N·m) 1.3/13.6 – 4.5) 107 .5) 19.1 – 17.1) Tighten the adjusting plate bolts to the specified torque after cooling drive belt installation.ft/N·m) 3. Oil Filter Tighten the oil filter bolts to the specified torque.ENGINE ASSEMBLY ( 3 ) 15.1 – 17.4 (10.ft/N·m) 1.3 – 45. Alternator and Adjusting Plate Tighten the alternator bolts and the adjusting plate bolts to the specified torque.7 – 23.6 (26. Adjusting Plate Bolt Torque kgf·m(lb.4 – 2.4 – 2.0 – 33.3/35.4 (10.3/13. Alternator Bolt Torque kgf·m(lb.7 – 23.

MEMO 108 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LUBRICATING SYSTEM SECTION 6 LUBRICATING SYSTEM TABLE OF CONTENTS ITEM PAGE Main data and specifications . . . . . . . . . . . . . . . . . 110 General description . . . . . . . . . . . . . . . . . . . . . . 117 109 . . . . . . . . . . . . . . . . 114 Oil filter with built-in oil cooler . . . . . . . . . . . . . . . 111 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0) 47 – 53 (116.9 – 117.4 – 264.5 (18.14 – 66.07/78.40/225.6) .4 – 460.0 (56.38 – 17.83/421.3 – 4.89/392.8 – 1.3 – 2.6 – 127.2 (11.7 (61.6) Oil cooler type (if so equipped) Safety valve opening pressure 110 Water-cooled 2 kgf/cm (psi/kPa) 2. Pump speed Delivery pressure 17.70 – 38.6) Safety valve opening pressure kgf/cm2(psi/kPa) 0.LUBRICATING SYSTEM MAIN DATA AND SPECIFICATIONS Item A-4JA1·A-4JB1 Oil pump type Trochoid Delivery volume Lit(qts)/min.4) 1000 2 kgf/cm (psi/kPa) Oil temperature °C(°F) Engine oil 4.4) SAE 30 Oil filter type Full flow with cartridge paper element 2 Relief valve opening pressure kgf/cm (psi/kPa) 4.7 (32.

Filter cartridge Partial flow oil filter (If so equipped) Main flow oil filter Crank shaft bearing Camshaft bearing Vacuum pump Oil pipe Rocker arm shaft Oil cooler Relief valve Connecting rod bearing Timing gears Oil pump Rocker arm Regulating valve (Orifice) Oil strainer Oil pan The A-4J Series engine lubricating system is a full flow type.LUBRICATING SYSTEM GENERAL DESCRIPTION LUBRICATING OIL FLOW Battery Warning Light Oil pressure switch Cylinder block oil gallery Idle gear shaft Oil filter and cooler assembly. 111 . Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is then delivered to the vital parts of the engine from the cylinder body oil gallery.

The oil filter and the water cooled oil cooler are a single unit to increase the cooling effect. 112 .LUBRICATING SYSTEM OIL PUMP A-4J Series engine are equipped with a trochoid type oil pump.

LUBRICATING SYSTEM MAIN OIL FILTER OIL FILTER WITH BUILT-IN OIL COOLER 113 .

Oil pipe 2. Vane v 5. Pump cover 114 4. Pump body with rotor and pinion . Strainer case 3.LUBRICATING SYSTEM OIL PUMP DISASSEMBLY 1 5 4 3 2 051ET001 Disassembly Steps 1.

Rotor and Vane Clearance Standard 0.006) Rotor and Vane Clearance Use a feeler gauge to measure the clearance between the rotor and the vane. If the clearance between the rotor and the exceeds the specified limit.15 (0. repairs.016) 115 . the entire pump assembly must be replaced.14 (0. and Cover Clearance Standard 0. the rotor set (pin.011) 0.07 (0. Vane.006) or less mm(in) Limit 0. and the cover exceeds the specified limit.0028) mm(in) Limit 0. Rotor. rotor. and vane) must be replaced. Vane and Pump Body Clearance Standard mm(in) Limit 0.LUBRICATING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments.20 (0.0008 – 0. rotor. If the clearance between the vane and the pump body exceeds the specified limit.02 – 0. and part replacements if excessive wear or damage is discovered during inspection. Rotor. and vane) must be replaced.008) Vane and Pump Body Clearance Use a feeler gauge to measure the clearance between the vane and the pump body.40 (0. the rotor kit (shaft. and the cover. and Cover Clearance Use a feeler gauge to measure the clearance between the vane.008 – 0. Vane.20 – 0. the rotor.27 (0. the rotor. shaft. If the clearance between the vane.

Pump cover 116 4. Pump body with rotor and pinion 2. Strainer case 5. Oil pipe .LUBRICATING SYSTEM REASSEMBLY 5 1 2 3 4 051ET002 Reassembly Steps 1. Vane 3.

O-ring 5. Oil filter body 117 . Safety valve 6. Drain plug 2. Relief valve 7.LUBRICATING SYSTEM OIL FILTER WITH BUILT-IN OIL COOLER DISASSEMBLY 2 3 5 4 7 1 6 Disassembly Steps 1. Cartridge oil filter 3. Oil cooler 4.

0 – 608.LUBRICATING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments.18/569. 2. 2.49 – 88. Plug one side of the oil cooler water passage.8 – 6.2 (82. 118 . If air bubbles rise to the surface. Apply compressed air (2 kgf/cm2 (28. Relief Valve Opening Pressure kgf/cm2(psi/kPa) 5.2) Oil Cooler Water Leakage At Water Passage 1. Start the engine to check the relief valve opening pressure. Submerge the oil cooler in water. there is water leakage.45 psi/196 kPa)) to the other side of the oil cooler water passage. repairs. 3. Relief Valve 1. Attach an oil pressure gauge to the oil gallery near the oil filter. and part replacements if excessive wear or damage is discovered during inspection.

Drain plug 4.LUBRICATING SYSTEM REASSEMBLY 6 5 3 4 1 7 2 Reassembly Steps 1. Oil filter cartridge v 7. Relief valve v 3. Safety valve v 5. Oil filter body v 2. O-ring 119 . Oil cooler v 6.

Drain Plug Tighten the drain plug to the specified torque.LUBRICATING SYSTEM Important Operations 2.5 – 34.0 – 2.3) 6.6) 120 .1 – 25.3/24.5 (18.8 – 19. Relief Vale Tighten the relief valve to the specified torque.5 – 3.5 (18.2 – 14.0 (7. Oil Filter Cartridge 1) Apply engine oil to the O-ring.5 – 3. Relief Valve Torque kgf·m(lb.5 – 34. 3) Turn in the cartridge oil filter an additional 1 and 1/4 of a turn.4/9. 2) Turn in the cartridge oil filter until the filter sealing face makes contact with the O-ring.ft/N·m) 1. Oil Cooler 1) Align the oil filter holes with the body knock pins at installation. 2) Tighten the oil cooler to the specified torque. 7.ft/N·m) 2.3/24.ft/N·m) 2.3) 5. Oil Cooler Torque kgf·m(lb.1 – 25. Drain Plug Torque kgf·m(lb.

. . . . . . . . . . .COOLING SYSTEM SECTION 7 COOLING SYSTEM TABLE OF CONTENTS ITEM PAGE Main data and specifications . . . . 125 Thermostat . . . . . . . . . . . . . . . . . . . . . 131 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Water pump . . . . .

31) .COOLING SYSTEM MAIN DATA AND SPECIFICATIONS Item Water pump type Pump to crankshaft speed ratio (To 1) Delivery volume Lit(qts)/min.0 (0.5) Double row shaft Wax pellet with jiggle valve 82 (180) 95 (203) 8.1 100 (105. Pump speed at 3000 rpm Water temperature at 30°C (86°F) Pump bearing type Thermostat type Valve initial opening temperature °C(°F) Valve full opening temperature °C(°F) Valve lift at fully open position mm(in.) 122 Centrifugal impeller 1.

123 . and the thermostat. the coolant is circulated by the water pump and thermostat through the by-pass hose and back to the cylinder body. The thermostat will be fully open when the coolant temperature reaches 95°C (203°F). To quickly increase cold engine coolant temperature for smooth engine operation. All of the coolant is now circulating through the radiator for effective engine coolant. the thermostat will begin to open and a gradually increasing amount of coolant will circulate through the radiator. The coolant does not circulate through the radiator. the water pump. the cooling fan. When the coolant temperature reaches 82°C (180°F).COOLING SYSTEM GENERAL DESCRIPTION COOLANT FLOW The engine cooling system consists of the radiator.

124 .COOLING SYSTEM WATER PUMP THERMOSTAT A centrifugal type water pump forcefully circulates the coolant through the cooling system. A wax pellet type thermostat is used. The jiggle valve accelerates engine warm-up.

v 3. v 4. Bearing unit Thrower Water pump body 125 . 7. 6. O-ring Set screw Cooling fan center Impeller and seal unit v 5.COOLING SYSTEM WATER PUMP DISASSEMBLY 2 ★ ★ ★ 1 4 ★ 6 ★ 7 5 3 Disassembly Steps v 1. 2.

4.COOLING SYSTEM Important Operations 3. Cooling Fan Center Remove the fan center with a bench press and a bar. Impeller and Seal Unit Remove the impeller and seal unit with a bench press and bar. 126 . Damage to the impeller will result. Note: Do not drive out the impeller with a hammer.

Bearing Unit Check the bearing for abnormal noise. and other abnormal conditions. repairs.COOLING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments. biding. and part replacements if excessive wear or damage is discovered during inspection. 127 .

v 6. 7. v 4.COOLING SYSTEM REASSEMBLY 4 ★ ★ ★ 7 5 ★ 2 ★ 1 3 6 Reassembly Steps 1. v 3. 2. 128 Water pump body Thrower Bearing unit Set screw v 5. Impeller and seal unit Cooling fan center O-ring .

8 (3. Impeller Projection mm(in. Install the seal unit.0 (0. Set Screw 1) Align the bearing set screw hole with the pump body set screw hole.COOLING SYSTEM Important Operations 3.2 – 79.98) 6.) 25. Cooling Fan Center Measure the distance between the cooling fan fitting face and the water pump body fitting face. 5. Impeller and Seal Unit 1) 2) 3) Apply a thin coat of liquid gasket to the seal unit outer periphery.14) 129 . 3) Secure the bearing with the set screw. 2) Press the bearing unit into place. Bearing Unit 4.) 79. Cooling Fan Center Distance mm(in.12 – 3. Measure the impeller protection from the water pump body fitting face.

Damage to the bearing will result.COOLING SYSTEM Note: 1.96 kN). Removing and reinstalling the fan center and the impeller a second time may result in the breakdown of the water pump during engine operation and subsequent serious overheating problems. Never attempt to remove and reinstall the fan center and the impeller a second time. The water pump assembly must be replaced whenever the fan center and impeller pressure force falls below 200 kgf (1. Do not attempt to strike the bearing into position with a hammer or similar object. 130 . 2. Replace the entire water pump assembly. The fan center and the impeller are installed to the water pump shaft with a press. 3.

Heat the water. 1 3. Thermostat Initial Opening Temperature 2 °C(°F) 82 (180) 4. repairs.COOLING SYSTEM THERMOSTAT INSPECTION AND REPAIR Make the necessary adjustments. Operating Test 1. 2. Stir the water constantly to avoid direct heat being applied to the thermostat. Completely submerge the thermostat in water.) 8.0 (0. and part replacements if excessive wear or damage is discovered during inspection. Check the thermostat full opening temperature.315) 1 Thermostat 2 Agitating Rod 3 Wooden Piece 131 . Check the thermostat initial opening temperature. Thermostat Full Opening Temperature 3 °C(°F) 95 (203) Valve Lift at Fully Open Position mm(in.

MEMO 132 .

. . . . . . . . 143 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 General description .FUEL SYSTEM SECTION 8 FUEL SYSTEM TABLE OF CONTENTS ITEM PAGE Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Injection pump data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

) Governor type Fuel feed pump type Injection nozzle type Number of injection nozzle orifices Injection nozzle orifice inside diameter mm(in.128 – 0.FUEL SYSTEM MAIN DATA AND SPECIFICATIONS Item Injection pump type Plunger outside diameter mm(in.35) 3.039) 185 (2.0 (0.35 (0.25 – 3.0 (0.) Plunger lift mm(in.630/18.132) RSV variable speed mechanical type Single action Hole type 4 1.1) Cartridge paper element water separator Water separator (if so equipped) .) 2 Injection nozzle opening pressure kg/cm (psi/MPa) Main fuel filter type 134 Bosch A type 9.

the fuel filter. 135 .FUEL SYSTEM GENERAL DESCRIPTION COOLANT FLOW Fuel filter Nozzle Water separator Injection pump Fuel tank The fuel system consists of the fuel tank. The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other foreign material are removed from the fuel. the water separator (if so equipped). the injection pump. fed by the injection pump plunger. and the injection nozzle. Fuel. is delivered to the injection nozzle in the measured volume at the optimum timing for efficient engine operation.

136 .FUEL SYSTEM INJECTION NOZZLE Nozzle holder Adjusting shim Spring Spring seat Injection nozzle Retaing nut A hole (with 4 orifices) type injection nozzle is used. The injection nozzle sprays pressurized fuel from the injection pump into the combustion chamber through the nozzle body injection orifice. It consists of the nozzle body and the needle valve assembly.

The fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches the injection pump.FUEL SYSTEM FUEL FILTER AND WATER SEPARATOR Drain Level A cartridge type fuel filter and a water separator are used. As the inside of the injection pump is lubricated by the fuel which it is pumping. 137 . When the float reaches the drain level. The water separator has an internal float. the fuel must be perfectly clean. remind you to drain the water from the water separator.

6.FUEL SYSTEM INJECTION NOZZLE DISASSEMBLY 6 5 7 4 3 2 1 Disassembly Steps 1. Spring Adjusting shim Nozzle holder . v 2. 138 Retaining nut Injection nozzle Spacer Spring seat 5. 7. 4. 3.

1) Install the injection nozzle to the nozzle tester. Injection Nozzle 1) Remove the injection nozzles from the nozzle holders. The nozzle needle valve and nozzle body combinations must be interchange.630 psi/18.1 MPa) to the injection nozzle. the injection nozzle and the injection body must be replaced as a set. 3) Check the area around the nozzle seat for fuel leakage. If there is fuel leakage. 2) Use the nozzle tester to apply compressed fuel at 185 kgf/cm 2 (2.FUEL SYSTEM Important Operations Performance this test before disassembling the injection nozzle. 2) 139 . Immerse the injection nozzles in a tool tray filled with clean diesel fuel to protect them from dust. 2.

