Professional Documents
Culture Documents
DIESEL ENGINE
A-4JA1, A-4JB1
MODELS
WORKSHOP MANUAL
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2.
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
SECTION 3.
29
SECTION 4.
47
SECTION 5.
81
SECTION 6.
SECTION 7.
SECTION 8.
SECTION 9.
GENERAL INFORMATION
SECTION 1
GENERAL INFORMATION
TABLE OF CONTENTS
ITEM
PAGE
GENERAL INFORMATION
GENERAL INFORMATION
4. When the same servicing operation is applicable to several different units, the manual will direct you
to the appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail.
6. Each service operation section in this Workshop Manual begins with an exploded view of the
applicable area. A brief explanation of the notation used follows.
13
10
12
5
11
16
17
14
Repair kit
15
Disassembly Steps - 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Inverted Engine
GENERAL INFORMATION
7. Below is a sample of the text of the Workshop Manual.
This is the item shown in the illustration. It is marked with a triangle
() on the Major Components page.
kgfm(lb.ft/Nm)
10
2) Tighten the flywheel housing bolts to the specified torque a little at a time in the sequence
shown in the illustration.
2
7
kgfm(lb.ft/Nm)
10.51.0 (76.07.2/103.09.8)
8. The following symbols appear throughout this Workshop Manual. They tell you the type of service
operation or step to perform.
....
Removal
....
Adjustment
....
Installation
....
Cleaning
....
Disassembly
...
....
Reassembly
....
....
Alignment (marks)
....
....
Directional indication
....
....
Inspection
....
Lubrication (oil)
....
Measurement
....
Lubrication (grease)
....
Sealant application
GENERAL INFORMATION
9. Measurement criteria are defined by the terms "standard" and "limit".
A measurement falling within the "standard" range indicates that the applicable part or parts are
serviceable.
"Limit" should be thought of as an absolute value.
A measurement which is outside the "limit" indicates that the applicable part or parts must be either
repaired or replaced.
10. Components and parts are listed in the singular form throughout the Manual.
11. Directions used in this Manual are as follows:
Front
The cooling fan side of the engine viewed from the flywheel.
Right
The right hand side viewed from the same position.
Left
The left hand side viewed from the same position.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is the final cylinder number of the engine.
The engine's direction of rotation is counterclockwise viewed from the flywheel.
GENERAL INFORMATION
A-4JB1
4JB1T
Item
Engine type
Direct injection
Dry
mm(in.)
4 - 93.0 x 92.0
(3.66 x 3.62)
4 - 93.0 x 102.0
(3.66 x 4.02)
4 - 93.0 x 102.0
(3.66 x 4.02)
lit(cid)
2.449 (152.4)
2.771 (169.0)
2.771 (169.0)
18.4
18.2
18.2
mm(in.)
kg(lb.)
Specified fuel
14
In-line plunger, Bosch A type
Governor
rpm
Injection nozzle
850 1,000
Multi-hole type
185 (2630/18.1)
Cartridge papaer element
kgf/cm (psi/MPa)
2
mm(in.)
0.40 (0.0157)
0.40 (0.0157)
Pressurized circulation
Oil pump
Trochoid type
31 (441/3.04)
mm(in.)
Lubrication method
Not equipped
lit.(qts) 5.5 (5.8) 6.6 (7.0) 4.6 (4.9) 6.4 (6.8) 4.6 (4.9) 6.3 (6.7)
Cooling method
Water pump
5.0 (5.3)
Belt driven impeller type
Thermostat type
12 35
V-kW
12 2.2
Specifications marked with an asterisk (*) will vary according to engine application.
Bosch distributor
VE type
*Starter
245 (540)
Diesel fuel
Injection pump
*Alternator
220 (486)
1 3 4 2
Coolant volume
218 (480)
GENERAL INFORMATION
STANDARD BOLT
Strength
Class
kgfm (lb.ft/Nm)
4.8 (4T)
8.8
Refined
Bolt
Identification
Bolt
Diameter
pitch (mm)
(7T)
9.8 (9T)
Non-Refined
No mark
M 6 1.0
0.4 0.8
(2.9 5.8/3.9 7.8)
0.5 1.0
(3.6 7.2/4.9 9.8)
M 8 1.25
0.8 1.8
(5.8 13.0/7.8 17.7)
1.2 2.3
(8.7 16.6/11.8 22.6)
1.7 3.1
(12.3 22.4/16.7 30.4)
M10 1.25
2.1 3.5
(15.2 25.3/20.6 34.3)
2.8 4.7
(20.3 34.0/27.5 46.1)
3.8 6.4
(27.5 46.3/37.3 62.8)
M12 1.25
5.0 7.5
(36.2 54.2/49.0 73.6)
6.2 9.3
(44.8 67.3/60.8 91.2)
7.7 11.6
(55.7 83.9/75.5 113.8)
M14 1.5
7.8 11.7
(56.4 84.6/78.5 114.7)
9.5 14.2
(68.7 102.7/93.2 139.3)
11.6 17.4
(83.9 125.6/113.8 170.6)
M16 1.5
10.6 16.0
(76.7 115.7/103.0 156.9)
13.8 20.8
(99.8 150.4/135.3 204.0)
16.3 24.5
(118.9 177.2/159.9 240.3)
M18 1.5
15.4 23.0
(111.1 166.4/151.0 225.6)
19.9 29.9
(143.9 216.3/195.2 391.3)
23.4 35.2
(169.3 254.6/229.5 345.2)
M20 1.5
21.0 31.6
(151.9 228.6/205.9 307.9)
27.5 41.3
(198.9 298.7/269.7 405.0)
32.3 48.5
(233.6 350.8/316.8 475.6)
M22 1.5
25.6 42.2
(185.2 305.2/251.1 413.8)
37.0 55.5
(267.6 401.4/362.9 544.3)
43.3 64.9
(313.2 469.4/424.6 636.5)
M24 2.0
36.6 55.0
(264.7 397.8/358.9 539.4)
43.9 72.5
(317.5 523.9/430.5 711.0)
56.5 84.7
(408.7 612.6/554.1 830.6)
*M10 1.5
2.0 3.4
(14.5 24.6/19.6 32.4)
2.8 4.6
(20.3 33.3/27.5 45.1)
3.7 6.1
(26.8 44.1/36.3 59.8)
*M12 1.5
4.6 7.0
(33.3 50.6/45.1 68.7)
5.8 8.6
(42.0 62.2/56.9 84.3)
7.3 10.9
(52.8 78.8/71.6 106.9)
*M14 2.0
7.3 10.9
(52.8 78.8/71.6 106.9)
9.0 13.4
(65.1 96.9/88.3 131.4)
10.9 16.3
(78.8 118.9/106.9 159.9)
*M16 2.0
10.2 15.2
(73.8 110.0/100.0 149.1)
13.2 19.8
(95.5 143.2/129.5 194.2)
15.6 23.4
(112.8 169.3/162.8 229.5)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