The nozzle and body must be replaced if either of these two conditions are discovered during inspection. 2. 3 1 2. If the nozzle needle does not moves smoothly. Nozzle Body and Needle Valve Inspection Check the nozzle body and the needle valve for damage and deformation. Injection Nozzle Needle Inspection 1.) Nozzle Lapping Procedure 2 Lap the nozzle needle 1 and the nozzle body 2 by applying a compound of oxidized chrome and animal oil 3.FUEL SYSTEM INSPECTION AND REPAIR Make the necessary adjustments. Note: Do not apply an excessive amount of the oxidized chrome and animal oil compound to the injection needle valve seat area. 3. it must be repaired (See “Nozzle Lapping Procedure” below. Carefully wash the needle valve and the nozzle body in clean diesel fuel after lapping. and part replacements if excessive wear or damage is discovered during inspection. repairs. 140 . Check that the nozzle needle moves smoothly inside the injection nozzle body. 1. Carefully wash the nozzle needle and the nozzle body in clean diesel fuel. Remove the nozzle needle from the nozzle body.

Nozzle holder Adjusting shim Spring Spring seat 5. 3. v 2. v 7. 4.FUEL SYSTEM REASSEMBLY 2 3 1 4 5 6 7 Reassembly Steps 1. Spacer Injection nozzle Retaining nut 141 . 6.

Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure.50 (0./N·m) 4. mm(in.02-0.0) Injection Nozzle Adjustment 1. install or remove the appropriate number of adjusting shims to adjust it.ft. 142 . KEEP YOUR HANDS AWAY FROM THE INJECTION NOZZLE TESTER AT ALL TIMES. WARNING: TEST FLUID FROM THE INJECTION NOZZLE TESTER WILL SPRAY OUT UNDER GREAT PRESSURE. Adjust Shim Adjust Shim Availability Range 0. Retaining Nut Torque kgf·m(lbs.025 (0.FUEL SYSTEM Important Operations 3.) 40 Retaining Nut Tighten to the retaining nut to the specified torque. If the injection nozzle does not open at the specified pressure.50-0.6 psi/369. 2.2 – 49.77 kgf/cm2 (53.9 – 36.0 – 5.2/39.7 kPa).001) Total No. Attach the injection nozzle holder to the injection nozzle tester.0 (28. IT CAN EASILY PUNCTURE A PERSON’S SKIN. of Shims 7. (Reference) Removing or installing one shim will increase or decrease the nozzle opening pressure approximately 3.06) Increment 0.

079) 6.75/157) ISO4113 or SAE Standard Test Oil (SAEJ967D) 40 – 45 (104 – 113) Clockwise (Viewed from the drive side) 143 .: 105780-2080 Bosch Type No.) kgf/cm2(psi/kPa) °C(°F) ZEXEL No.0 (0.: 105780-0000 Bosch Type No. INJECTION VOLUME ADJUSTMENT TEST CONDITIONS Injection Nozzle Injection Nozzle Holder Injection Starting Pressure Injection Line Dimensions Inside Diameter Outside Diameter Length Transfer Pump Pressure Testing Diesel Fuel Operating Temperature Pump Rotation Direction kgf/cm2(psi/MPa) mm(in.6) 1.0 (0.16) 2.236) 600.6 (22.5/17.: DN12SD12T ZEXEL No.: EF8511/9 175.0 (2488.0 (23.FUEL SYSTEM INJECTION PUMP DATA INJECTION PUMP IDENTIFICATION Refer to the Item “INJECTION PUMP IDENTIFICATION” on Page 1– of the “SERVICING” Section of this Workshop Manual.

05 mm Injection Order: 1-3-4-2 (Plunger numbered from the drive side) Tappet Clearance: More than 0.6 D 8.3 A 7.0 Rack Adjust max. var.1 8.1 Plunger 3.3±0.3 ± 0.3 500 9. GOVERNOR ADJUSTMENT Full Adjustment Above 14.500 64 – 65 ± 2.1 500 6.5 – 13.1±0. bet.0 100 (70 – 85) — Lever Confirm that the timing of D is advanced 1°30’ from A.5 Lever Basic About 6. spec. gov.0 D Idle-sub spring setting 13.4 0 C 160±30 250 500 (610) (1535)1545 1610 Pump speed (rpm) 144 .3 9.5 ± 15. cyl. Above 14. Pre-Stroke: No.3 4. Adjust governor as per. adj.FUEL SYSTEM INJECTION QUANTITY Adjusting Point Rod Position Pump Speed (mm) (rpm) A Injection Quantity (cc/1000 Strokes) Maximum Variation (%) Fixed Remarks 1. at R = 6.8±0.0 Rack position (mm) Governor spring setting 9.3 mm for all cylinders * This performance drawing for A-4JB1PAW-01 only.6.

FUEL SYSTEM Speed Lever Angle 35°±3° 12°±5° Stop 25°±5° 145 .

MEMO 146 .

162 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ENGINE ELECTRICALS SECTION 9 ENGINE ELECTRICALS TABLE OF CONTENTS ITEM PAGE Starter . . . . 148 Alternator . . . . . . . . . .

Use of the wrong service data will result in starter damage.ENGINE ELECTRICALS STARTER STARTER IDENTIFICATION 1 C 2 3 12V HITACHI 4 MADE IN JAPAN A 4 1 Isuzu part number 2 Manufacturer‘s code number 1 2 Hitachi starter are identified by name plate attached to the yoke. (Illustration) 3 24V HITACHI 3 Rated voltage 4 Manufacturer‘s production mark MADE IN JAPAN Note: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number. 148 .

) mm(in.0 (0.) mm(in.03) 0.008) 149 .059) Yoke outside diameter mm(in.05 (0.ENGINE ELECTRICALS MAIN DATA AND SPECIFICATION Isuzu Part No.52/15.0 (3.2 (0.3) 1. Load) Starter motor minimum operating speed (No.8 (0.0 (0.7–4.5/24.27 1.15) Number of poles Magnetic switch (at 20°C [68°F]) Series coil resistance Shut coil resistance Brush length Standard Limit Brush spring standard fitting load Commutator Outside diameter Standard Limit Difference between the largest and smallest diameters Standard Depth of undercut mica Limit Standard Limit 4 Ω Ω mm(in.6) (2.5 (1.02 – 0.0 (1.0 (0.002) mm(in.59) 9.5 – 0.5 30 Clockwise Roller V A 11 160 23 90 rpm 3900 3100 Pinion gear Modules Number of teeth Outside diameter Travel distance mm(in.) 0.51 (0.4/19.) 2.2 24 3.44) 35.) mm(in. Rated voltage Rated output Rating Direction of rotation (Viewed from the pinion side) Clutch type Terminal voltage (No.10 (0. Load) V kW Sec 8-94423-452-0 S24-07 12 2.) kgf(lb. Load) Minimum current (No.18) 29.) – 0.) 80.25 15.5–7.) 0.) mm(in.3) 30.35) (3.40) mm(in.) mm(in.35) 15.75 9 33.0 (0.0 (4.0 (1. 8-97084-877-0 S13-11 Hitachi code No.5 (1.14) 36.7/34./N) mm(in.59) 9.004) 0.

ENGINE ELECTRICALS

GENERAL DESCRIPTION

This starter is equipped with a reduction gear between the armature shaft and the flywheel ring gear drive
pinion.
This construction enable the starter to reduce 27% of the armature shaft revolution speed at the pinion
contributing to achieve more compact size and higher cold engine starting ability than the non-reduction
gear type starter.

150

ENGINE ELECTRICALS

DISASSEMBLY

3

6
2

18
13
12

16

5

4

19

15 14

7

17
20
1

8
9
10
11

Disassembly Steps
v 1.

2.
v 3.
v 4.
v 5.
v 6.
v 7.
8.
9.
10.

Lead wire
Bolt
Magnetic switch
Torsion spring
Plunger
Shim
Through bolt
Rear cover
Brush holder
Yoke

11.
12.
v 13.
v 14.
15.
16.
17.
18.
19.
20.

Armature
Screw
Bearing retainer
Snap ring
Pinion stopper
Return spring
Pinion shaft
Overrunning clutch
Dust cover
Shift lever

151

ENGINE ELECTRICALS

Important Operations

1. Lead Wire
Disconnect lead wire at the magnetic switch.

3. Magnetic Switch
Remove the magnetic switch fixing bolts, then
remove the switch from the shift lever.

4. Torsion Spring
5. Plunger
6. Shim
Remove the torsion spring, plunger and shim from
the magnetic switch.

7. Through bolt
Remove the yoke, armature and brush holder
together from the gear case.

152

ENGINE ELECTRICALS
9. Brush Holder
Using long-nose pliers remove the 4 brushes.

13. Bearing retainer
Remove the bearing retainer, then remove the pinion from the gear case.

14. Snap Ring
Remove the snap ring using a screw driver or
equivalent, then disassemble the pinion assembly.

153

Armature Winding Ground Test Check for continuity across the commutator segments and the core. A short circuited armature must be replaced. and part replacements if excessive wear or damage is discovered during inspection. Place the armature on a growler tester 1. the hack saw blade will vibrate and will be attracted to the armature core. If the armature is short circuited. Armature Winding Continuity Test Check for continuity across the commutator segment. the armature coil is open and must be replaced. repairs. 2. ARMATURE 2 Armature Short Circuit Test 1 1. Hold a hack saw blade 2 against the armature core while slowly rotating the armature. 154 . If there is no continuity.ENGINE ELECTRICALS INSPECTION AND REPAIR Make the necessary adjustments. the armature is internally grounded due to insulation failure and must be replaced. If there is continuity.

44) 35.) Standard Limit S13 – 11 30.2 (0.0 (1. Commutator Outside Diameter mm(in. the segment mica must be undercut.18) 29.03) 0. it must be replaced.5 (1.40) Segment Mica Depth Measurement Use a depth gauge to measure the segment mica depth.02 (0.02 – 0. If the measured value exceeds the limit. the commutator must be replaced.5 – 0. If the measured value exceeds the limit.8 (0.05 (0.5 (1. Commutator Run-Out mm(in. If the bearing is worn or damaged. Segment Mica Depth mm(in.) Standard Limit 0. the armature must be replaced.) Standard Limit 0.0 (1.008) Bearing Inspection Visually inspect the bearing. If the measure value exceeds the limit. 155 .002) Commutator Outside Diameter Measurement Use a vernier caliper to measure the commutator outside diameter.14) S24 – 07 36.0008) 0.ENGINE ELECTRICALS Commutator Run-Out Test Use a dial indicator and a V-block to measure the commutator runout.

2. Brush Length mm(in. Touch one probe to the brush field winding end. Field Winding Continuity Test Use a circuit tester to check the field winding continuity. the brush and/ or the yoke must be replaced. the field windings are open. If the measured value exceeds the limit. 1.51) . 2. the field windings are grounded.0 (0. Touch one probe to the field winding lead wire. Repair or replace the field windings.79) 156 Limit 13.0 (0. There should be no continuity. Touch the other probe to the brush.) Standard 20.ENGINE ELECTRICALS YOKE Field Winding Ground Test Use a circuit tester to check the field winding ground. 1. There should be continuity. Repair or replace the field windings. Touch the other probe to the bare surface of the yoke body. If there is continuity. BRUSH AND BRUSH HOLDER Brush Length Measurement Use a vernier caliper to measure the brush length. If there is no continuity.

The pinion should turn freely. If the measured valve exceeds the limit. the brush spring must be replaced. The pinion should lock. PINION CLUTCH Pinion Inspection Use your hand to turn the pinion in the direction of starter motor rotation. 1. Touch the other probe to the brush.ENGINE ELECTRICALS Brush Spring Inspection Visually check the brush spring for weakness and rusting. If there is continuity. MAGNETIC SWITCH Check for continuity across the magnetic switch “S” terminal and coil case. the shunt coil is open and should be replaced. Try to turn the pinion in the opposite direction. Brush Holder Insulation Test Use a circuit tester to check the brush holder insulation. Use a spring balancer to measure the spring tension. 2. There should be no continuity. Touch one probe to the field winding lead wire. If no continuity exists. Replace the brush spring if it is weak or rusted. the brush holder must be repaired or replaced. Check the bearing for binding or play by spinning the ball bearing by holding the outer race with fingers. 157 .

158 . If no continuity exists.ENGINE ELECTRICALS Check for continuity across magnetic switch “S” terminal and “M” terminal. series coil are open and should be replaced.

8. 14. v 4. 13. v 5. v 9. 2. 12. 18. 16. Pinion stopper Snap ring Bearing retainer Bolt Armature Yoke Brush holder Rear cover Through bolt Lead wire 159 .ENGINE ELECTRICALS REASSEMBLY 1 2 7 8 13 14 10 3 4 6 11 12 19 9 5 20 18 17 16 15 Reassembly Steps 1. Magnetic switch Shim Plunger Torsion spring Shift lever Dust cover Bolt Overrunning clutch Pinion Return spring 11. v 19. 15. v 20. v 17. v 6. 3. 7. 10.

160 .9 – 7.9) 9. exercise care so as not to cause damage to the commutator face. Install the brush holder by aligning it with the yoke.ENGINE ELECTRICALS Important Operations 4.8/6. Make sure to install the dust cover. Insert the shift lever. Dust Cover Install the magnetic switch in gear case. 6. Shift Lever Set the torsion spring to the hole in magnetic switch. Brush Holders When installing brushes. Pinion Install the pinion after applying grease to the reduction gear. into plunger hole in the magnetic switch. Torsion Spring 5. 17. via the torsion spring.ft./N·m) 0.1 – 5.7 – 0. Install the brush by raising the end of the brush spring. Dust Cover Bolt Torque kgf·m(lb.8 (5.

8 mm (0.ENGINE ELECTRICALS 19.5 (0.8) Inspection After Reassembly The pinion jumps out as the magnetic switch “S” terminals is connected to the battery positive terminal and negative terminal is connected to the gear case.6 – 5.1/4. Lead Wire Tighten the lead wire to the specified torque. Adjusting shims are available in thicknesses of 0.8 – 9.7 (3.) and 0. When Pinion Gap Deviates From Specified Value Make and adjustment using a shim.ft.060) When checking the pinion gap avoid keeping magnetic switch engaged for more than 30 seconds.) 161 .) 0.8 – 1. Pinion Gap mm(in.5 – 0.0 (5. Lead Wire Torque kgf·m(lb.02 in. Through Bolt Torque kgf·m(lb.3 – 1.012 – 0.8 – 7.2/7.9) 20./N·m) 0. Check the difference between the point to which the pinion is jumped out and point to which pinion can be pulled out (in direction of arrow) with fingers.9 – 6.ft.5 mm (0. Through Bolt Tighten the through bolts to the specified torque a little at a time./N·m) 0.03 in.

(Illustration) R 1 Isuzu part number L 2 Manufacturer‘s code number IC REG BUILT IN Hitachi.ENGINE ELECTRICALS ALTERNATOR 2 ALTERNATOR IDENTIFICATION 1 4 Hitachi alternators are identified by name plate attached to the rear cover. Japan 3 3 Rated output 4 Manufacturer‘s production mark Note: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number. Ltd. Use of the wrong service data will result alternator damaged. 162 .

0 (0.) Negative 80 (3.) Shaft diameter Front Rear Clockwise Regulator(s) applicable Isuzu Part No. 8-94423-756-0 Rated voltage Rated output Operating speed Rated output at rpm No-load output at 0 amperes V A rpm A/V/rpm V/rpm 5-81200-335-0 LR135-127 Manufacturer‘s Code No.0 (0. 8-94431-560-0 LR215-50 LR200-24 12 35 1000–13500 33-37/13.5 (0.15) 3.20) 15.) mm(in.57) 7.47) 5-81270-004-0 TR1Z-63 Built-in 5-81251-016-0 TR2Z-47 5-81251-016-0 TR2Z-47 163 .) mm(in.0 (0.24) 30.59) 12.5 (0.0 (0.) Coil resistance at 20°C Rotor coil Stator coil Ω Ω Brush length Standard Limit mm(in.47) 17.6 (1.30) mm(in.402 14.0 (0.30) 16.0 (0.0 (0.0 (0.5/1000 or less 24 15 1000–5000 15/27/5000 27/1000 or less 24 20 1000–13500 20/27/5000 27/1000 or less Direction of rotation (viewed from the pulley side) Polarity grounded Pulley diameter (P.63) 7.5 (0. 31.28) 14.13 18.70) 12.72 0.2 0.199 12.57) 7.C.47) 15.5 (0.) mm(in.) mm(in.5/5000 13.11 0.59) 12.D.6 (1.ENGINE ELECTRICALS MAIN DATA AND SPECIFICATION Engine Model to be Equipped A – 4J Series Manufacturer‘s name HITACHI Isuzu Part No. Manufacturer(s) code No.) Slip ring diameter: Standard Limit mm(in.

the built-in IC regulator (some engines use a Tirrell alternator with separate regulator). and the rear cover. 164 .ENGINE ELECTRICALS GENERAL DESCRIPTION The alternator consists of the front cover. This small size and light weight alternator provides excellent reliability. the rotor. The built-in IC regulator minimizes circuit wiring. Its simple construction makes it very easy to service. the stator.

6. Ball bearing Front cover Stator Rectifier with brush holder IC regulator Rear cover 165 . 11. 2. Through bolt Rear cover and stator Pulley and fan Spacer collar Rotor with bearing Bearing retainer 7. 5 6 7 3 8 4 12 11 1 10 2 9 Disassembly Steps 1. v 9. 8. v 10.ENGINE ELECTRICALS DISASSEMBLY These disassembly steps are based on the built-in IC regulator type. 5. v 4. v 3. 12.

Front Cover Use screwdrivers to pry the front cover 1 from the stator 2. 2 8. 1 (3) Remove the pulley 2 along with the spacer collar. Pulley and Fan (1) Clamp the rotor shaft in a soft jaw vise. 1 Note: Do not attempt to pry the coil wires from the stator. 2 4. (2) Loosen the pulley lock nut 1. 2 9.ENGINE ELECTRICALS Important Operations 3. 2 166 Note: 1 Hold the rectifier leads between the rectifier and the soldering iron with the long nose pliers. Rectifier with Brush Holder Use a soldering iron 1 and a pair of long nose pliers 2 to remove the rectifiers. . Rotor and Bearing (1) Use a plastic hammer or a press 1 to remove the rotor from the front cover 2. This will protect the rectifier from the heat. Stator 10. 1 (2) Remove the spacer collar.

dress with a fine sand paper (#500 – 600).6 (1.6 (1. Slip Ring Outside Diameter mm(in. If found to be roughened. Ball Bearing Check that the ball bearings rotate smoothly. If found to be contaminated. If the measured value exceeds the limit. ROTOR AND BEARING Check the face of the slip rings for contamination and roughness. the rotor must be replaced. and part replacements if excessive wear or damage is discovered during inspection. repairs.ENGINE ELECTRICALS INSPECTION AND REPAIR Make the necessary adjustments. they must be replaced.20) 167 . Use a vernier caliper to measure the slip ring outside diameter.24) 30. clean with a cloth saturated with alcohol.) Standard Limit 31. If the ball bearings are noisy.

1. If there is still no rotor coil continuity. the rotor is grounded and must be replaced. The circuit tester should show infinity (no needle movement) at both measuring points. 2. 2. Move one of the circuit tester probes to a third wire. If the circuit tester does not show infinity (the needle moves) at both measuring points. Note the circuit tester reading. the rotor must be replaced. 2. The circuit tester should register approximately 9 ohms. 3. Note the circuit tester reading. 1. Touch the circuit tester probe to the other slip ring. 1. 3. 4. 168 . If the circuit tester does not show continuity. Touch the circuit tester probes to two of the bare stator wires. Touch the other circuit tester probe to one of slip rings. 5. Rotor Coil Ground Test Use an circuit tester to test the rotor coil for grounding. Touch one of the circuit tester probes to the rotor shaft. STATOR COIL Stator Coil Continuity Test Use an circuit tester to test the stator coil continuity. Note the circuit tester reading. 3. check the connections between the lead wire and the slip rings. Note the circuit tester reading.ENGINE ELECTRICALS Rotor Coil Continuity Test Use an circuit tester to test the rotor coil continuity. Touch both circuit tester probes to the rotor coil slip rings. If breaks are founded. repair and repeat the rotor coil continuity test.

5. If the two readings (Steps 2 and 4) are identical. 2. 1. there is no stator continuity. If breaks are found. Note the circuit tester reading. If the two circuit tester readings are different. Check the neutral junction (arrow mark) for breaks. 2. The circuit tester should show infinity (no needle movement). Touch one circuit tester probe to the bear metal surface of the stator. If there is still no stator coil continuity. 1. 169 . the stator is grounded and must be replaced. Touch the other circuit tester probe to a bare stator lead wire. Touch the circuit tester negative probe to each of the diode terminals in turns. repair and repeat the stator coil continuity test. 3. Touch the circuit tester positive probe to the rectifier holder. the stator must be replaced.ENGINE ELECTRICALS 4. Stator Coil Ground Test Use an circuit tester to test the stator coil for grounding. RECTIFIER BAD GOOD Rectifier (Positive Diode) Continuity Test Use an circuit tester to test rectifier continuity. the stator coil has continuity. Note the circuit tester reading. If the circuit tester shows a value other than infinity (the needle moves).

If a diode shows no continuity. Rectifier (Negative Diode) Continuity Test BAD Use a circuit tester to test the rectifier continuity. it is shorted. BAD 5. The rectifier assembly must be replaced. 1. 6. The rectifier assembly must be replaced. 2. it is open circuit. If a diode shows continuity.ENGINE ELECTRICALS 3. it is open. The rectifier assembly must be replaced. GOOD BAD 5. Connect the three outside lead wires 2 to the outside terminals. . All of the diode should show continuity. 3. Note the meter reading for each diode terminal. 6. 2 170 3. GOOD 1. The rectifier assembly must be replaced. If a diode shows continuity. Note the meter reading for each diode terminal. Rectifier Assembly Replacement Procedure 1 Use the Rectifier Service Kit to replace the rectifier assembly in the following steps. Note the meter reading for each diode terminal. Touch the circuit tester positive probe to each of the diode terminals in turn. it is shorted. 4. None of the diodes should show continuity. Touch the circuit tester negative probe to the rectifier holder. All of the diode should show continuity. Note the meter reading for each diode terminal. Connect the three inside lead wires to the “N” terminals 1. 2. Touch the circuit tester positive probe to the rectifier holder. None of the diode should show continuity. GOOD 4. Touch the circuit tester negative probe to each of the diode terminals in turn. Wind the stator lead wires around the rectifier lead wires (included in the Rectifier Service Kit) and solder them. Touch the circuit tester negative probe to the rectifier holder. If a diode shows no continuity. Touch the circuit tester positive probe to each of the diode terminals in turn.

28) 5-81200-335-0 14.57) 7. The stator lead wires must be cut to the proper length before they are connected to the rectifier lead wires.30) 8-94431-560-0 16.) Standard Limit 8-94423-756-0 14.0 (0.5 (0.ENGINE ELECTRICALS Note: 1.57) 7.0 (0.32) 2. Take care not to damage the rectifier paint surfaces. Stator Lead Wire Length mm(in. BRUSH Use a vernier caliper to measure the brush.63) 7.5 (0. 171 . trouble may occur.5 (0.5 (1. the brush must be replaced.) 33. If the stator lead wires are too long or too short.5 (0. If the measured value exceeds the limit.30) Brushes are provided with a line which indicates the limit of usage. Brush Length mm(in.

5. 6. v 3. 8. 9. 10. v 11. v 4.ENGINE ELECTRICALS REASSEMBLY 9 8 7 11 6 10 1 2 12 3 5 4 Reassembly Steps 1. 172 Rear cover IC regulator Rectifier with brush holder Stator Rear cover and stator Front cover v 7. Ball bearing Bearing retainer Rotor with bearing Spacer collar Pulley and fan Through bolt . 2. 12.

/N·m) 5.7/49. Pulley and Fan Tighten the pulley and fan to the specified torque.0 – 63.7) 173 . Pulley and Fan Nut Torque kgf·m(lb. Rectifier with Brush Holder 4.5 (36.ENGINE ELECTRICALS Important Operations 3. Stator When connecting stator coil leads and diode leads using solder. 11. use long-nose pliers and finish the work as quickly as possible to prevent the heat from being transferred to the diodes.0 – 6.ft.2 – 47.

MEMO 174 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TROUBLESHOOTING SECTION 10 TROUBLESHOOTING TABLE OF CONTENTS ITEM PAGE Hard starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Excessive oil consumption . . 190 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Excessive fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Insufficient power . . 177 Unstable idling . . 194 Oil pressure does not rise . . . . . . . . . . . . . . . . . . . . . . 195 Abnormal engine noise . . . . . . . . . . . . . . . . . . 193 Dark exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 White exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hard Starting 1) Starter inoperative 2) Starter operates but engine does not turn over 3) Engine turns over but does not start 2. Overheating 7. Unstable Idling 3. Oil Pressure Does Not Rise 10. Excessive Oil Consumption 6. Excessive Fuel Consumption 5.TROUBLESHOOTING TROUBLESHOOTING Refer to this Section to quickly diagnose and repair engine problems. Each troubleshooting chart has three headings arranged from left to right. 176 Abnormal Engine Noise . (1) Checkpoint (2) Trouble Cause (3) Countermeasure This Section is divided into ten sub-sections: 1. Insufficient Power 4. Dark Exhaust Smoke 9. White Exhaust Smoke 8.

1. Checkpoint Neutral switch (If so equipped) Battery HARD STARTING STARTER INOPERATIVE Trouble Cause NG NG NG NG Defective neutral switch Loose battery cable terminals Poor connections due to rusting Battery discharged or weak Fan belt loose or broken Countermeasure NG NG NG NG Replace the neutral switch Clean and/or retighten the battery cable terminals Recharge or replace the battery Adjust or replace the fan belt OK Fusible link NG Fusible link shorted NG Replace the fusible link OK Starter switch NG Defective starter switch or starter relay NG Replace the starter switch or the starter relay NG Defective magnetic switch or starter relay NG Repair or replace the magnetic switch OK Starter OK Starter NG Defective starter NG Repair or replace the starter motor 177 .TROUBLESHOOTING 1.

TROUBLESHOOTING

1.
2.

HARD STARTING

STARTER OPERATES BUT ENGINE DOES NOT TURN OVER

Checkpoint

Battery

Trouble Cause

NG

NG

NG

Loose battery cable terminals
Poor connections due to rusting

Battery discharged or weak

Fan belt loose or broken

Countermeasure

NG

NG

NG

Clean and/or retighten the battery cable terminals

Recharge or replace the battery

Adjust or replace the fan belt

OK

Starter

NG

NG

Defective pinion gear

Defective magnetic switch

NG

Replace the pinion gear

NG

Repair or replace the magnetic
switch

NG

Brush wear
Weak brush spring

NG

Replace the brush and/or the
brush spring

NG

Piston, crank bearing seizure,
or other damage

NG

Repair or replace the related
parts

OK

Engine

178

TROUBLESHOOTING

1.
3.

HARD STARTING

ENGINE TURNS OVER BUT DOES NOT START

Checkpoint

Engine stop mechanism

Trouble Cause

NG

NG

Defective engine stop mechanism
control wire improperly adjusted
(In line pump)

Defective fuel cut solenoid valve
(VE pump)

Countermeasure

NG

NG

Replace the engine stop
mechanism
Adjust the control wire

Replace the fuel cut solenoid
valve

FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP

Fuel

NG

Fuel tank is empty

NG

Fill the fuel tank

OK

Fuel piping

Repair or replace the fuel lines
Retighten the fuel line
connections

NG

Clogged or damaged fuel lines
Loose fuel line connections

NG

NG

Fuel filter overflow valve does
not close

NG

Repair or replace the fuel filter
overflow valve

NG

Replace the fuel filter element or
the fuel filter cartridge

OK

Fuel filter

NG

Clogged fuel filter element

OK

Fuel system

NG

Air in the fuel system

NG

Bleed the air from the fuel system

Continued on the next page

179

TROUBLESHOOTING

1.
3.

HARD STARTING

ENGINE TURNS OVER BUT DOES NOT START

FUEL IS BEING DELIVERED TO THE INJECTION PUMP
Checkpoint

Trouble Cause

Countermeasure

Continued from the previous page
OK

Injection nozzle

NG

Injection nozzle injection starting
pressure too low
Improper spray condition

NG

Adjust or replace the injection
nozzle

OK

Injection pump

NG

Defective fuel injection nozzle
resulting in fuel drippage after
fuel injection

NG

Replace the delivery valve

NG

Defective injection pump control
rack operation

NG

Repair or replace the injection
pump control rack

NG

Injection pump plunger worn or
stuck

NG

Replace the injection pump
plunger assembly

NG

Injection pump drive shaft
seizure or other damage

NG

Replace the injection pump drive
shaft

NG

Injection pump governor spring
seizure

NG

Replace the injection pump
governor spring

OK

Injection pump (VE pump)

180

TROUBLESHOOTING

2.
Checkpoint

Idling system

UNSTABLE IDLING
Trouble Cause

NG

Idling improperly adjusted

Countermeasure

NG

Adjust the idling

OK

Fast idling speed control device

NG

Defective fast idling speed
control device

NG

Repair or replace the fast idling
speed control device

NG

Accelerator control system
improperly adjusted

NG

Adjust the accelerator control
system

OK

Accelerator control system

OK

Fuel system

NG

NG

NG

Fuel system leakage or blockage

Air in the fuel system

Water particles in the fuel system

NG

NG

NG

Repair or replace the fuel system

Bleed the air from the fuel system

Change the fuel

OK

Fuel filter

NG

Clogged fuel filter element

NG

Replace the fuel filter element or
the fuel filter cartridge

Continued on the next page

181

TROUBLESHOOTING 2. Checkpoint UNSTABLE IDLING Trouble Cause Countermeasure Continued from the previous page OK Injection pump NG NG NG NG NG NG NG Continued on the next page 182 Defective governor lever operation Regulator valve improperly adjusted (VE pump only) Broken plunger spring Worn plunger Worn camshaft (In-line pump only) Worn roller tappet (In-line pump only) Worn cam disc (VE pump only) NG Repair or replace the governor lever NG Adjust or replace the regulator valve NG NG NG NG NG Replace the plunger spring Replace the plunger assembly Replace the camshaft Replace the roller tappet Replace the cam disc .