GENERAL INFORMATION
kgfm (lb.ft/Nm)
Bolt head
marking
Nominal
size
(dia. x pitch)
0.5 0.9
(3.61 6.50/4.6 8.5
0.6 1.2
(4.33 8.67/5.88 11.76)
M 8 1.25
1.1 2.0
(7.95 14.46/10.78 19.61)
1.4 2.9
(4.33 8.67/5.88 11.76)
1.9 3.4
(13.74 24.59/18.63 33.34)
M10 1.25
2.3 3.9
(17.35 28.20/23.53 38.24)
3.6 6.4
(26.03 44.12/35.30 59.82)
4.3 7.2
(31.10 52.07/42.16 70.60)
2.3 3.8
(16.63 27.48/22.55 37.26)
3.5 5.8
(25.31 41.95/34.32 56.87)
4.1 6.8
(29.65 49.18/40.20 66.68)
M12 1.25
5.6 8.4
(40.50 60.75/54.91 82.37)
7.9 11.9
(57.14 86.07/77.47 116.69)
8.7 13.0
(62.92 94.02/85.31 127.48)
*M12 1.75
3.5 9.5
(37.61 56.41/50.99 76.49)
7.3 10.9
(52.80 78.83/71.58 106.89)
8.1 12.2
(58.58 88.24/79.43 119.64)
M14 1.5
8.5 12.7
(61.48 91.85/83.35 124.54)
11.7 17.6
(84.62 127.30/114.73 172.59)
12.6 18.9
(91.13 136.70/123.56 185.34)
7.6 11.5
(57.14 85.34/77.47 115.71)
11.1 16.6
(80.28 120.06/108.85 162.79)
11.8 17.7
(85.34 128.02/115.71 173.57)
11.8 17.7
(85.34 128.02/115.71 173.57)
17.1 26.5
(125.85 189.50/170.63 256.93)
18.0 27.1
(130.19 196.01/176.52 265.76)
11.2 16.7
(81.00 120.79/109.83 163.77)
16.6 24.9
(120.06 180.10/162.79 244.18)
17.2 25.7
(124.40 186.61/168.67 253.01)
M6 1
*M10 1.5
*M14 2
M16 1.5
*M16 2
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
GENERAL INFORMATION
5.0 6.0
(36.2 43.4/49.0 58.8)
1.0 2.0
(7.2 14.4/9.8 19.6)
1st Step
2nd Step
New bolt
3.0 5.0
8.2 9.2
(21.7 36.1/29.4 49.0) (59.4 66.5/80.4 90.2)
Reused
bolt
8.0 9.0
10.0 11.0
(57.9 65.1/78.4 88.2) (72.4 79.6/98.1 107.9)
GENERAL INFORMATION
11.5 12.5
(83.2 90.4/112.8 122.6)
8.0 9.0
(57.9 65.1/78.4 88.2)
16.0 18.0
(115.7 130.2/159.6 176.5)
20.1 24.5
(145.4 177.2/197.1 240.3)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
14 24
(1.4 2.4/4.4 7.2)
10
GENERAL INFORMATION
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
10.0 12.0
(72.4 86.8/98.1 117.7)
1.0 1.5
(7.2 10.9/9.8 14.7)
1.4 2.4
(10.1 17.3/13.7 23.5)
6.6 8.7
(48 63/66 85)
11
GENERAL INFORMATION
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
12
GENERAL INFORMATION
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
13
GENERAL INFORMATION
Engine Electrical
kgfm(lb.ft./Nm)
1.4 2.4
(10.1 17.3/13.7 23.5)
2.0 2.5
(14.4 18.1/19.6 24.5)
3.6 4.6
(26.0 33.3/35.3 45.1)
6.0 8.0
(43.4 57.9/58.8 78.4)
14
GENERAL INFORMATION
20 4.0
(14.4 28.9/19.6 39.2)
3.2 4.4
(23.1 31.8/31.4 43.2)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
1.4 2.4
(10.1 17.3/13.7 23.5)
15
MEMO
16
MAINTENANCE
SECTION 2
MAINTENANCE
TABLE OF CONTENTS
ITEM
PAGE
Model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Injection pump identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Compression pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
17
MAINTENANCE
MAINTENANCE
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
Maintenance interval such as fuel or oil filter changes should be refered to INSTRUCTION MANUAL.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
A Identification number
In-line type
Distributor type
LUBRICATING SYSTEM
Main Oil Filter
Replacement Procedure
1. Loosen the drain plug to drain the engine oil.
2. Wait a few minutes and then retighten the drain
plug.
3. Loosen the used oil filter by turning it counterclockwise with a filter wrench.
Filter Wrench
18
MAINTENANCE
4. Clean the oil cooler fitting face.
This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the O-ring.
6. Turn in the new oil filter until the filter O-ring is
fitted against the sealing face.
FUEL SYSTEM
Fuel Filter
Replacement Procedure
1. Loosen the used fuel filter by turning it counterclockwise with the filter wrench.
Filter Wrench
19
MAINTENANCE
2
1
kgfm(lb.ft./Nm)
Air Bleeding
1.
2.
Air bleeding screw
20
MAINTENANCE
Injection Nozzle
Injection Nozzle Inspection
Use a nozzle tester to check the injection nozzle opening
pressure and the spray condition.
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or reconditioned.
If the spray condition is bad, the injection nozzle must be
replaced or reconditioned.
Injection Nozzle Opening Pressure
kgf/cm2(psi/MPa)
185 (2,630/18.1)
1
Spray Condition
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dripping)
kgfm(lb.ft./Nm)
mm(in.)
0.50 1.50 (0.02 0.06)
0.025 (0.001)
40
(Reference)
Removing or installing one shim will increase or
decrease the nozzle opening pressure approximately
3.77 kgf/cm2 (53.6 psi/370kPa).
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN
EASILY PUNCTURE A PERSONS SKIN. KEEP YOUR
HANDS AWAY FROM THE INJECTION NOZZLE TESTER
AT ALL TIMES.
21
MAINTENANCE
COOLING SYSTEM
D
mm(in.)
10.0 (0.39)
Thermostat
Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
C(F)
82 (180)
4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature
95 (203)
22
C(F)
mm(in.)
MAINTENANCE
TDC
kgfm(lb.ft/Nm)
mm(in.)
0.40 (0.016)
23
MAINTENANCE
Rotate the crankshaft 360.
Realign the crankshaft damper pulley TDC line with the
timing pointer.
Adjust the clearances for the remaining valves as shown
in the illustration. (At TDC on the compression stroke of
the No. 4 stroke)
INJECTION TIMING
Injection Timing Confirmation Procedure
1.
1) Rotate the crankshaft clockwise to align the camshaft gear timing mark O with the timing gear
case cover pointer.
The No. 1 cylinder will now be at the point where
nearly injection timing.
2) Remove the No. 1 fuel injection pipe.
kgfm(lb.ft/Nm)
17
2
1
kgfm(lb.ft/Nm)
24
MAINTENANCE
2.
1) Rotate the crankshaft clockwise to align the camshaft gear timing mark O with the timing gear
case cover pointer.
The No. 1 cylinder will now be at the point where
nearly injection timing.
2) Remove injector pump distributor head plug.
3) Fit a dial gauge and set lift to 1 mm (0.039 in).
4) Set crankshaft damper pulley Top Dead Center mark
about 45 before Top Dead Center from the pointer.
5) Set dial gauge in the 0 position.
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.
7) Turn the crankshaft in the normal direction and read
the measuring devices indication at TDC.
Starting Timing
mm(in.)
0.5 (0.02)
080ES002
080ES003
kgfm(lb.ft/Nm)
1.9 (13.7/18.6)
Injection Pump
Distributor Head Plug
kgfm(lb.ft/Nm)
1.7 (12.3/16.7)
25
MAINTENANCE
26
Standard
Limit
31 (441/3.04)
22 (313/2.157)
MAINTENANCE
RECOMMENDED LUBRICANTS
ENGINE TYPE
TYPES OF LUBRICANTS
Without turbocharger
With turbocharger
[Single grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
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SAE 20, 20W
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;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 40
;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;
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;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
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SAE 10W
SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
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Ambient
Temperature
30C
(22F)
15C
(5F)
0C
(32F)
15C
(59F)
25C 30C
(77F) (86F)
27
MAINTENANCE
19
2
17
18
14
15
13
19
10
11
12
1
6
19
7
9
8
16
*
*
*
28
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
*
*
*
*
*
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
ENGINE ASSEMBLY ( 1 )
SECTION 3
ENGINE ASSEMBLY ( 1 )
TABLE OF CONTENTS
ITEM
PAGE
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
29
ENGINE ASSEMBLY ( 1 )
ENGINE ASSEMBLY
GENERAL DESCRIPTION
This illustration is based on the A-4JA1 engine.
The A-4J Series of industrial engines features the unique ISUZU troidal square combustion chamber. This
design provides superior fuel economy for a wide range.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine
noise when the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable.
This type of gasket eliminates cylinder head bolt retightening.
The tufftrided crankshaft has a long service life. Because it is tufftrided, it cannot be reground.
The crankshaft main bearings and the connecting rod bearings are aluminum plated. These bearings are
especially sensitive to foreign material such as metal scraps. It is very important that the oil ports and
other related parts be kept clean and free of foreign material.
30
ENGINE ASSEMBLY ( 1 )
DISASSEMBLY
These disassembly steps are based on the A-4JA1 engine.
21
20
18
7 8
13
14
12
11
10
16
17
19
15
Disassembly Steps - 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
14.
15.
16.
17.
18.
19.
20.
21.
Intake manifold
Starter
Oil filter
Oil pressure switch
Cooling water rubber hose
Cooling water intake pipe
Front engine hanger
Exhaust manifold
31
ENGINE ASSEMBLY ( 1 )
2)
3)
2)
3)
Note:
Plug the injection pump delivery holder ports with the
shipping caps (or the equivalent) to prevent the entry of
foreign material.
32
ENGINE ASSEMBLY ( 1 )
13
10
12
5
11
16
17
14
Repair kit
15
Disassembly Steps - 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
12.
13.
14.
15.
16.
17.
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
ENGINE ASSEMBLY ( 1 )
16
15
7
6
14
4
3
11
13
12
3a
10
1a
Repair kit
Disassembly Steps - 3
1.
1a.
2.
3.
3a.
4.
5.
6.
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. Timing gear case
8. Connecting rod cap with
lower bearing
34
ENGINE ASSEMBLY ( 1 )
2)
9. Cylinder Head
14
6
10
15
11
13
17
16
7
3
12
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely effect the cylinder
head lower surface.
35
ENGINE ASSEMBLY ( 1 )
11. Crankshaft Damper Pulley with Dust Seal
1)
2)
2)
mm(in.)
Standard
Limit
0.100.17 (0.00390.0067)
0.30 (0.012)
36
mm(in.)
Standard
Limit
0.07 (0.0028)
0.30 (0.012)
ENGINE ASSEMBLY ( 1 )
1
4
5
3
1)
2)
2)
Note:
Be careful not to damage the camshaft journal, the cam,
and the camshaft during the disassembly procedure.
2)
If the connecting rod upper bearings are to be reinstalled, mark their fitting positions by tagging each
bearing with the cylinder number from which it was
removed.
37
ENGINE ASSEMBLY ( 1 )
10. Crankshaft Bearing Cap with Lower Bearing
1) Measure the crankshaft end play at the center
journal of the crankshaft.
Do this before removing the crankshaft bearing
caps.
If the measured value exceeds the specified
limit, the crankshaft thrust bearing must be
replaced.
Crankshaft End Play
2)
3
10
mm(in.)
Standard
Limit
0.10 (0.0039)
0.30 (0.0118)
14. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder
number from which it was removed.
38
ENGINE ASSEMBLY ( 1 )
DISASSEMBLY
SINGLE UNIT
ROCKER ARM SHAFT AND ROCKER ARM
6
7
5
1
4
3
Disassembly Steps
1. Rocker arm shaft snap ring
2. Rocker arm
3. Rocker arm shaft bracket
4. Rocker arm
39
ENGINE ASSEMBLY ( 1 )
Important Operations
2)
3)
40
ENGINE ASSEMBLY ( 1 )
CYLINDER HEAD
1
2
3
5
6
Disassembly Steps
1. Split collar
41
ENGINE ASSEMBLY ( 1 )
Important Operations
1. Split Collar
1)
2)
42
ENGINE ASSEMBLY ( 1 )
6
7
4
Disassembly Steps
1.
2.
3.
4.
5. Connecting rod
6. Piston pin snap ring
7. Piston
43
ENGINE ASSEMBLY ( 1 )
Important Operations
2. Piston Ring
1)
2)
5. Piston Pin
7. Piston
Tap the piston pin out with a hammer and a brass
bar.
If the pistons are to be reinstalled, mark their installation positions by tagging each piston with the
cylinder number from which it was removed.
44
ENGINE ASSEMBLY ( 1 )
4
3
2
1
Disassembly Steps
1. Camshaft timing gear
2. Thrust plate
3. Feather key
4. Camshaft
45
ENGINE ASSEMBLY ( 1 )
Important Operations
1)
2)
3)
46
ENGINE ASSEMBLY ( 2 )
SECTION 4
ENGINE ASSEMBLY ( 2 )
TABLE OF CONTENTS
ITEM
PAGE
47
ENGINE ASSEMBLY ( 2 )
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure
the four sides and the two diagonals of the cylinder
head lower face.