Checkpoint UNSTABLE IDLING Trouble Cause Countermeasure Continued from the previous page OK Valve clearance NG Valve clearance improperly adjusted NG Adjust the valve clearance OK Compression pressure NG Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat NG Replace the related parts 183 .TROUBLESHOOTING 2.

TROUBLESHOOTING 3. Checkpoint Air cleaner INSUFFICIENT POWER Trouble Cause NG Clogged air cleaner element Countermeasure NG Clean or replace the air cleaner element OK Fuel NG Water particles in the fuel NG Replace the fuel OK Fuel filter NG Clogged fuel filter element NG Replace the fuel filter element or the fuel filter cartridge NG Repair or replace the fuel feed pump OK Fuel feed pump NG Defective fuel feed pump OK Injection nozzle NG NG Injection nozzle sticking Injection nozzle injection starting pressure too low Improper spray condition NG NG Replace the injection nozzle Adjust or replace the injection nozzle OK Fuel injection pipes Continued on the next page 184 NG Fuel injection pipes damaged or obstructed NG Replace the fuel injection pipes .

TROUBLESHOOTING 3. Checkpoint INSUFFICIENT POWER Trouble Cause Countermeasure Continued from the previous page OK Injection pump NG NG NG NG NG NG NG Defective regulating valve (VE pump only) Defective delivery valve Defective timer Worn cam disc (VE pump only) Improper control lever operation Defective injection timing Weak governor spring NG NG NG NG NG NG NG Repair or replace the regulating valve Replace the delivery valve Repair or replace the timer Replace the cam disc Adjust or replace the control lever Adjust the injection timing Repair or replace the injection pump timer Replace the governor spring Continued on the next page 185 .

TROUBLESHOOTING 3. Checkpoint INSUFFICIENT POWER Trouble Cause Countermeasure Continued from the previous page OK Injection pump NG NG NG NG Worn plunger Worn camshaft (In-line pump only) Worn roller tappet (In-line pump only) Worn cam disc (VE pump only) NG NG NG NG Replace the plunger assembly Replace the camshaft Replace the roller tappet Replace the cam disc OK Turbocharger NG NG NG Continued on the next page 186 Booster compensator pipe broken or cracked Exhaust gas leakage from the exhaust system Air leakage from the intake system Defective power echo gate NG Replace the booster compensator pipe NG Repair or replace the related parts NG Repair or replace the power echo gate .

Checkpoint INSUFFICIENT POWER Trouble Cause Countermeasure Continued from the previous page OK Turbocharger NG Defective turbocharger assembly NG Replace the turbocharger assembly OK Compression pressure NG Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat NG Replace the related parts OK Valve clearance NG Valve clearance improperly adjusted NG Adjust the valve clearance OK Valve spring NG Valve spring weak or broken NG Replace the valve spring OK Exhaust system NG Exhaust pipe clogged NG Clean the exhaust pipe OK Full load adjusting screw seal NG Open and improperly set adjusting screw seal NG Adjust and reseal the adjusting screw 187 .TROUBLESHOOTING 3.

TROUBLESHOOTING 4. EXCESSIVE FUEL CONSUMPTION Checkpoint Fuel system Trouble Cause NG Fuel leakage Countermeasure NG Repair or replace the fuel system related parts NG Clean or replace the air cleaner element OK Air cleaner NG Clogged air cleaner element OK Idling speed NG Poorly adjusted idling speed NG Adjust the idling speed OK Injection nozzle NG Injection nozzle injection starting pressure too low Improper spray condition NG Adjust or replace the injection nozzle OK Fuel injection timing NG Fuel injection timing improperly adjusted NG Adjust the fuel injection timing OK Injection pump NG Defective delivery valve resulting is fuel drippage after fuel injection NG Replace the delivery valve OK Turbocharger Continued on the next page 188 NG Air leakage from the turbocharger intake side NG Repair the turbocharger intake side .

TROUBLESHOOTING 4. EXCESSIVE FUEL CONSUMPTION Checkpoint Trouble Cause Countermeasure Continued from the previous page OK Turbocharger NG Defective turbocharger assembly NG Replace the turbocharger assembly OK Valve clearance NG Valve clearance improperly adjusted NG Adjust the valve clearance OK Compression pressure NG Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat NG Replace the related parts OK Valve spring NG Valve spring weak or broken NG Replace the valve spring 189 .

EXCESSIVE OIL CONSUMPTION Checkpoint Engine oil Trouble Cause Countermeasure NG Engine oil unsuitable Too much engine oil NG Replace the engine oil Correct the engine oil volume NG Oil leakage from the oil seal and/or the gasket NG Replace the oil seal and/or the gasket OK Oil seal and gasket OK Air breather NG Clogged air breather NG Clean the air breather OK Inlet and exhaust valves Valve seals NG Defective valve seals Worn valves stems and valve guides NG Replace the valve seals. the valves. broken or improperly installed NG NG Cylinder lines scored or worn NG OK Cylinder liners 190 Replace the cylinder liners .TROUBLESHOOTING 5. and the valve guides Replace the piston rings or properly install OK Piston rings NG Piston rings worn.

TROUBLESHOOTING 6. Checkpoint Cooling water OVERHEATING Trouble Cause NG Insufficient cooling water Countermeasure NG Replenish the cooling water OK Fan coupling (if so equipped) NG Oil leakage from the fan coupling NG Replace the fan coupling OK Fan belt NG Fan belt loose or cracked causing slippage NG NG Defective radiator cap or clogged radiator core NG Replace the fan belt OK Radiator Replace the radiator cap or clean the radiator core OK Water pump NG Defective water pump NG Repair or replace the water pump OK Cylinder head and cylinder body sealing cap NG Defective sealing cap resulting in water leakage NG Replace the sealing cap OK Thermostat NG Defective thermostat NG Replace the thermostat Continued on the next page 191 .

Checkpoint OVERHEATING Trouble Cause Countermeasure Continued from the previous page OK Cooling system NG Cooling system clogged by foreign material NG NG Fuel injection timing improperly adjusted NG Clean the foreign material from the cooling system OK Fuel injection timing 192 Adjust the fuel injection timing .TROUBLESHOOTING 6.

the valves. and the valve guides Replace the piston rings or properly install OK Piston rings NG Piston rings worn. broken or improperly installed NG NG Cylinder lines scored or worn NG OK Cylinder liners Replace the cylinder liners 193 .TROUBLESHOOTING 7. Checkpoint Fuel WHITE EXHAUST SMOKE Trouble Cause NG Water particles in the fuel Countermeasure NG Replace the fuel OK Fuel injection timing NG Delayed fuel injection timing NG Adjust the fuel injection timing OK Compression pressure NG Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat NG Replace the related parts OK Turbocharger NG Defective turbocharger NG Replace the turbocharger OK Inlet and exhaust valves Valve seals NG Defective valve seals Worn valves stems and valve guides NG Replace the valve seals.

Checkpoint Air cleaner DARK EXHAUST SMOKE Trouble Cause NG Clogged air cleaner element Countermeasure NG Clean or replace the air cleaner element NG Adjust or replace the injection nozzle OK Injection nozzle NG Injection nozzle injection starting pressure too low Improper spray condition OK Fuel injection timing NG Fuel injection timing improperly adjusted NG Adjust the fuel injection timing OK Injection pump NG NG 194 Defective delivery valve resulting in fuel drippage after fuel injection Excessive injection volume NG NG Replace the delivery valve Adjust the injection volume .TROUBLESHOOTING 8.

TROUBLESHOOTING 9. OIL PRESSURE DOES NOT RISE Checkpoint Engine oil Trouble Cause NG Improper viscosity engine oil Too much engine oil Countermeasure NG Replace the engine oil Correct the engine oil volume OK Oil pressure gauge or unit Oil pressure indicator light NG Defective oil pressure gauge or unit Defective indicator light NG Repair or replace the oil pressure gauge or unit Replace the indicator light OK Oil filter NG Clogged oil filter element NG Replace the oil filter element or the oil filter cartridge NG Replace the relief valve and/or the by-pass valve spring OK Relief valve and by-pass valve NG Relief valve sticking and/or weak by-pass valve spring OK Oil pump NG NG Clogged oil pump strainer Worn oil pump related parts NG NG Clean the oil pump strainer Replace the oil pump related parts OK Rocker arm shaft NG Worn rocker arm bushing NG Replace the rocker arm bushing Continued on the next page 195 .

TROUBLESHOOTING 9. OIL PRESSURE DOES NOT RISE Checkpoint Trouble Cause Countermeasure Continued from the previous page OK Camshaft NG Worn camshaft and camshaft bearing NG Replace the camshaft and the camshaft bearings NG Replace the crankshaft and/or the bearings OK Crankshaft and bearings 196 NG Worn crankshaft and bearings .

Exhaust pipes Gas Leakage Noise NG Loosely connected exhaust pipes Broken exhaust pipes NG NG Loose injection nozzles and/or glow plugs NG Tighten the exhaust pipe connections Replace the exhaust pipes OK Injection nozzles and/or glow plugs Replace the washers Tighten the injection nozzles and/or the glow plugs Continued on the next page 197 .TROUBLESHOOTING 10. ABNORMAL ENGINE NOISE 1. Fuel NG Fuel unsuitable NG Replace the fuel OK Fuel injection timing NG Fuel injection timing improperly adjusted NG NG Improper injection nozzle starting pressure and spray condition NG Adjust or replace the injection nozzle NG Blown out head gasket Broken piston ring NG Replace the head gasket or the piston ring Adjust the fuel injection timing OK Injection nozzle OK Compression pressure 2. Checkpoint Engine Knocking Trouble Cause Countermeasure Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

Checkpoint Gas Leakage Noise Trouble Cause Countermeasure Continued from the previous page OK Exhaust manifold NG Loosely connected exhaust manifold and/or glow plugs NG Tighten the exhaust manifold connections OK Cylinder head gasket NG Damaged cylinder head gasket 3. Fan belt NG NG Replace the cylinder head gasket Continuous Noise Loose fan belt NG Readjust the fan belt tension OK Cooling fan NG Loose cooling fan NG Retighten the cooling fan OK Water pump bearing NG Worn or damaged water pump bearing NG NG Defective alternator or vacuum pump NG NG Valve clearance improperly adjusted NG Replace the water pump bearing OK Alternator or vacuum pump Repair or replace the alternator or the vacuum pump OK Valve clearance 198 Adjust the valve clearance .TROUBLESHOOTING 10. ABNORMAL ENGINE NOISE 2.

Checkpoint Valve clearance Slapping Noise Trouble Cause NG Valve clearance improperly adjusted Countermeasure NG Adjust the valve clearance OK Rocker arm NG Damaged rocker arm NG Replace the rocker arm OK Flywheel NG Loose flywheel bolts NG Retighten the flywheel bolts OK Crankshaft and thrust bearings NG Worn or damaged crankshaft and/or thrust bearings NG Replace the crankshaft and/or the thrust bearings NG Worn or damaged crankshaft and/or connecting rod bearings NG Replace the crankshaft and/or the connecting rod bearings NG Worn or damaged connecting rod bushing and piston pin NG Replace the connecting rod bushing and/or the piston pin NG Replace the piston and the cylinder liner OK Crankshaft and connecting rod bearings OK Connecting rod bushing and piston pin OK Piston and cylinder liner NG Worn or damaged piston and cylinder liner Foreign material in the cylinder 199 . ABNORMAL ENGINE NOISE 4.TROUBLESHOOTING 10.

MEMO 200 .

SPECIAL TOOL LIST SECTION 11 SPECIAL TOOL LIST 201 .

PARTS NAME PAGE 1 Measuring Device 25 2 5-8840-2675-0 Compression Gauge 26 3 5-8840-9029-0 Compression Gauge Adapter 26 4 5-8840-0019-0 Sliding Hammer 35 71 5 5-8840-2034-0 Nozzle Holder Remover 35 6 5-8840-2363-0 Oil Seal Remover (Axial Type) 38 7 9-8523-1423-0 Valve Spring Compressor 42 85 8 5-8840-0086-0 Camshaft Timing Gear Universal Puller 46 64 9 9-8523-1212-0 Valve Guide Replacer 49 50 10 202 5-8840-0145-0 5-8840-2039-0 Cylinder Liner Remover 57 .SPECIAL TOOL LIST SPECIAL TOOL LIST ITEM NO. ILLUSTRATION PART NO.

SPECIAL TOOL LIST

ITEM NO.

ILLUSTRATION

PART NO.

PARTS NAME

PAGE

11

5-8840-2040-0

Cylinder Liner Installer

58

12

5-8840-2038-0

Camshaft Bearing Replacer

63
64

13

9-8840-2057-0

Crankshaft Timing Gear
Remover

70

14

9-8522-0020-0

Crankshaft Timing Gear
Installer

70

15

5-8840-2000-0

Crankshaft Pilot Bearing
Remover

71

16

5-8522-0024-0

Crankshaft Pilot Bearing
Installer

71

17

5-8840-2061-0

Crankshaft Front Oil Seal
Installer

79

18

5-8840-2033-0

Valve Stem Oil Seal
Installer

85

19

5-8840-0141-0

Crankshaft Rear Oil Seal
Installer

98

20

5-8840-9057-0

Oil Seal Installer
(Axial Type)

98

203

MEMO

204

REPAIR STANDARDS

SECTION 12

REPAIR STANDARDS
TABLE OF CONTENTS
ITEM

PAGE

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Repair standards chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

General Rules
1.

These tables provide standards relating the repair of the following diesel engine;
Model A-4JA1, A-4JB1

2.

These Repair Standards are based on inspection items, together with dimensions, assembly standards,
limit values, and repair procedures.
(1) Nominal dimensions are the standard production values.
(2) Assembly standards considered to be the values used as objectives during the assembly
procedures which follow repairs; as a result, they may be somewhat at variance with the assembly
dimensions of a new engine.
(3) Limit values refer to the measured values resulting from wear, etc., beyond which a part must not
be used. If a measured value falls beyond the limit value, the part involved must be repaired or
replaced.
(4) “Repair Procedures” indicates normal repair methods.
(5) Unless otherwise stated, the unit of numerical values in tables should be taken to refer to
millimeters, mm (in).

3.

Explanation of Terms Used in Tables
(1) The dimension of “wear” refers to the difference between the dimensions of a part which is not
worn (or the “nominal dimension” of a part without wear) and the dimension of the part suffering
from the most wear (the dimension of the worn part).
(2) Uneven wear means the difference between the maximum and minimum wear values.