2. Regrind the cylinder head lower face if the measured values are greater than the specified limit but
less than the maximum grinding allowance.
If the measured values exceed the maximum grinding allowance, the cylinder head must be replaced.
A
E
mm(in)
Standard
Limit
Maximum Grinding
Allwance
0.05
(0.002) or less
0.2 (0.008)
0.3 (0.012)
mm(in)
Standard
Limit
91.65 (3.60)
Note:
If the cylinder head lower face is reground, valve
depression must be checked.
48
ENGINE ASSEMBLY ( 2 )
Manifold Fitting Face Warpage
mm (in)
Standard
Limit
Maximum Grinding
Allwance
0.05
(0.002) or less
0.2 (0.008)
0.4 (0.016)
VALVE GUIDE
Valve Stem and Valve Guide Clearance
Measuring Method - I
1. With the valve stem inserted in the valve guide, set
the dial indicator needle to 0.
2. Move the valve head from side to side.
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as a
set.
Valve Stem Clearance
mm(in)
Standard
Limit
Intake Valve
0.039 0.069
(0.0015 0.0027)
0.20
(0.008)
Exhaust Valve
0.064 0.096
(0.0025 0.0038)
0.25
(0.0098)
Measuring Method - II
1. Measure the valve stem outside diameter.
Refer to the Item Valve Stem Outside Diameter.
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.
49
ENGINE ASSEMBLY ( 2 )
Valve Guide Installation
1. Apply engine oil to the valve guide outer circumference.
2. Attach the valve guide replacer to the valve guide.
3. Use a hammer to drive the valve guide into position
from the cylinder head upper face.
Valve Guide Replacer: 9-8523-1212-0
mm(in)
13.0 (0.512)
H
Note:
If the valve guide has been removed, both the valve and
the valve guide must be replaced as a set.
mm(in)
Standard
Limit
Intake Valve
7.949 7.961
(0.3129 0.3134)
7.88
(0.3102)
Exhaust Valve
7.921 7.936
(0.3118 0.3124)
7.88
(0.3102)
Valve Thickness
Measure the valve thickness.
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Intake and Exhaust Valve Thickness
50
mm(in)
Standard
Limit
1.8 (0.071)
1.5 (0.059)
ENGINE ASSEMBLY ( 2 )
Valve Depression
2
Valve Depression
mm(in)
Standard
Limit
Intake
0.73 (0.029)
1.28 (0.050)
Exhaust
0.70 (0.028)
1.20 (0.047)
mm(in)
Standard
Limit
Intake
1.7 (0.067)
2.2 (0.087)
Exhaust
2.0 (0.079)
2.5 (0.098)
51
ENGINE ASSEMBLY ( 2 )
3. Use a screwdriver 3 to pry the valve seat insert
free.
Take care not to damage the cylinder head 4 .
4. Carefully remove carbon and other foreign material
from the cylinder head insert bore.
150
90
30
45
Note:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
52
ENGINE ASSEMBLY ( 2 )
3. Apply abrasive compound to the valve seat insert
surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
VALVE SPRING
Valve Spring Free Height
Use a vernier caliper to measure the valve spring free
height.
If the measured value is less than the specified limit, the
valve spring must be replaced.
Valve Spring Free Height
mm(in)
Standard
Limit
49.7 (1.96)
48.2 (1.90)
Square
mm(in)
Standard
Limit
2.5 (0.098)
kgf(lb/N)
Compressed Height
Standard
Limit
32.6
(71.9/319.6)
29.0
(63.9/284.4)
53
ENGINE ASSEMBLY ( 2 )
mm(in)
Standard
Limit
0.2 (0.008)
0.6 (0.024)
mm(in)
Standard
Limit
18.85 (0.742)
mm(in)
Standard
Limit
19.05 (0.750)
54
mm(in)
Standard
Limit
0.2 (0.008)
ENGINE ASSEMBLY ( 2 )
3. Check that the rocker arm oil port is free of obstructions.
If necessary, use compressed air to clean the rocker
arm oil port.
CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner.
Refer to Cylinder Liner Replacement.
Standard
Limit
0.2 (0.008)
A
E
mm(in)
55
ENGINE ASSEMBLY ( 2 )
Cylinder Body Height (Reference)
mm(in)
Standard
247.945 248.105 (9.7616 9.7679)
4. Reinstall the cylinder liner.
Refer to Cylinder Body Bore Measurement.
5. Reinstall the cylinder body dowel.
X
Y
Y
X
mm(in)
Standard
Limit
93.10 (3.665)
Note:
The inside of the dry type cylinder liner is chrome
plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or scorched,
the cylinder liner must be replaced.
mm(in)
Standard
2
0 0.10 (0 0.0039)
The difference in the cylinder liner projection height
between any two adjacent cylinders must not
exceed 0.03 mm (0.0012 in).
56
ENGINE ASSEMBLY ( 2 )
Cylinder Liner Replacement
mm(in)
X
W
Y
Z
X
95
Cylinder Body
Bore Diameter
Liner Grade
95.001 95.010
(3.74019 3.74055)
95.011 95.020
(3.74059 3.74094)
95.021 95.030
(3.74098 3.74133)
95.031 95.040
(3.74138 3.74173)
57
ENGINE ASSEMBLY ( 2 )
Cylinder Liner Installation
1. Cylinder Liner Installation Using The Special Tool.
1) Use new kerosene or diesel oil to thoroughly
clean the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder
liner and bore surfaces.
Note:
All foreign material must be carefully removed from the
cylinder liner and the cylinder bore before installation.
3) Insert the cylinder liner 1 into the cylinder body
2 from the top of the cylinder body.
1
2
58
ENGINE ASSEMBLY ( 2 )
WARNING:
DRY ICE MUST BE USED WITH GREAT CARE. CARELESS HANDLING OF DRY ICE CAN RESULT IN SEVERE
FROSTBITE.
Piston Selection
Select the same grade number as the one for the
cylinder liner inside diameter.
Grade of cylinder
inside diameter
Grade of piston
Combination
AX
AX
OK
CX
CX
OK
AX
CX
NG
CX
AX
NG
59
ENGINE ASSEMBLY ( 2 )
Y
Z
Y
W
X
1
Calculate the average value of the eight measurements to determine the correct cylinder liner bore.
Measuring Points 1 : 20 mm (0.79 in) for all A-4J models
2 : 140 mm (5.51 in) for A-4JA1
160 mm (6.30 in) for A-4JB1
Cylinder Liner Bore
mm(in)
Standard
Limit
93.10 (3.665)
Note:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will result
in engine failure.
mm(in)
Piston Outside Diameter
4JA1
4JB1
AX
92.979 92.994
(3.6606 3.6611)
92.989 93.004
(3.6610 3.6615)
CX
92.995 93.010
(3.6612 3.6618)
93.005 93.020
(3.6616 3.6622)
mm(in)
60
ENGINE ASSEMBLY ( 2 )
1
2
3
4
5
Pitting
Cracking
Normal contact
Irregular contact
Irregular contact
Note:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort to
repair the tappet. If the tappet is damaged, it must be
replaced.
mm(in)
Standard
Limit
12.95 (0.5098)
61
ENGINE ASSEMBLY ( 2 )
Tappet and Cylinder Body Clearance
mm(in)
Standard
Limit
0.03 (0.0012)
0.1 (0.0039)
mm(in)
Limit
0.3 (0.012)
CAMSHAFT
Visually inspect the journals, the cams, the oil pump
drive gear, and the camshaft bearings for excessive
wear and damage. The camshaft and the camshaft
bearings must be replaced if these conditions are
discovered during inspection.
62
mm(in)
Standard
Limit
49.945 49.975
(1.9663 1.9675)
49.60
(1.953)
ENGINE ASSEMBLY ( 2 )
Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the
camshaft must be replaced.
H
Cam Height H
mm(in)
Standard
Limit
42.08 (1.65)
41.65 (1.64)
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit,
the camshaft must be replaced.
Camshaft Run-Out
mm(in)
Standard
Limit
0.02 (0.0008)
0.10 (0.004)
mm(in)
Standard
Limit
50.0 50.03
(1.9685 1.9697)
50.08
(1.9716)
mm(in)
Standard
Limit
0.05 (0.002)
0.12 (0.005)
63
ENGINE ASSEMBLY ( 2 )
Camshaft Bearing Installation
1. Align the bearing oil holes with the cylinder body oil
holes.
2. Use the camshaft bearing replacer installer to install
the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
3
2
mm(in)
Standard
Limit
0.2 (0.008)
kgfm(lb.ft/Nm)
64
ENGINE ASSEMBLY ( 2 )
Judgment
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty seconds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.
2. Steam clean the crankshaft surface immediately
after completing the test.
65
ENGINE ASSEMBLY ( 2 )
Note:
The ammonium cuprous chloride solution is highly corrosive. Because of this, it is imperative that the surfaces
being tested be cleaned immediately after completing
the test.
Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft
journal.
2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit,
the crankshaft must be replaced.
Crankshaft Run-Out
mm(in)
Standard
Limit
0.08 (0.0031)
Bearing Tension
Check to see if the bearing has enough tension, so that a
good finger pressure is needed to fit the bearing into
position.
1
2
2
1
66
ENGINE ASSEMBLY ( 2 )
Crankshaft Journal Diameter
mm(in)
Standard
Limit
A-4JA1
59.917 59.932
(2.3589 2.3595)
59.910
(2.3587)
A-4JB1
69.917 69.932
(2.7526 2.7531)
69.910
(2.7524)
Crankpin Diameter
mm(in)
Standard
Limit
52.906 (2.0829)
mm(in)
Standard
Limit
0.08 (0.0031)
kgfm(lb.ft./Nm)
mm(in)
Standard
Limit
0.11 (0.0043)
kgfm(lb.ft/Nm)
67
ENGINE ASSEMBLY ( 2 )
Crankpin and Bearing Clearance
If the clearance between the measured bearing inside
diameter and the crankpin exceeds the specified limit,
the bearing and/or the crankshaft must be replaced.
Crankpin and Bearing Clearance
mm(in)
Standard
Limit
0.10 (0.0039)
kgfm(lb.ft/Nm)
68
ENGINE ASSEMBLY ( 2 )
9. Compare the width of the Plastigage attached to
either the crankshaft or the bearing against the scale
printed on the Plastigage container.
If the measured value exceeds the limit, perform the
following additional steps.
1) Use a micrometer to measure the crankshaft
outside diameter.
2) Use an inside dial indicator to measure the
bearing inside diameter.
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the
bearing must be replaced.
Crankshaft Journal and Bearing Clearance
Standard
Limit
0.035 0.080
(0.0014 0.0036)
0.11
(0.0043)
mm(in)
69
ENGINE ASSEMBLY ( 2 )
5. Install the bearing cap and tighten it to the specified
torque.
Do not allow the connecting rod to move when
installing and tightening the bearing cap.
Connecting Rod Bearing Cap Bolt
Torque
kgfm(lb.ft/Nm)
mm(in)
Standard
Limit
0.029 0.066
(0.0011 0.0026)
0.10
(0.0039)
70
ENGINE ASSEMBLY ( 2 )
71
ENGINE ASSEMBLY ( 2 )
Flywheel
1. Inspect the flywheel friction surface for excessive
wear and heat cracks.
2. 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.
There will be a ridge on the flywheel surface area.
Be sure to measure the surface wear in the area
inside the ridge.
If the measured value is between the standard and
the specified limit, the flywheel may be reground.
If the measured value exceeds the specified limit,
the flywheel must be replaced.
Flywheel Friction Surface Depth 1
mm(in)
Limit
1.0 (0.04) or more
Note:
Because a ridge is produced at the flywheel friction surface as illustrated, 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.
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.
72
ENGINE ASSEMBLY ( 2 )
Ring Gear Installation
1. Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200C (390F).
2. Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer
facing the clutch.
Note:
Another method of heating the ring gear to invite thermal expansion is to soak a rag in diesel fuel, wrap the
diesel fuel soaked rag around the rim of the ring gear,
and then light the rag.
PISTON
Piston Grade Selection and Cylinder Liner Bore
Measurement
Refer to the Section CYLINDER BODY, Item Cylinder
Liner Bore Measurement for details on piston grade
selection and cylinder or liner bore measurement.
PISTON RING
Piston Ring Gap
1. Insert the piston ring horizontally into the cylinder
liner.
2. 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.
Cylinder liner diameter is the smallest at these two
points.
Do not allow the piston ring to slant to one side or
the other. It must be perfectly horizontal.
3. Use a feeler gauge to measure the piston ring gap.
2
1
or
73
ENGINE ASSEMBLY ( 2 )
Piston Ring Gap
mm(in)
Standard
1 s t Compression Ring
2nd Compression Ring
Oil Ring
0.20 0.40
(0.008 0.016)
0.10 0.30
(0.004 0.012)
Limit
1.5
(0.059)
0.090 0.125
(0.0035 0.0049)
0.050 0.075
(0.002 0.003)
Oil Ring
mm(in)
Limit
0.15
(0.006)
0.030 0.070
(0.0012 0.0028)
74
ENGINE ASSEMBLY ( 2 )
PISTON PIN
Piston Pin Diameter
Use a micrometer to measure the piston pin outside
diameter at several points.