4.

When repairs are requested on the overall engine, first perform bench tests to determine what parts
require repairs, then perform the minimum disassembly and repairs required to correct the problems.
When repairs on a specific engine part are requested, repairs to be made in reference to the relevant
items in accordance with the repair standards listed in this manual.

205

Name
of Part

Cylinder Body

Engine Body

206

Time for engine
disassembly
and repair

Major
Category

Nominal
Dimension

Cylinder compression pressure
kgf/cm2 (psi/MPa)

Assembly
Standard Value

L/h

Lubricating oil consumption

A

Dia. 93
(3.661)

100%

100%

0.20
(0.008)

Dia 93.1
(3.665)

200%

140%

New engine performance is assumed
100%

Warm engine
engine speed 200
rpm
(varies depending on
altitude)

Comments

5
(71.1/490)

Pressure test: 3 minutes
kgf/cm2 (psi/kPa)

Leaks require repair or
replacement

Not repairable; must
be replaced

0.05 (0.002)
or less

Cylinder block upper face warpage

Difference in liner
projection between
neighboring cylinders
not to exceed 0.02

Upper step wear must (Ref)
be repaired, or replace Cylinder & liner
with standard dimen- clearance
sion liner
0.017 – 0.055
(0.0007 – 0.0022)

Disassemble and
repair engine

Repair Procedure

Some projection must
be present

Liner projection

A

20.0

Wear on liner bore
Measured at A–A

L/h

Fuel consumption

22
(313/2.157)

Limit

0 – 0.10
(0 – 0.0039)

31
(441/3.04)

Inspection Item

REPAIR STANDARDS

2 (0.1 – 490) Water-pressure test.9) 1st Step 3.1/ 78.4 – 90.5 (0.7 – 36.029) Assembly Standard Value 5 (71.3 (0.6/ 98.28 (0.008) 2nd Step 0.2 – 9.0 – 5.0) 8.05 (0.047) 1.0 (57.012) Repair with valve seat cutter Replace insert Repair Procedure After repair.05 (0.050) Limit 8.Name of Part Cylinder Head Major Category Same for ( inlet & exhaust ) (Valve) Must not protrude from lower surface of cylinder head 45 A Exhaust side 2.067) Exhaust side 0.4 – 79.2 (59.4 – 66.2 (0.5/ 80.7 (0.0 – 11.2) 10.1 – 107.079) Inlet side 1.4 – 49.008) 0.20 (0.002) or less Warpage of manifold mounting surface 0.0 (21. be sure to lap contact surfaces Valve seat angle: α Inlet side 30° Exhaust side 45° Comments REPAIR STANDARDS 207 Engine Body .087) 1.73 (0.2) New bolt Nominal Dimension Warpage and flatness of cylinder head lower face (mounting surface) Contact width with valve seat: A Bottom surface to cylinder B (Cylinder head) (Insert) Valve seat depression: B (both inlet and exhaust) Inspection Item Reused bolt • Apply engine oil to the cylinder need fixing bolt threads and setting faces.0 (72.1/ 29.9 – 65.0 (0.0 – 9. Leaks require repair or replacement repair Maximum Allowable Griding stock 0.70 (0.002) or less 2.4 – 88.2 (0.028) Inlet side 0.098) 2. 3 minutes kgf/cm2 (psi/kPa) Cylinder head bolts tightening torque kgf·m(lb·ft/N·m) 0.

0 (1.0) 0.075 (0.125 (0.2 – 58.015 (0.30 (0.2205) Oil ring 2nd compression ring 1st compression ring Oil ring 2nd compression ring 1st compression ring Oil ring Ring gap orientation Clearance between piston ring and ring groove Tension kgf (lb/N) Piston Ring Gap Pin wear 0.8) Dia.012) 0.090 – 0.76 in) Inspection Item At 120° intervals Replace rings or piston Replace Replace Replace rings or piston Replace piston pin Replace piston or piston pin Repair Procedure When assembling compression rings on piston.002 – 0.006) 1.992 – 30.20 – 0.10 – 0. be sure ring’s marked surface is up.40 (0.45 – 3. Backwards installation will result in excessive oil consumption.2202 – 1.003) 0. No top/bottom to oil ring. Measure with expander attached Comments REPAIR STANDARDS .008 – 0.0035 – 0.15 (0.98 (1.2197) 4.0006) Piston pin and piston pin hole clearance Assembly Standard Value Clearance with major axis 0.0022) Nominal Dimension Clearance with cylinder: grade position from upper face 70 mm (2.2/ 39.0049) 1st compression ring 1.82 – 13.050 – 0.0012 – 0.59 (2.006) 0.017 – 0.030 – 0.50/ 10.004 – 0.95 (1. 30.11 – 1.2185) Limit 0.070 (0.055 (0.0007 – 0.Main Operating Parts Name of Part Pistons 208 Piston Ring Major Category 0.9 – 16.00008 – 0.002 – 0.016) 30.5 (0.059) Dia.15 (0.006) 0.15 (0. 31.0 – 6.0 (8.0028) 2nd compression ring 0.

0039) Replace bearing Use those with projection and proper arc.7 – 130.0118) Perform lapping on gears with burrs.0 (115. take care with back side fit A-4JA1 Dia.0035) Limit Use those with projection and proper arc.002) or less 0. 53 and pins Pin (2. 0.066 (0. take care work back side fit Apply engine oil to threads and seating areas of bolts before tightening Replace crankshaft Replace thrust bearings Bearing cup bolt tightening torque kgf·m (lb·ft/N·m) 0.9 – 176.087) Inspection Item Do not catch foreign matter in bolts Measure at crankshaft’s No.0014 – 0.10 (0.0 – 18.0039) Undersize bearings cannot be used Ring gear Crankshaft runout Crankshaft end play Journal bearing undersize Replace bearing Clearance between journal and bearing 0.30 (0.09 (0. 1 bearing thrust surface Do not attempt to grind: always replace with new parts Comments REPAIR STANDARDS 209 .029 – 0.0037) 0.362) Uneven Journal A-4JB1 Dia. in cases of severe damage.5) 0.094 (0.035 – 0.08 (0. replace.0031) Assembly Standard Value Replace Repair Procedure Clearance between connecting rod bearing and crankpin Connecting rod bearing runout 0.0011 – 0.0043) Journal and bearing spread 0.Main Operating Parts Name of Part Crankshaft Connecting Rods Major Category Nominal Dimension 0.70(2.60(2.2/ 156.0031) 0.11 (0.756) wear on journal Dia.05 (0.0026) 16.10 (0.080 (0.

53 (2.0 – 9.4 – 88.007 – 0.008) 0.175 – 0.0033) 8.008 – 0.002) 0.12 (0.15 (0.1/ 78.001 – 0.945 – 49.085 (0. 49.0008) Limit Clearance between smallend bushing and piston pin Assembly Standard Value Replace parts with poor contact or abrasions Nominal Dimension Contact between connecting rod bearing and crankpin Inspection Item Crank must not be ground (no undersizes available) Sufficient gap to allow smooth rotation when holding big end Take special care with crankpin precision Comments REPAIR STANDARDS .975 (1.05 (0.002) or less Dia.0047) 0. 50 (1.05 (0.002) or less Big end to small end hole parallelism (per 100 mm) 0.2) Bearing cap bolt tightening torque (angular tightening method) kgf·m (lb·ft/N·m) Journal uneven wear 0.969) Dia.0114) 0.60 (1.025 – 0.290 (0.087) Big end to small end hole twist (per 100 mm) Connecting rod and crankpin end play Connecting rod bearing undersize Dia.953) 0.9 – 65.05 (0.9675) 0.0 (57.Main Operating Parts Name of Part Connecting Rods 210 Camshaft Major Category Journal wear Clearance between journal and bearing Dia.35 (0.002) Repair Procedure Replace camshaft Replace bearing Replace camshaft Apply engine oil to bolts before tightening Repair or replace Repair or replace Replace connecting rod Replace bushing or pin 0.20 (0.05 (0. 50 (1.969) 49.006) 0.0138) 0.0003 – 0.9663 – 1.020 (0.

65) Assembly Standard Value 41.08 (1.0045) Camshaft runout Cam height: Inspection Item Camshaft end play Replace thrust plate Replace camshaft Replace camshaft Repair Procedure Minor step wear on cams can be repaired Comments REPAIR STANDARDS 211 Main Operating Parts .008) 0.20 (0.64) Limit 0.004) 0.114 (0.65 (1.05 – 0.10 (0.002 – 0.0008) or less H Nominal Dimension 0.02 (0.Name of Part Camshaft Major Category 42.

9 mm (1.039 – 0.3134) Assembly Standard Value 0.5 (0.0 (63.85 (0.6) 1.949 – 7.02 (0.0 (0.0008) Interference between valve guide and cylinder head Valve thickness 0.05 (0. 18.2 (0.88 (0.747 – 0.25 (0.4) 0.059) 0.5 (0.5 (0.002) 1.512) Inlet Free length Tension kgf (lb/N) (When compressed to Installed length) 38.2 (0.8 (0.069 (0.0004 – 0.01 – 0.921 – 7.0098) 0.0015 – 0.0027) Dia. 7.53 in) Height of valve guide above cylinder head Thickness 0.3118 – 0.00 (0.3124) Dia.3129 – 0.9/284.315) Nominal Dimension Clearance between inlet valve stem and valve guide Exhaust valve stem wear Inlet valve stem wear Valve spring Valves Major Category Replace rocker arm shaft Replace bushing or shaft Replace valve and valve guide together Replace valve and valve guide together Replace valve Repair Procedure Reference value Apply oil to valve guide and press in Measure valve stem at three positions Comments REPAIR STANDARDS Valve System .06) or less 32.0038) Clearance between exhaust valve stem and guide Dia.40 (0.512) 1.7 (1.96) Exhaust 13.90) 29.98 – 19.9/319.098) 48.0025 – 0.3102) Limit Clearance between rocker arm shaft and bushing Valve clearance (inlet & exhaust) (cold) mm Inclination 49.096 (0. 7.0 (0.936 (0. 18.016) 2.008) 0.742) Dia.2 (1.212 Name of Part Inspection Item 13.961 (0.064 – 0. 8 (0. 7.071) mm Dia.6 (71.748) Rocker arm shaft wear Adjust 0.008) Dia.

03 (0.10 (0.5098) 12.Valve System Intake System Name of Part Tappet Air cleaner Major Category Out diameter Air cleaner element condition Tappet wear Clearance between tappet and cyl.5106 – 0.97 – 12.5114) Limit 0.99 (0.0012) Assembly Standard Value Replace tappet Replace tappet Repair Procedure Special order item from manufacturer Comments REPAIR STANDARDS 213 .95 (0.0039) 12. body Inspection Item Nominal Dimension 0.

006) or less 5.9 psi/392 kPa) oil temp.0008 – 0. pumping pressure 4 kgf/cm2 (56.0 (28.0026) 0. rotor and cover clearance Lubricating oil pressure (1400 rpm) kgf/cm2 (psi/kPa) Name of Part Oil pressure Oil lpump and Relief valve 214 Oil filter Major Category Nominal Dimension 2.02 – 0.0 – 4.2) 13 0.011) 0.49 – 88. rotor or cover Repair Procedure Comments REPAIR STANDARDS . 50°C (122°F) Clearance between pump body and vane Rotor and vane clearance Vane.00 /392 – 441) Assembly Standard Value Replace Repair or replace Replace rotor set Replace vane.4/196) Limit 0.8 – 6.008 – 0.5 (56.07 (0.20 – 0.27 (0.2 (82.Lubricating System Inspection Item ) Initial operating pressure of main oil filter relief valve kgf/cm2 (psi/kPa) Clogging and damage to oil filter ( Pumping rate L/min 1000 rpm.20 (0.15 (0.006) 4.40 (0.89 – 64.14 (0.008) 0.18 /569 – 608.016) 0. SAE #30.

0512) 100 Assembly Standard Value Repair or replace 82°C (180°F) Nominal Dimension Clogged.3 – 1.3 (0. Thermostat full-open temperature (at sea level) mm(in) Press with finger Initial thermostat operating temperature (at sea level) Fan belt deflection Clearance between pump impeller and pump body mm ( pumping speed 3000 rpm.0118 – 0.0079) Limit Fuel filter element clogging or damage 95°C (203°F) 80 – 84°C (176 – 183°F) 8 – 12 (0. nozzle holders.Cooling System Fuel System Name of Part Water pump Piping. defective seals. Adjust Repair or replace if impeller and pump body are touching Replace Repair Procedure Replace 0. cracked.0 lb/98N) each Comments REPAIR STANDARDS 215 .31 – 0. (Reference) 10 kgf (22. loose fuel pipes. injection pipes.2 (0.5 m or more Pumping rate Water pump ball bearing chatter (radial direction) Inspection Item Cartridge type Replace thermostat if operation is incorrect. water temp 30°C (86°F) Total head 14. etc.315in) or more. Major Category ) L/min A Temperature at whic thermostat lift reaches 8mm(0.47) 0.

0 (0.24) Nominal Dimension Loose mount Length Slip ring dia waler Thrust side chatter Bearing chatter Shaft runout Check for looseness.35) Brush length 7. Comments REPAIR STANDARDS . 2. cuts or damaged insulation to wiring. Warning lamp indication Rotor 216 Brush Major Category If coil resistance value is severely abnormal.8 (0. 29.14) 0.27 — Repair Replace armature Replace 9.012) Repair Replace bearings 0.008) Dia.59) Assembly Standard Value Repair If warning indicator lights when engine is operating at normal speeds. Rotate by hand and check for smooth rotation: no abnormal sound or resistance should be felt.03) 0.D.0 (1.20) 0.2 (0.6 (1.1 (0. 35A (Hitachi 1-81200-756-0) Starter 12V.0 (0.Electrical Name of Part Charge/ Discharge indication Wiring Alternator 12V.18) 0. replace switch.02 – 0.5 – 0.6 (1.0039) Replace rotor or ress Limit Repair 14. Jeries coil Magnetic resistance (Ω) switch (at 20°C [68°F]) Shut coil resistance (Ω) Dia. check and repair electrical system.5 (0.3 (0. 30.5 (0.57) 31.0 (1.2 kW (Hitachi 8-97084-879-0) Inspection Item 15.3) 30. Repair Procedure Replace Commutator Undercut depth O.