If the measured value is less than the specified limit, the
piston pin must be replaced.
Piston Pin Diameter
mm(in)
Standard
Limit
31.0 (1.220)
30.97 (1.219)
mm(in)
Standard
29.002 29.007
mm(in)
mm(in)
Standard
Limit
0.008 0.020
(0.0003 0.0008)
0.05
(0.002)
75
ENGINE ASSEMBLY ( 2 )
Connecting Rod Bushing Installation
1. Clamp the connecting rod in a vice.
2. Use the connecting rod bushing installer to install
the connecting rod bushing.
Connecting Rod Bushing Replacer:
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.
If either the measured distortion or parallelism exceed
the specified limit, the connecting rod must be replaced.
Connecting Rod Alignment
Per Length of 100 mm (3.94 in)
Standard
Distortion
Parallelism
76
0.05 or Less
(0.002)
mm(in)
Limit
0.20
(0.008)
0.15
(0.006)
ENGINE ASSEMBLY ( 2 )
Connecting Rod Side Face Clearance
1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance
between the connecting rod big end side face and
the crankpin side face.
If the measured value exceeds the specified limit,
the connecting rod must be replaced.
Connecting Rod and Crankpin Side Face
Clearance
mm(in)
Standard
Limit
0.23 (0.009)
0.35 (0.014)
mm(in)
Standard
Limit
44.95 44.98
(1.770 1.771)
44.90
(1.767)
77
ENGINE ASSEMBLY ( 2 )
Idler Gear A Inside Diameter
1. Use an inside dial indic ator to measure the idler
gear
Idler Gear Inside Diameter
mm(in)
Standard
Limit
45.0 45.03
(1.7717 1.7728)
45.10
(1.7756)
mm(in)
Standard
Limit
0.025 0.085
(0.0010 0.0033)
0.2
(0.008)
Idler Gear B
Bearing replacement
Use a suitable bar and a bench press or hammer.
1
2
Height
78
ENGINE ASSEMBLY ( 2 )
79
MEMO
80
ENGINE ASSEMBLY ( 3 )
SECTION 5
ENGINE ASSEMBLY ( 3 )
TABLE OF CONTENTS
ITEM
PAGE
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
81
ENGINE ASSEMBLY ( 3 )
REASSEMBLY
SINGLE UNIT
ROCKER ARM SHAFT AND ROCKER ARM
3
4
5
6
1
Reassembly Steps
1. Rocker arm shaft
82
5. Rocker arm
6. Rocker arm shaft spring
7. Rocker arm shaft snap ring
ENGINE ASSEMBLY ( 3 )
Important Operations
83
ENGINE ASSEMBLY ( 3 )
CYLINDER HEAD
7
6
5
3
2
Reassembly Steps
1.
2.
3.
4.
84
Cylinder head
Valve spring lower washer
Valve stem oil seal
Intake and exhaust valve
5. Valve spring
6. Valve spring upper seat
7. Split collar
ENGINE ASSEMBLY ( 3 )
Important Operations
5. Valve Spring
1) Turn the cylinder head up to install the valve
springs.
2) Install the valve springs with the fine pitched
end (painted pink) facing down.
Take care not to allow the installed valves to fall
free.
7. 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.
3) Set the split collar by tapping around the bead
of the collar with a rubber hammer.
85
ENGINE ASSEMBLY ( 3 )
2
1
4
Reassembly Steps
86
1.
2.
3.
4.
Piston
Piston pin snap ring
Connecting rod
Piston pin
ENGINE ASSEMBLY ( 3 )
Important Operations
1. Piston
2. Piston pin snap ring
3. Connecting rod
1) Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2) Use a pair of snap ring pliers to install the piston
pin snap ring to the piston.
The piston head front mark 1 and the connecting rod ISUZU casting mark 2 must be
facing the same direction.
2
4. Piston pin
1) Apply a coat of engine oil to the piston pin and
the piston pin hole.
2) Use your fingers to force the piston pin into the
piston until it makes contact with the snap ring.
87
ENGINE ASSEMBLY ( 3 )
6. Piston Ring
3
88
ENGINE ASSEMBLY ( 3 )
1
2
3
4
Reassembly Steps
1. Camshaft
2. Feather key
3. Thrust plate
4. Camshaft timing gear
89
ENGINE ASSEMBLY ( 3 )
Important Operations
kgfm(lb.ft/Nm)
90
ENGINE ASSEMBLY ( 3 )
MEMO
91
ENGINE ASSEMBLY ( 3 )
REASSEMBLY
13
7
8
2
14
15
5
3
15a
10
11
12
16a
16
Repair kit
Reassembly Steps 1
Cylinder body
Tappet
Crankshaft upper bearing
Crankshaft with crankshaft timing gear
Crankshaft thrust bearing
Crankshaft bearing cap with lower
bearing
7. Timing gear case
8. Camshaft with camshaft timing gear
and thrust plate
9. Piston and connecting rod with upper
bearing
92
1.
2.
3.
4.
5.
6.
10.
11.
12.
13.
14.
15.
15a
16.
16a
Inverted Engine
ENGINE ASSEMBLY ( 3 )
17
14
11
13
10
12
15
7
16
Repair kit
Reassembly Steps 2
1. Idler gear shaft
2. Idler gear A
3. Idler gear B
seal
16. Injection nozzle holder
93
ENGINE ASSEMBLY ( 3 )
1. Cylinder Body
Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder body, the oil
holes, and the water jackets.
2. Tappet
1) Apply a coat of engine oil to the tappet 1 and
the cylinder body tappet insert holes 2 .
1
94
ENGINE ASSEMBLY ( 3 )
5. Crankshaft Thrust Bearing
1) Apply an ample coat of engine oil to the crankshaft thrust bearings.
2) Install the crankshaft thrust bearings to the
crankshaft center journal.
The crankshaft thrust bearing oil groove must
be facing the sliding face.
Nile
kgfm(lb.ft/Nm)
10
kgfm(lb.ft/Nm)
95
ENGINE ASSEMBLY ( 3 )
8. Camshaft with Camshaft Timing Gear and Thrust
Plate
1) Apply a coat of engine oil to the camshaft and
the camshaft bearings.
2) Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
3) Tighten the thrust plate to the specified torque.
Thrust Plate Bolt Torque
kgfm(lb.ft/Nm)
96
ENGINE ASSEMBLY ( 3 )
6) Position the piston head front mark so that it is
facing the front of the cylinder body.
7) Use a piston ring compressor to compress the
piston rings.
Piston Ring Compressor
8) Use a hammer grip to push the piston in until
the connecting rod makes contact with the
crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
9) Install the connecting rod bearing caps.
The bearing cap front marks must be facing the
front of the engine.
The bearing cap number (at the side of the
bearing cap) and the connecting rod number
must be the same.
Note:
It is absolutely essential that the bearing caps be
installed in the correct direction. 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.
11) Tighten the connecting rod caps to the specified
torque.
Connecting Rod Cap Bolt Torque
kgfm(lb.ft/Nm)
5
1
6
8
4
2
7
kgfm(lb.ft/Nm)
97
ENGINE ASSEMBLY ( 3 )
12. Oil Pump with Oil Pipe
Install the oil pump with the oil pipe and tighten the
bolts to the specified torque.
Oil Pump Bolt Torque
kgfm(lb.ft/Nm)
10
2) Tighten the flywheel housing bolts to the specified torque a little at a time in the sequence
shown in the illustration.
2
7
98
kgfm(lb.ft/Nm)
M10x1.25 (0.39x0.05)
M12x1.25 (0.47x0.05)
M12x1.75 (0.47x0.07)
ENGINE ASSEMBLY ( 3 )
15. Flywheel
1) Block the flywheel with a piece of wood to prevent it from turning.
1
4
5
8
2
kgfm(lb.ft/Nm)
5
1
kgfm(lb.ft/Nm)
4
2
7
3
99
ENGINE ASSEMBLY ( 3 )
2. Idler Gear A
1) Apply engine oil to the idler gear 1 and the
idler gear shaft 2 .
1
4
kgfm(lb.ft/Nm)
X
3
3. Idler Gear B
100
kgfm(lb.ft/Nm)
ENGINE ASSEMBLY ( 3 )
5. Timing Case Cover
1) Before installing the timing gear case, apply a 3
mm x 5 mm (0.12 in x 0.20 in) strip of liquid
gasket to the portion of the feather key indicated
by the arrow in the illustration.
2) Check that the timing case cover O-ring is firmly
inserted into the gear case groove.
3) Tighten the timing case cover bolts to the specified torque.
Timing Case Cover Bolt Torque
kgfm(lb.ft/Nm)
M 8x1.25 (0.31x0.05)
Bolt
M12x1.25 (0.47x0.05)
Bolt
kgfm(lb.ft/Nm)
Front
101
ENGINE ASSEMBLY ( 3 )
9. Cylinder Head
1) Align the cylinder body dowels and the cylinder
head dowel holes.
Carefully set the cylinder head to the cylinder
head gasket.
2) Apply engine oil to the cylinder head fixing bolt
threads and setting faces.
13
17
12
8
16
18
14
2
6
15
10
3
11
New Bolt
kgfm(lb.ft/Nm)
2nd Step
3.0 5.0
8.2 9.2
(21.736.1/29.449.0) (59.466.5/80.490.2)
8.0 9.0
10.0 11.0
Reused Bolt (57.965.1/78.488.2) (72.479.6/98.1107.9)
11. Rocker Arm Shaft and Rocker Arm
Tighten the rocker arm shaft bracket bolts in the
numerical order shown in the illustration.
Rocker Arm Shaft Bracket Bolt Torque
kgfm(lb.ft/Nm)
kgfm(lb.ft/Nm)
kgf.m(lb.ft/N.m)
102
ENGINE ASSEMBLY ( 3 )
15. Glow Plug and Glow Plug Connector
1) Tighten the glow plugs to the specified torque.
Glow Plug Torque
kgfm(lb.ft/Nm)
2
1
1) Install the injection nozzle gasket 1 and the Oring 2 to the injection nozzle holder 3 .
2) Install the nozzle holder 3 together with the
nozzle holder bracket 4 to the cylinder head.
3) Tighten the holder nuts with washer 5 to the
specified torque.
Injection Nozzle Holder Nut Torque
kgfm(lb.ft/Nm)
103
ENGINE ASSEMBLY ( 3 )
12
18
14
19
7 6
4
10
16
17
13
15
20
21
11
Reassembly Steps 3
1. Intake manifold
2. Injection pump
3. Fuel injection pump with clip
104
11. Starter
12. Exhaust manifold
13.
14.
15.
16.
17.
18.
19.
20.
21.
ENGINE ASSEMBLY ( 3 )
1. Intake Manifold
Install the intake manifold gasket with the end having the sharp corners facing the front of the engine.
2. 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 .
kgfm(lb.ft/Nm)
kgfm(lb.ft/Nm)
105
ENGINE ASSEMBLY ( 3 )
kgfm(lb.ft/Nm)
11. Starter
Tighten the starter bolts to the specified torque.
Starter Bolt Torque
kgfm(lb.ft/Nm)
kgf.m(lbft/Nm)
106
ENGINE ASSEMBLY ( 3 )
15. Alternator and Adjusting Plate
Tighten the alternator bolts and the adjusting plate
bolts to the specified torque.
Alternator Bolt Torque
kgfm(lb.ft/Nm)
kgfm(lb.ft/Nm)
kgfm(lb.ft/Nm)
107
MEMO
108
LUBRICATING SYSTEM
SECTION 6
LUBRICATING SYSTEM
TABLE OF CONTENTS
ITEM
PAGE
109
LUBRICATING SYSTEM
A-4JA1A-4JB1
Trochoid
Delivery volume
Lit(qts)/min.
Pump speed
Delivery pressure
1000
2
kgf/cm (psi/kPa)
Oil temperature
C(F)
Engine oil
4.0 (56.89/392.0)
47 53 (116.6 127.4)
SAE 30
kgf/cm (psi/kPa)
kgf/cm2(psi/kPa)
110
17.5 (18.4)
Water-cooled
2
kgf/cm (psi/kPa)
LUBRICATING SYSTEM
GENERAL DESCRIPTION
LUBRICATING OIL FLOW
Battery
Warning
Light
Idle gear
shaft
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
111
LUBRICATING SYSTEM
OIL PUMP
A-4J Series engine are equipped with a trochoid type oil pump.
The oil filter and the water cooled oil cooler are a single unit to increase the cooling effect.
112
LUBRICATING SYSTEM
113
LUBRICATING SYSTEM
OIL PUMP
DISASSEMBLY
4
3
051ET001
Disassembly Steps
1. Oil pipe
2. Strainer case
3. Pump cover
114
4. Vane
5. Pump body with rotor and pinion
LUBRICATING SYSTEM
mm(in)
Limit
0.15 (0.006)
mm(in)
Limit
0.20 (0.008)
mm(in)
Limit
0.40 (0.016)
115
LUBRICATING SYSTEM
REASSEMBLY
2
3
051ET002
Reassembly Steps
1. Pump body with rotor and pinion
2. Vane
3. Pump cover
116
4. Strainer case
5. Oil pipe
LUBRICATING SYSTEM
5
4
7
1
6
Disassembly Steps
1. Drain plug
2. Cartridge oil filter
3. Oil cooler
4. O-ring
5. Safety valve
6. Relief valve
7. Oil filter body
117
LUBRICATING SYSTEM
Relief Valve
1. Attach an oil pressure gauge to the oil gallery near
the oil filter.