30 (1.0 – 4. Comments REPAIR STANDARDS 217 .7874) 3900 rpm or more Assembly Standard Value Front (armature) Dia. 20 (0. 160A or less) 6006 DDU Dia.3937) Nominal Dimension Replace if cut wiring or shorts are found Performance Ball bearings Rear side (armature) Inspection Item When new engine output is 100% 1400 rpm Oil Temp About 80°C (176°F) Warm engine Warm engine Smooth pinion operation without noise Replace if rotation is not smooth or if abnormal sounds are heard.Final Inspection Electrical Name of Part Starter 12V.5 (392 – 441) 90% or more 110% or less Lubricating oil pressure kgf/ cm2 (psi/KPa) Output check Fuel consumption check 5% or less Adjust Inspect Cylinder compression pressure kgf/ cm2 (psi/MPa) about 200 rpm Difference in compression between cylinders kgf/ cm2 (psi/MPa) about 200 rpm Inspect Engine run-in operation 31 (441/3.811) Pinion shaft (shaft) 4.04) 30 minutes or more Glow plug Unloaded characteristics (11V.2 kW (Hitachi 8-97084-879-0) Preheater Major Category 6200 Z Repair Procedure 6204 DDU 22 (313/2.157) Limit Dia. 2. 10 (0.

MEMO 218 .

.7313 9. . . . . .0866 2.5719 3. . . . . . . .5197 2.2835 2. . . .3500 6.CONVERSION TABLE SECTION 13 CONVERSION TABLES INDEX CONTENTS PAGE Length . 224 Torque .0079 2. . . . . . .7008 3. . . . . . .1969 0.5433 3. . . .0709 3. . . . . . . . . . . . . .1339 4.5250 9. . . . . . . .9375 8.4488 4. . .2598 1.4331 5. . .1260 2.1125 11. . .0344 21. .2913 111 112 113 114 115 116 117 118 119 4. . . . . . .9921 3. .7953 2. . .0157 4. . . .3813 2. . . .3150 0.2756 5. . . . .9764 4. . . . . . . .1732 4. . . . . 220 Area .3701 4. . . . . . . . mm 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 101 102 103 104 105 106 107 108 109 3. . . . .8906 14. . . . . .6142 1. . . .6929 1.2441 2. . . . . 221 Volume . . .3543 0. .1750 3. . . . . . .9528 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 2. . .3188 10. . . .8438 20. . . .5984 2. . . mm in.8504 1.7717 1. . .6614 3.3150 5. . . . . . . . . . . . . . .4567 1. .3969 0.9685 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 2. . . . . .2205 1. . . . .6299 0. .9531 6.9213 4. . .5094 11. . . . . . 221 Mass .6063 4. . .1496 3. . . . . . . . . . .8750 16. . . . .0394 5. .8594 18.9370 in. .7165 2.2520 4. . .6688 17.5512 0.4803 2.5039 3. . . . . . . . .7480 0. . .2094 24. .3031 12. .1811 1. . .9063 12. . . .4409 2. . .0630 1. . . . .8583 3. . . .5276 4.2250 22. . . . . . . . .4156 23.0000 5.1181 0. . .4016 2.1968 5. .0031 25. . . .7781 3.6375 21. .3656 4. . .8661 0. . . . . . . .7323 1. . .1575 5. .5669 4. . .6693 0. . . . . . .6531 19. . . . . . .7156 11.3858 3. . . . .5875 1.6850 121 122 123 124 125 126 127 128 129 4. . . . . . . . .9055 0.4938 13. . . .8898 1.0236 1.0188 23. . .0394 0. . .1594 5. . . . . .4625 17.1890 3. . .5563 5. .2719 16.4094 4. . .7874 0. . .1281 9. . . . . . . . .5406 7.6772 2.1024 1.4000 219 . . . .3465 3. .4646 3.9606 5. . . . . . . . . . . .8268 0.9291 1. . .7469 7. .0472 2. . . . . . .6535 1. . . . . . . .0969 13.2756 0. . . . .4469 19.8976 3. .9219 10. . .4781 15.2047 2. . .1438 7. . .2406 20.8819 4.9134 2. .3937 0.5906 0. .4313 21. . .4173 1. . . . . . .3071 3.3228 2.0315 3. .6220 3. . . . . .8189 3.2283 3. . . .7938 1. . .7625 5. . .5354 1. . . . .0945 4.3543 5. . . .7087 0. . .3386 1.2875 14.1102 3.8425 4. .2992 1. . . . . .0500 19.5827 3.4252 3. .4724 0. .5118 0. . . . .9449 0.0551 4. . . .3622 2.7795 3.6844 15. . . . .0787 0.2362 0. . . 226 LENGTH MILLIMETERS TO INCHES INCHES TO MILLIMETERS mm in.0813 15. . mm 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 13. . .7000 in. . . .2126 4. . . . . . . . . . . . .3344 8. .6457 4.8110 1. . . .4961 1.8740 2. . . . . . mm in.8346 2. . . . . . . .3780 1. . .2677 3. . . . .8125 24. . .3937 5. . . . . . . . . . . . . . . .4882 4. . . . .1654 2. . .5591 2.4331 0. .8031 4. mm in.6063 25. . . .1575 0.9843 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1. .9844 2. .1417 1.4724 27/64 7/16 29/64 15/32 31/64 1/2 0. . . . .2362 5. . . . . . . . . . .0656 17. . . . .6219 23.0787 131 132 133 134 135 136 137 138 139 5. 223 Pressure . .6378 2. . . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 0.5748 1. . .9688 4. . .2563 18.8281 22. . 225 Temperature . . . . . . . . . . . .7402 3. .7638 4.1906 1.7559 2.

0840 3.6719 157.962 34.6850 52.873 131.282 43.155 77.785 0.088 55.908 28.2546 246.641 24.933 39.9948 324.3990 341.409 64.806 18.822 29.890 65.754 12.079 27.572 7.078 14.200 12.651 31.346 31.0971 255.701 136.305 3.091 135.476 31.8032 357.9396 265.7480 298.401 9.3911 154.398 23. ft.059 60.224 53.516 67.127 30.942 16.971 11.013 156.3570 177.170 114.998 119.7743 88.4593 108.858 94.632 47.716 173.093 32.250 25.555 25.384 27.219 4.406 51.919 140.5144 167.952 57.758 1.622 3.185 17.612 29.6116 ––– 10 20 30 40 50 60 70 80 90 100 MILES TO KILOMETERS miles ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 km km km km km km km km km km –––00 16.828 20.678 20.762 6.5827 121.545 62.127 27.583 34.614 2.8163 252. ft.045 127.1995 187.855 31.5223 354.7402 111.047 24.098 32.422 23.106 16.048 6.5276 62.342 109.232 159.326 17.706 9.0289 301.437 22.144 12.6509 75.117 50.566 32.914 3.1864 291.049 19.499 67.223 ft. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 m m m m m m m m m m –––0 3.497 15.263 130.069 20.670 19.6378 180.576 149.603 28.658 6.843 57.327 72.470 26.487 4.389 46.315 10.829 4.505 26.624 54. ft.699 1.966 148.6168 98.077 98.654 128.278 14.273 66.743 5.860 25.870 32.716 16.668 13.994 28.934 1.435 125.411 16.9186 183.230 11.791 8.850 18.234 56.531 38.137 0.298 28.058 13. ft.372 8.9869 137.090 0.449 12.561 112.578 46.2887 223.669 165.5617 39.887 14.845 54.331 56.107 9.905 102.877 7.3701 72.280 64.153 4.865 4.450 162.3097 305.3360 95.750 41.794 152.360 51.554 39.719 32. ft.253 48.213 29.607 120.534 11.546 75.357 146.6037 203.336 24.020 24.482 133.864 8.156 22.826 36.797 41.8084 65.956 32.3307 29.2415 351.894 67.2756 328.2677 141.524 4.015 53.1234 45.1444 127.8504 229.8373 334.518 29.2126 82.6588 262.802 15.925 10.529 141. –––00 32.5354 249.456 13.826 123.350 10.779 115.249 93.835 13.485 8.497 170.4042 49.545 18.9055 288.496 49.796 49.923 62.946 24.217 122.134 5.7690 22.138 143.671 62.918 2.9606 347.204 35.748 27.165 26.514 104.703 33.353 6.214 12.108 69.3648 6.507 22.7139 321.686 99.0761 173.921 37.404 154.146 45.010 10.968 45.748 144.7270 216.187 48.574 57.8714 311.3018 118.1785 104.062 61.7612 193. ft.728 9.2074 16.311 38.699 14.777 22.839 11.1312 232.809 14.609 17.4803 190.962 7.8976 101.031 24.4672 295.240 18.2808 36.0499 26.656 25.0630 278.244 3.096 9.875 49.2467 59.768 45.243 7.812 22.737 30.4882 19.811 86.592 83.369 28.973 14.7060 134.884 26.340 33.123 106.689 27.6798 344.0551 91.6457 9.5013 272.467 96.202 85.374 80.4252 131.7822 275.310 138.175 33.904 44.1181 337.192 15.5486 144.983 82.525 44.359 43.140 40.544 3.288 21.389 117.363 13.8635 124.030 65.981 52.418 41.563 16.630 17. ft.8845 206.9318 78.010 47.592 11. ft.913 21.582 14.202 22.039 42.8294 147.452 59.8425 42.681 60.764 78.888 168. ––– 10 20 30 40 50 60 70 80 90 100 METERS TO FEET m ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 ft.816 59.1522 314.936 74.603 52.042 31.726 23.935 17.981 9.261 32.459 19.898 21.764 19.175 40.9738 242.4462 213.841 160.182 8.622 157.590 11.CONVERSION TABLE LENGTH FEET TO METERS ft.652 65.718 70.6929 239.302 61.380 1.620 10.991 29.4934 85.292 20.106 172.021 17.2205 269.432 30.1102 150.774 26.185 151.233 30.733 107.9659 55.729 ––– 10 20 30 40 50 60 70 80 90 100 .030 90.951 111. ft.2336 164.166 63.5564 331.484 30.690 37.5906 308.325 175.5696 226.438 59.486 8.001 2.267 7.480 0.418 ––– 10 20 30 40 50 60 70 80 90 100 KILOMETERS TO MILES km ––– 10 20 30 40 50 60 70 80 90 100 220 0 1 2 3 4 5 6 7 8 9 miles miles miles miles miles miles miles miles miles miles –––0 6.7953 170.0892 68.394 1.739 50.312 35.534 21.3780 259.610 3.309 2.321 15.593 21.374 20.427 18.3228 200.6247 285.661 42.3438 282.621 6.004 1.467 54.0210 114.641 24.710 55.069 37.639 91.420 88.154 19.9528 160.262 25.295 101.108 5.117 23.0079 219.278 167.438 5.447 36.1654 209.787 64.9265 13.983 21.4331 318.060 164.219 19.265 27.195 58.0420 196.875 28.4121 236.

160 6.837 1130.790 4.612 12.1870 5.710 103.644 868.806 90.193 238.9764 1.903 77.7086 2.190 ––– 10 20 30 40 50 60 70 80 90 100 cm3(cc) CUBIC CENTIMETERS TO CUBIC INCHES cm3(cc) ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 in3 in3 in3 in3 in3 in3 in3 in3 in3 in3 –––0 0.385 1196.4921 6.5866 2.484 311.516 129.085 2.805 6.192 638.484 200.871 327.005 12.967 535.805 690.064 522.610 11.902 677.418 38.2342 3.6141 6.677 573.0748 2.875 5.870 548.384 1704.451 270.804 1425.5767 5.997 1687.773 561.580 187.064 122.483 399.3425 1.064 589.161 109.255 81.6713 1.3937 5.934 606.820 8.8818 5.644 645.901 1048.440 8.354 683.452 70.225 639.3190 2.161 309.9901 3.355 7.870 348.160 12.880 16.416 131.158 1737.655 0.029 114.838 419.226 167.545 1753.9665 4.999 464.806 409.5492 1.902 540.1831 0.030 1392.975 8.2441 0.289 625.0984 1.096 651.902 477.015 3.7598 5.145 10.190 16.525 10.094 1310.935 13.735 7.990 10.516 329.354 283.665 8.160 509.355 83.932 1769.3661 0.340 5.3090 5.450 670.289 1065.6850 3.838 619.3700 5.063 19.803 147.6476 2.193 438.127 1015.417 1409.6377 5.838 219.0374 1.7224 4.677 174.320 1278.966 966.642 98.223 1655.967 458.451 470.7697 2.370 9.773 58.126 1523.450 1114.725 16.128 507.192 934.579 950.965 1474.999 664.1122 3.742 232.8071 3.115 6.905 9.495 6.675 1589.7362 6.4173 4.0413 6.257 496.595 9.695 12.480 4.8208 5.129 180.740 1.810 0.161 213.706 16.8307 2.612 655.1633 0.483 819.500 0.773 704.933 1261.258 96.934 753.950 15.871 148.676 1081.645 360.170 3.7460 3.031 884.580 587.063 1097.1023 0.386 688.4310 6.325 3.513 1540.275 0.965 0.481 49.780 13.935 206.720 5.315 12.870 45.9429 5.548 458.483 599.3326 4.354 475.319 1786.838 622.2106 4.032 393.193 426.415 15.449 1622.515 524.3563 3.290 225.385 11.644 445.020 14.060 9.096 451.9153 1.191 1442.245 13.090 13.260 15.330 14.710 14.7933 1.966 32.611 1163.6614 4.300 10.387 212.410 4.400 13.451 606.5393 4.705 3.708 786.868 65.625 13.795 15.419 341.430 1.8543 1.6515 ––– 10 20 30 40 50 60 70 80 90 100 221 .230 11.836 1638.225 367.465 2.930 2.097 294.419 393.4409 3.224 ––– 10 20 30 40 50 60 70 80 90 100 cm2 SQUARE CENTIMETERS TO SQUARE INCHES cm2 1 2 3 4 5 6 7 8 9 in2 ––– 10 20 30 40 50 60 70 80 90 100 0 in2 in2 in2 in2 in2 in2 in2 in2 in2 –––0 1.062 1605.565 5.903 277.3799 2.741 491.650 6.100 4.806 290.175 14.0039 5.2480 5.9291 3.105 15.806 490.418 541.4783 4.610 1671.0610 0.290 425.270 6.515 529.485 15.967 335.8444 4.900 1556.680 10.345 16.998 1179.774 196.7972 6.6751 6.620 2.288 1573.547 658.185 5.514 1032.387 180.240 2.635 4.2952 3.CONVERSION TABLE AREA SQUARE INCHES TO SQUARE CENTIMETERS in2 in2 1 2 3 4 5 6 7 8 9 cm2 ––– 10 20 30 40 50 60 70 80 90 100 0 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 –––00 64.386 612.064 322.612 316.4272 1.709 503.895 ––– 10 20 30 40 50 60 70 80 90 100 in3 VOLUME CUBIC INCHES TO CUBIC CENTIMETERS in3 ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) –––00 163.256 1360.4882 1.3051 0.865 14.093 32.643 1376.585 1.353 983.2815 1.860 3.890 7.9055 4.548 229.550 3.419 141.580 387.2854 0.613 116.774 361.935 245.470 13.257 696.676 574.2579 2.257 852.1732 3.4646 2.740 999.709 278.850 12.2205 1.2243 0.640 15.6004 4.000 264.225 567.0275 4.482 1327.805 917.5295 0.741 432.290 557.0649 5.159 1229.310 1.945 4.425 6.4035 2.869 1343.322 554.739 1507.215 9.935 406.321 770.354 483.1496 4.4074 0.709 303.774 161.6240 3.030 5.418 901.8917 2.920 11.5905 0.352 1491.130 8.096 251.5157 5.5256 2.224 1147.455 11.510 8.031 593.0512 3.258 344.870 835.255 4.750 9.775 2.5531 6.8681 3.555 14.7323 1.677 374.960 6.578 1458.6102 1.645 245.032 376.258 296.741 632.128 380.1259 5.1968 2.1594 1.095 802.9803 6.128 580.6988 5.7834 4.707 1294.8582 6.546 1245.0138 2.515 25.968 135.032 193.160 721.4547 5.580 7.765 11.708 703.035 16.999 671.0885 4.570 16.9527 2.772 1212.285 8.835 10.4684 0.580 442.1220 0.547 737.045 7.5020 3.548 258.075 11.386 412.2716 4.395 2.120 0.5630 3.3464 0.322 262.321 51.322 154.612 516.322 354.540 12.771 1720.9192 6.1358 2.155 1.200 7.

7005 219.6791 11.8261 34.7551 7.8118 8.3220 17.0578 17.6671 359.1417 52.4400 2. –––00 37.0098 145.7393 168. gal.8507 377.8991 12.5792 10.8981 23.4188 15.0392 445.2081 313.4172 0.2754 174.S.7774 147.1337 158.7925 3.6769 459.7734 200.3027 12.2834 7.6610 10.4161 15.2987 16.5753 350.1181 23.9191 162.5668 98.2179 413.4982 490.S.0384 20.5197 5. gal.4590 90.8889 28.9059 5.1519 14.2279 20.6276 238.9960 90.2754 72.7573 412.1212 354.9818 11.6818 13.8556 427.9798 4.5548 257.4783 20.8605 477.0204 21.9180 136.4793 9.1796 6. gal. gal.9455 0.3770 181.) liters ––– 10 20 30 40 50 60 70 80 90 100 222 0 1 2 3 4 5 6 7 8 9 gal.3391 12.0918 54.1864 405.6524 209.2785 18.1065 204.1338 23. gal.3195 27.6054 23.9151 215.0385 12.5802 400.2097 1.9231 109.5900 4.5487 22.8492 4.9030 374.7947 ––– 10 20 30 40 50 60 70 80 90 100 Imp gal.3199 3.6397 79.9990 13.6814 0.6388 15.9229 186.2999 322.1134 4.7295 68.3968 10.1326 9.9572 40.3209 3.3402 261.7185 18.4639 140.2846 21.5379 1.9278 236.9474 436.2190 13.5590 12.3721 131.5655 250. gal.1934 163.0595 7.5628 151.9425 386.8789 14.3362 314.5984 19.5295 17. gal.3442 208.0011 16.2392 11.9395 8.1584 19.1945 299. –––00 2.4064 481.2901 222.7188 25.CONVERSION TABLE VOLUME GALLONS (U.6377 59.5187 16.0245 295.1163 304.6844 18.6995 20.5782 21.1530 28.5507 310.7397 5.5389 14.1383 21.0527 283.1836 63.8396 7. GALLONS (IMP.2642 2.7687 468.4546 25.0608 177.9263 24.7045 166.2795 7.4015 431.3868 281.8502 128.7540 318.7344 118.2460 11.0193 7.5306 2.5113 26.8779 1.7613 359.3986 17.7992 10.9596 6. gal.1377 105.8685 9.8184 20.1594 8.3917 331.2180 0. gal.5606 200.1256 264. gal.8194 9.4940 117.6196 344.0787 16. gal.1985 246.6621 24.0447 389.0407 30.2803 122.7085 113.2997 5.0487 336.0967 104.0585 18.6622 309.6186 17.5557 150.0760 8.1216 317. gal.1359 9.4688 190.8458 327.4859 223.8990 15.6720 409.7562 21.3966 381.8129 22.0567 3.4354 20.3794 8.9788 15.8409 277.9252 10.8543 75.8597 5.2130 363.3819 231.3179 1.9920 143.6247 28.2065 140.9718 408.9131 86.1885 113.4909 7.1310 454.1712 19.1261 404.7790 12.2032 263.2713 227.7588 14.2025 193.0397 26.4591 11.2086 15.7177 11.1998 4.0952 13.5031 ––– 10 20 30 40 50 60 70 80 90 100 liters LITERS TO GALLONS (IMP.8462 181.0979 1.9830 25.3775 5.4779 329.4050 348.3605 28.5850 4.2653 16.3784 19. gal.7744 12. gal.S.3038 26.5680 27.5459 50.6965 272.7598 3.4535 11.1135 11.1988 15.5580 23.3189 14.3996 6.6236 14.6579 0.6993 9.0147 195.1904 24.0648 124.3482 155.6924 325.0771 22.8503 18.3787 19.2268 6.6398 4.0441 495.9799 302.4920 21.4581 22.4090 295.8262 127.9193 10. gal.9183 21.4728 16.1893 10.2471 25.4390 13.5704 300.6599 2.4251 83.8322 27.5476 8.1145 18.5851 450.7491 268.3672 81.0182 22.2794 121.7653 306.8654 31.9444 15.8213 77.0196 245. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 liters liters liters liters liters liters liters liters liters liters U.8311 177.6316 185.5399 3.7755 26. gal.0294 345.8311 13.2834 68.4819 276.6983 20.4113 36.4198 4.9271 56.6984 6.1296 211.4698 22.2105 87.7369 16.0989 14.7126 60.3412 22.6589 13.2583 20.7195 7.9070 19.7693 253.0999 3.6156 397.1191 12.4737 240.5861 18.2633 333.4884 390.9110 268.1786 17.0797 5.3523 102.2553 26.8386 18.gal.6115 ––– 10 20 30 40 50 60 70 80 90 100 liters LITERS TO GALLONS (U.7736 22.0688 71.3281 7.5467 363.9070 321.1701 5.7589 368.8301 393.0192 11.1176 370.4342 6.4131 242.9839 249.2593 9.3979 24.1016 154.3401 8. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 liters liters liters liters liters liters liters liters liters liters –––00 45.8422 234.9327 286.7854 41.1393 10.8360 227.3321 367.2673 280.0343 395.1983 213.2382 22.9376 336.0022 1.5427 3.0568 230.0394 9.6781 22.0049 95.6196 6.3381 23.9385 19.1114 254.2277 18.7387 16.2664 2.6803 15.4171 189.7578 1.3563 49.6573 259.6884 378.5102 12.4995 7.4739 1.) TO LITERS U.5669 13.2852 172.2593 386.3592 10.8799 3.3097 422.3582 21.9523 486.9626 6.6357 132.4786 290.5994 8.8877 14.) liters ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 gal.7381 1. gal.8587 16.) TO LITERS Imp gal.3146 472.4985 18.9778 ––– 10 20 30 40 50 60 70 80 90 100 .7936 17.4738 382.9879 196.7638 418.5508 100.5709 45.7982 21.0963 27.6475 159.7814 94.9637 20.8342 340.5283 3.3594 14.2228 463.4835 340.7780 23.8696 23.4211 136.5588 204.9586 17.6236 291.4980 64.2200 2.2950 272.9759 355.6426 109.6043 9.4899 170.8382 287. –––00 2. gal.3048 372.9980 0.4933 440.1904 352. gal.S.4010 401.7442 218.4380 0.6417 5.6428 19.

69 823.66 774.099 19.400 82.393 209.81 107.735 99.340 15.01 402.20 392.793 16.454 33.412 24.89 813.183 71.834 40.980 108.053 238.814 104.729 83.422 19.085 66.174 2.203 72.277 154.242 74.380 81.99 961.045 64.072 13.133 27.26 186.690 15.195 41.893 108.366 101.992 2.43 431.494 29.592 40.162 99.320 79.061 18.629 8.594 114.051 23.990 9.83 1019.886 15.319 25.10 245.479 86.347 187.690 45.868 149.47 19.073 152.62 421.513 36.030 33.302 77.142 185.228 35.667 4.696 97.006 62.897 10.11 853.81 411.05 755.545 48.775 101.911 74.555 43.276 24.731 46.262 75.825 224.416 220. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 kg kg kg kg kg kg kg kg kg kg lbs.27 794.67 9.49 529.751 36.112 37.730 47.84 156.019 38.566 38.12 88.618 13.75 617.916 44.025 63.823 45.36 333.68 215.08 39.459 145.31 843.804 11.720 1.03 147.538 89. lbs.687 158.329 20.597 23.947 59.13 294.308 30.75 313.247 16.096 163.298 35.216 31.809 52.783 21.24 745.59 676.350 10.888 63.98 657.185 110.842 41.960 194.53 578.102 42.091 47.07 500.828 53.321 78.86 1068.316 26. lbs.154 17.33 588.69 519.29 235.597 211.854 106.007 216.676 96.254 143.73 872.958 24.504 24.039 12.370 198.957 97.552 38.845 138.485 13.597 92.49 225.482 156.822 127.907 5.484 34.297 68.123 32.25 1049.515 19.608 18. –––00 22.46 480.63 725.454 4.78 362.733 180. lbs.335 27.690 22.104 67.267 1.175 7.865 25.70 58.37 637.663 147.119 174.85 460.802 213.44 1039.15 902.722 7.251 46.876 20.756 191. lbs.300 165.414 31.887 56.436 134.627 2.548 92.21 1000.571 103.211 218.576 33.158 18.197 20.779 202.02 1010.63 1029.01 706.030 227.023 33.640 136.177 19.683 61.814 6.375 29.046 44.762 31.91 254.059 13.558 90.706 72.42 127.769 49.578 91. –––0 4.277 45.361 80.499 87.525 81.443 9.459 85.934 85.234 229. lbs.848 235.CONVERSION TABLE MASS POUNDS TO KILOGRAMS lbs.95 912.914 171.05 1059.813 0.656 95.970 19.772 26.011 3.355 28.04 451.258 240.17 343.432 37.165 12.536 9.208 121.43 735.680 27.14 598.660 50.144 69.818 30.420 83.076 8.927 58.71 264.124 68.525 14.848 54.23 137.749 48.223 73.611 41.439 231.648 42.462 2.149 N ––– 100 200 300 400 500 600 700 800 900 1000 223 .079 14.21 696.433 14.617 125.47 784.966 60.274 57.617 93.413 123.359 0.776 105.205 36.651 43.08 804.92 862.532 37.913 109.710 169.637 39.463 43.905 49.256 23.72 568.040 28.440 84.069 55.82 715.710 46.65 470.110 8.050 141.988 4.455 48.217 21.79 970.031 4.502 70.237 22.986 61.614 28.341 79.391 34.31 78.57 931.130 9.380 39.937 34.865 52.071 6.370 44.659 37.003 119.937 182.76 921.891 160.23 441.741 41.282 76.95 608.051 5.574 200.287 40.56 627.45 176.226 26.020 11.296 25. lbs.587 28.27 490.572 39.390 112.138 17.621 222.834 105.55 323.92 ––– 10 20 30 40 50 60 70 80 90 100 NEWTON TO KILOGRAMS N ––– 100 200 300 400 500 600 700 800 900 1000 0 10 20 30 40 50 60 70 80 90 kgf kgf kgf kgf kgf kgf kgf kgf kgf kgf –––00 10.60 980.17 647.34 892.789 50.855 30.304 ––– 10 20 30 40 50 60 70 80 90 100 kgf KILOGRAMS TO NEWTON kgf ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 N N N N N N N N N N –––0 98.638 47.94 304.493 35.394 30.670 44.61 117.281 11.41 990.755 100.716 98.144 22.479 59.65 166.795 102.907 57.505 167.637 94.116 77.065 65.361 5.082 8.409 26.984 205.163 70.18 951.33 284.91 558.11 549.257 11. lbs.40 686.237 21.933 110.452 48. lbs.972 1.401 29.099 15.895 17.979 14.268 6.165 196.205 24.528 178.844 35.53 882.39 382.118 16.87 205.009 43.669 32.188 207.79 666.59 372.97 353.534 3.37 941.952 111.081 3.89 49.092 66.442 ––– 10 20 30 40 50 60 70 80 90 100 kg KILOGRAMS TO POUNDS kg ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 lbs.701 17.473 34.927 39.631 42. lbs.434 32.139 88.343 90.518 88.799 116.07 196.753 94.231 132.50 833.473 39.948 29.52 274.85 764.551 189.871 6.090 7.711 12.30 539.644 233.868 55.184 46.026 130.873 107.50 68.88 509.28 29.998 48.324 176.

992 2.868 55.2 8629.64 99.7263 4.26 796.085 66.144 69.92 711.17 1237.730 47.6717 3.8123 3.7 1961.85 1408.2 1274.5543 6.39 1123.2573 6.2655 1.592 40.4 7355.7106 5.5228 0.3979 7.3433 6.46 426.73 1208.69 568.532 37.8669 4.670 44.7 7943.0389 2.361 80.2184 4.56 241.60 1009.4 4511.262 75.302 77.873 107.4839 6.9 2353.6 6276.9 490.296 25.4 7453.090 7.23 284.59 753.947 59.91 455.4525 0.572 39.6 1863.0546 1.031 4.4 5884.27 1052.07 1422.7734 1.90 327.3 10198.276 24.83 1152.2887 4.237 22.3 8826.29 1308.84 1280.0 588.8 392.854 106.7420 3.2 10100.62 1393.578 91.14 597.4 1569.380 81.493 35.3358 2.9 8139.24 412.81 768.341 79.0 8335.6014 3.6560 4.67 184.1010 0.887 56.78 256.538 89.966 60.7 4903.3 2843.124 68.5 7551.74 1464.58 497.755 100.86 113.183 71.0464 6.158 18.42 85.27 924.0 6864.83 1024.1 8433.52 28.986 61.1638 3.93 839.2416 0.7031 1.5625 1.2341 3.597 92.1713 0.9 9610.775 101.9 3824.473 34.335 27.7966 4.9215 5.04 910.7 3530.414 31.5 1667.8512 5.6246 6.558 90.7809 5.01 398.96 1351.05 1038.006 62.420 83.5468 2.4061 2.9843 1.4 10395.49 938.6874 2.1 10002.690 45.6 7649.9918 5.0 2451.8 9512.CONVERSION TABLE PRESSURE POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS lb/in2 0 1 2 3 4 5 6 7 8 9 lb/in2 (psi) kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 (psi) ––– 10 20 30 40 50 60 70 80 90 100 –––0 0.0075 4.5857 4.952 111.70 696.12 341.28 1180.907 57.0307 0.7 9414.01 270.177 19.749 48.95 1223.8901 7.710 46.3515 1.4996 5.1 2549.1249 1.08 1550.5386 7.834 105.2 4216.6 7747.518 88.4450 4.80 512.5 10591.12 213.637 94.065 65.9 5197.9686 2.3 5785.110 8.57 369.9 6766.8280 2.795 102.71 952.45 298.9058 6.31 ––– 10 20 30 40 50 60 70 80 90 100 kgf/cm2 KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL kgf/cm2 1 2 3 4 5 6 7 8 9 KPa ––– 10 20 30 40 50 60 70 80 90 100 0 KPa KPa KPa KPa KPa KPa KPa KPa KPa –––00 980.282 76.82 896.197 20.2812 0.9 8237.020 11.93 967.011 3.37 867.6635 ––– 10 20 30 40 50 60 70 80 90 100 kgf/cm2 KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES kgf/cm2 1 2 3 4 5 6 7 8 9 lb/in2(psi) ––– 10 20 30 40 50 60 70 80 90 100 0 lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) –––00 142.96 1479.848 54.8 2157.45 170.4682 7.2730 5.0935 3.2 5687.47 554.68 440.1870 6.7 9316.1 1078.9604 7.025 63.059 13.479 86.9 5295.716 98.434 32.5 4609.3 1471.81 640.4764 2.1 4020.651 43.8 6472.06 1166.769 49.6 3334.48 810.97 56.617 93.513 36.37 739.63 1521.85 1536.7 7845.6 4805.809 52.4 3040.3904 3.5700 5.6089 7.3276 7.656 95.06 1294.454 33.9529 3.7 2059.60 881.89 199.36 611.0 9806.1481 4.223 73.4293 5.94 1095.8 8041.7 196.355 28.3 2942.039 12.8355 6.099 15.79 384.2 ––– 10 20 30 40 50 60 70 80 90 100 KPa KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS KPa –––0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 224 0 100 200 300 400 500 600 700 800 900 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 –––00 10.7 5001.2027 5.02 526.3119 0.58 625.16 981.1 8531.9140 1.9 2255.75 42.2109 0.8 5099.18 1365.893 108.7495 7.0703 0.1795 2.08 128.789 50.61 1137.8 6570.3747 4.1 4118.6328 1.1 5491.39 1251.051 5.933 110.0232 3.394 30.62 1265.0778 4.071 6.3822 0.1167 6.7 6374.5 6178.972 1.1 7060.5932 0.3 4413.9 9708.3 8727.4218 1.1952 1.22 156.50 1066.217 21.15 853.8198 7.552 38.5 9022.5 6080.19 71.50 1194.29 1436.1324 5.814 104.5 3236.256 23.4 5982.1 1176.68 312.3 1372.828 53.045 64.5 10493.7577 2.47 682.3 10297.70 824.03 654.735 99.04 782.13 469.19 1493.1 5589.611 41.52 1450.72 1080.104 67.2 882.35 355.7652 6.4136 6.5 1765.8437 1.9761 6.2 2745.163 70.8 3628.1 9904.34 227.927 58.1 784.631 42.4921 1.138 17.14 725.5311 3.3201 3.0621 5.5 9120.7 98.73 1336.40 1379.203 72.8 294.8983 2.316 26.1406 0.6 10689.149 –––0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 .24 540.459 85.499 87.7 3432.5 4707.3 4314.321 78.6792 7.1 2647.38 995.242 74.400 82.9 6668.4607 3.91 583.130 9.1 686.6949 6.375 29.0 3922.5 3138.8826 3.1 6962.0 5393.6403 5.5154 4.9372 4.913 109.4 8924.6171 2.2498 2.9 3726.3590 5.2 7158.1092 2.3044 4.30 14.079 14.25 668.440 84.41 1507.3 7256.696 97.51 1322.16 1109.118 16.6 9218.35 483.676 96.

788 50.069 6.118 16.659 3.138 17. ft.478 86.596 92.709 46.27 490.668 7.84 156.627 4.36 333.678 11.968 2. ft.95 412.28 484.295 9.98 506.17 108.636 8.08 804.954 11.93 57.23 36.028 13.05 1059.37 637.433 32.47 43.670 44.277 1.858 14.01 706.11 665.94 304.71 264.024 63.87 205.67 745.61 117.00 28.29 235.816 11.31 578.31 843.34 892.31 78.36 238.01 600.63 725.60 773.932 1.157 9.950 111.60 980.871 5.69 311.147 ––– 100 200 300 400 500 600 700 800 900 1000 225 .78 362.714 98.162 70.88 509.33 144.88 441.965 60.383 2.926 58.635 94.63 1029.359 80.753 100.903 4.572 9.91 535.62 421.15 902.042 4.977 6.719 14.424 5.26 186.337 12. lbs.872 107.768 49.281 76. ft.458 85.189 8.922 12.83 781. –––0 1.73 188.91 558.91 254.848 10.49 397.005 62.340 79.009 3.38 549.379 0.44 1039.244 2.34 672.240 0.102 0.079 14.70 94.56 151.655 0.15 542. lbs.128 9.180 4. –––0 72.70 50.498 7.23 441.55 368.72 568.17 636.099 15.675 96.123 68.615 93.221 73.881 9.591 40.059 13.613 12.83 253.507 11.35 455.552 38.691 2.08 571.13 294.67 9.392 6.272 14.350 3.318 4.887 56.694 97.16 65.148 5.394 30.07 196.21 1000.221 7.20 392.40 686.61 556.254 6.82 470.774 8.733 5.493 35.75 499.63 122.134 14. ft.42 127.784 12.96 195.59 676.261 75.399 82.867 55.66 216.10 137.68 528.22 296.453 33.82 715.826 0.414 31.72 405.320 78.752 13.95 912.53 578.852 106.985 61.47 784.27 701.08 39.199 12.12 88.039 12.556 90.530 6.65 470.029 4.76 921.46 303.29 267.009 5.438 84.77 21.074 3.80 159.27 794.241 74.06 260.39 382.46 480.064 65.595 4.92 318.42 426.202 72.16 325.02 1010.81 687.830 2.50 833.532 37.108 8.99 289.650 43.335 27.30 7.52 274.797 3.832 105. lbs.21 513.32 361.263 10.497 87.166 13.300 77.56 627.75 313. ft.690 45.75 617.81 411.23 137.21 696.49 529. ft.20 730.10 245.687 15.088 7.17 647.812 104.158 18.59 372.946 59.53 14.39 332.360 7.05 755.33 588.970 1.25 1049.473 34. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m ft lbs.09 354.418 83.987 10.604 8.92 862.646 12.913 8.26 173.060 12.14 759.931 110.81 107.84 564.489 3.04 694.212 3.85 764.571 39.18 419.43 431. ft.62 339.97 353. lbs.44 737.70 58.99 961.296 25.85 460.24 745.43 735.517 0.65 433.68 215.734 99.45 176.143 69.911 109.69 823.286 5.374 29.87 658.59 245.456 4.50 180.562 5.773 101.906 57.71 622.936 3.49 225.049 5.79 970.65 166.051 8.37 766.11 853.083 7.839 6.12 448.231 11.891 108.106 2.41 990.93 ––– 10 20 30 40 50 60 70 80 90 100 N-m NEWTONMETERS TO KILOGRAMMETERS N-m ––– 100 200 300 400 500 600 700 800 900 1000 0 10 20 30 40 50 60 70 80 90 kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m –––00 10.54 585.37 941.83 1019.78 593.57 679.04 451.89 813. lbs.521 2.084 66.33 284.044 64.411 14.093 11.512 36.581 13. ft.996 14.537 89.52 274.43 209.41 643.138 1.197 20.53 882.85 347.466 8. lbs.540 10.95 608.58 462.51 68.990 2.807 7.710 10.CONVERSION TABLE TORQUE FOOT POUNDS TO KILOGRAMMETERS ft.93 101.48 614.23 79.070 ––– 10 20 30 40 50 60 70 80 90 100 kgf-m KILOGRAMMETERS TO FOOT POUNDS kgf-m ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 ft.182 71.655 95. lbs.103 67.742 9.90 752.305 13.276 24.05 477.315 26. ft.517 88.07 500.47 86.40 ––– 10 20 30 40 50 60 70 80 90 100 kgf-m KILOGRAMMETERS TO NEWTONMETERS kgf-m ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 N-m N-m N-m N-m N-m N-m N-m N-m N-m N-m –––00 98.401 10.125 10.79 666.14 598.86 130.328 8.94 629.793 1. lbs.89 224. lbs.30 539.369 11. lbs.69 519.847 54.18 951.020 11.03 166.964 0. lbs.576 91.475 12.89 49.45 520.11 549.25 390.47 19.890 13.415 1.17 343.13 231.701 6.115 6.73 872.379 81.749 48.19 202.51 491.07 788.630 42.765 4.553 1.98 657.236 22.55 323.793 102.74 716.64 650.611 41.24 607.57 931.40 115.50 708.66 774.355 28.79 376.02 383.945 7.76 282.729 47.03 147.808 52.86 1068.28 29.97 723.827 53.434 9.443 13.019 9.549 14.177 19.217 21.256 23.01 402.

9 140.3 154.7 17.7 117.6 379.6 19.4 185.2 266.4 115.8 143.4 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 210 220 230 240 250 345.8 350.6 46.0 294.8 148.8 -22.1 82.4 30.3 114.6 66.0 213.0 181.1 162.0 81.4 210.9 180.8 386.8 98.4 -52.8 332.2 133.4 390.7 -45.2 23.4 183.0 21.8 188.2 -36.9 80.6 217.2 63.2 193.2 158.1 102.2 33.0 141.8 197.6 6.6 163.4 174.9 200.8 125.4 372.1 12.0 33.8 -36.0 41.0 121.0 61.4 246.6 127.2 41.0 222.9 -37.4 195.0 96.0 240.4 165.0 51.8 62.0 15.0 321.4 66.7 -35.4 75.6 126.8 314.6 -4.6 64.8 224.3 164.6 73.1 -30.0 141.1 -40.0 -56.4 39.7 37.8 -31.4 12.8 88.4 -33.2 -54.4 -25.2 86.8 341.8 58.0 123.4 210.4 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 45.4 48.0 -20.0 384.4 165.4 264.0 42.2 32.2 -45.4 147.6 199.0 195.9 -47.7 -5.0 375.2 -11.8 118.4 192.3 14.9 100.2 93.4 105.0 168.0 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 114.8 251.CONVERSION TABLE TEMPERATURE FAHRENHEIT TO CENTIGRADE °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C -60 -58 -56 -54 -52 -50 -48 -46 -44 -42 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -51.6 91.0 285.8 -13.2 173.0 132.7 -15.0 191.2 113.8 206.6 106.6 76.2 77.8 18.2 140.4 273.4 120.0 348.1 172.0 -11.2 374.0 60.4 -43.3 134.2 338.0 131.0 -38.0 111.6 136.1 -50.8 71.6 55.6 343.3 194.1 -20.8 188.3 -12.1 42.2 -27.8 48.6 154.6 -24.2 239.6 181.0 -38.8 116.4 55.6 56.0 161.7 172 174 176 178 180 182 184 186 188 190 192 194 196 198 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228 77.4 111.6 36.2 143.7 57.6 298.2 284.8 26.2 203.4 300.2 103.4 125.0 31.0 330.6 156.2 123.6 -44.0 177.6 190.0 11.4 354.3 64.6 146.4 85.3 -2.0 91.8 269.2 221.8 368.3 184.0 71.0 226 .2 -9.8 107.1 152.2 194.0 51.8 233.7 107.2 257.7 167.6 307.4 95.6 37.9 40.7 47.1 32.1 -10.2 -1.6 235.3 -32.2 293.9 10.6 352.0 -47.8 38.9 90.8 8.4 65.2 176.0 171.0 276.4 327.2 -18.8 -26.1 52.0 204.8 53.2 14.2 -41.3 104.2 302.0 78.2 329.4 336.9 190.2 167.8 161.8 -46.4 255.3 84.8 134.1 288 290 292 294 296 298 300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332 334 336 338 340 342 344 142.4 156.8 78.6 -50.0 482.4 1.6 316.1 182.6 10.2 95.4 309.3 94.8 215.4 -43.1 92.0 464.0 1.8 168.6 109.9 -7.8 260.0 -48.6 -5.3 144.2 83.0 267.0 150.6 325.8 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 287.2 383.6 100.7 87.2 212.3 346 348 350 352 354 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 400 410 420 430 440 174.8 108.6 208.3 124.8 179.8 158.7 157.2 50.7 137.6 86.6 118.6 262.8 305.0 -8.4 363.6 28.0 69.6 244.6 253.8 98.2 356.6 116.9 160.4 138.2 131.4 -3.8 28.2 3.6 271.8 -40.4 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 57.4 219.7 177.2 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 13.8 296.2 248.2 153.0 159.4 135.6 -23.2 73.2 347.0 -29.3 -42.2 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 -0.2 149.8 128.2 275.6 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 172.8 -4.0 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 -18.0 -28.9 70.6 -34.0 303.4 102.0 186.9 30.6 -14.6 280.0 446.3 74.2 185.2 -21.6 226.6 46.6 136.4 35.1 112.8 35.4 15.8 138.8 -16.4 155.2 163.6 221.3 -22.2 365.2 122.7 67.4 93.2 311.0 357.9 -27.8 152.2 104.9 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 110.0 204.2 113.4 21.8 89.9 20.0 -2.2 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 230.8 323.0 87.8 17.3 24.4 5.8 44.6 334.6 166.8 68.0 101.4 175.1 192.4 -7.4 -13.4 318.4 84.8 -6.8 170.4 75.2 5.4 381.6 -32.2 392.4 -16.3 34.3 54.7 CENTIGRADE TO FAHRENHEIT °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F -50 -49 -48 -47 -46 -45 -44 -43 -42 -41 -40 -39 -38 -37 -36 -35 -34 -33 -32 -31 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 -58.0 215.8 242.4 -34.0 366.1 122.7 147.7 97.0 428.0 249.2 -31.7 197.8 377.7 27.2 43.7 7.6 176.9 150.0 258.6 82.8 -49.6 145.7 -25.4 129.6 96.6 -41.0 151.8 198.4 237.0 24.8 80.0 312.6 26.9 130.4 3.0 6.1 62.9 60.3 44.4 201.4 228.9 50.2 23.1 132.9 120.4 291.6 196.8 178.9 -17.4 145.6 16.2 320.4 282.7 187.6 370.1 72.9 170.6 388.2 68.0 105.7 127.4 -23.4 25.8 359.3 4.6 -14.0 410.6 186.6 361.0 339.6 289.2 183.0 231.1 2.8 278.2 53.8 8.1 226.2 59.1 22.1 0.

. A-4JB1 (IDE-2310) Issued by ISUZU MOTORS LIMITED POWERTRAIN SERVICE & PARTS POWERTRAIN OPERATIONS 6-26-1.Copyright reserved for this manual may not be reproduced or copied. without the written consent of ISUZU MOTORS LIMITED. WORKSHOP MANUAL (INDUSTRIAL) A-4JA1. Japan TEL 03-5471-1111 First edition Jul. Minami-oi. 1998 107-03K . 140-8722.Tokyo. Shinagawa-ku. in whole or in part.

IDE-2310 PRINTED IN JAPAN .

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