2. Start the engine to check the relief valve opening
pressure.
Relief Valve Opening Pressure
kgf/cm2(psi/kPa)
Oil Cooler
Water Leakage At Water Passage
1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
3. Apply compressed air (2 kgf/cm2 (28.45 psi/196 kPa))
to the other side of the oil cooler water passage.
If air bubbles rise to the surface, there is water leakage.
118
LUBRICATING SYSTEM
REASSEMBLY
3
4
1
7
2
Reassembly Steps
1. Oil filter body
2. Relief valve
3. Safety valve
5. Oil cooler
6. Oil filter cartridge
7. Drain plug
4. O-ring
119
LUBRICATING SYSTEM
Important Operations
2. Relief Vale
Tighten the relief valve to the specified torque.
Relief Valve Torque
kgfm(lb.ft/Nm)
2.5 3.5 (18.1 25.3/24.5 34.3)
5. Oil Cooler
1) Align the oil filter holes with the body knock
pins at installation.
2) Tighten the oil cooler to the specified torque.
Oil Cooler Torque
kgfm(lb.ft/Nm)
2.5 3.5 (18.1 25.3/24.5 34.3)
7. Drain Plug
Tighten the drain plug to the specified torque.
Drain Plug Torque
kgfm(lb.ft/Nm)
1.0 2.0 (7.2 14.4/9.8 19.6)
120
COOLING SYSTEM
SECTION 7
COOLING SYSTEM
TABLE OF CONTENTS
ITEM
PAGE
121
COOLING SYSTEM
122
Centrifugal impeller
1.1
100 (105.5)
COOLING SYSTEM
GENERAL DESCRIPTION
COOLANT FLOW
The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated
by the water pump and thermostat through the by-pass hose and back to the cylinder body. The coolant
does not circulate through the radiator.
When the coolant temperature reaches 82C (180F), the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the radiator.
The thermostat will be fully open when the coolant temperature reaches 95C (203F). All of the coolant is
now circulating through the radiator for effective engine coolant.
123
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.
124
COOLING SYSTEM
WATER PUMP
DISASSEMBLY
1
4
7
5
Disassembly Steps
1.
2.
3.
4.
O-ring
Set screw
Cooling fan center
Impeller and seal unit
5.
6.
7.
Bearing unit
Thrower
Water pump body
125
COOLING SYSTEM
Important Operations
126
COOLING SYSTEM
Bearing Unit
Check the bearing for abnormal noise, biding, and other
abnormal conditions.
127
COOLING SYSTEM
REASSEMBLY
7
5
1
3
Reassembly Steps
1.
2.
3.
4.
128
5.
6.
7.
COOLING SYSTEM
Important Operations
3.
Bearing Unit
4.
Set Screw
1) Align the bearing set screw hole with the pump
body set screw hole.
2) Press the bearing unit into place.
3) Secure the bearing with the set screw.
5.
3)
Impeller Projection
mm(in.)
25.0 (0.98)
6.
mm(in.)
129
COOLING SYSTEM
Note:
1. The fan center and the impeller are installed to the
water pump shaft with a press.
Never attempt to remove and reinstall the fan center
and the impeller a second time. Replace the entire
water pump assembly.
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.
2. The water pump assembly must be replaced
whenever the fan center and impeller pressure force
falls below 200 kgf (1.96 kN).
3. Do not attempt to strike the bearing into position
with a hammer or similar object. Damage to the
bearing will result.
130
COOLING SYSTEM
THERMOSTAT
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.
Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3.
C(F)
82 (180)
4.
C(F)
95 (203)
Valve Lift at Fully Open Position
mm(in.)
8.0 (0.315)
1 Thermostat
2 Agitating Rod
3 Wooden Piece
131
MEMO
132
FUEL SYSTEM
SECTION 8
FUEL SYSTEM
TABLE OF CONTENTS
ITEM
PAGE
133
FUEL SYSTEM
134
Bosch A type
9.0 (0.35)
3.25 3.35 (0.128 0.132)
RSV variable speed mechanical type
Single action
Hole type
4
1.0 (0.039)
185 (2,630/18.1)
Cartridge paper element water separator
Water separator (if so equipped)
FUEL SYSTEM
GENERAL DESCRIPTION
COOLANT FLOW
Fuel
filter
Nozzle
Water separator
Injection
pump
Fuel tank
The fuel system consists of the fuel tank, the water separator (if so equipped), the fuel filter, the injection
pump, and the injection nozzle.
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.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the
optimum timing for efficient engine operation.
135
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. It consists of the nozzle body and the needle valve
assembly.
The injection nozzle sprays pressurized fuel from the injection pump into the combustion chamber
through the nozzle body injection orifice.
136
FUEL SYSTEM
Drain Level
137
FUEL SYSTEM
INJECTION NOZZLE
DISASSEMBLY
6
5
4
3
2
Disassembly Steps
1.
2.
3.
4.
138
Retaining nut
Injection nozzle
Spacer
Spring seat
5.
6.
7.
Spring
Adjusting shim
Nozzle holder
FUEL SYSTEM
Important Operations
Injection Nozzle
1)
2)
139
FUEL SYSTEM
2.
3.
2.
140
FUEL SYSTEM
REASSEMBLY
2
3
4
5
6
Reassembly Steps
1.
2.
3.
4.
Nozzle holder
Adjusting shim
Spring
Spring seat
5.
6.
7.
Spacer
Injection nozzle
Retaining nut
141
FUEL SYSTEM
Important Operations
3.
Adjust Shim
0.50-0.50 (0.02-0.06)
Increment
0.025 (0.001)
7.
mm(in.)
40
Retaining Nut
Tighten to the retaining nut to the specified torque.
kgfm(lbs.ft./Nm)
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN
EASILY PUNCTURE A PERSONS SKIN. KEEP YOUR
HANDS AWAY FROM THE INJECTION NOZZLE TESTER
AT ALL TIMES.
142
FUEL SYSTEM
kgf/cm2(psi/MPa)
mm(in.)
kgf/cm2(psi/kPa)
C(F)
143
FUEL SYSTEM
INJECTION QUANTITY
Adjusting
Point
Injection
Quantity
(cc/1000
Strokes)
Maximum
Variation
(%)
Fixed
Remarks
8.3
1,500
64 65
2.5
Lever Basic
About 6.6
500
9.5 13.5
15.0
Rack
Above 14.0
100
(70 85)
Lever
GOVERNOR ADJUSTMENT
Full Adjustment
Above 14.0
D
Idle-sub spring setting
13.0
7.80.1
500
6.3
4.30.4
16030 250
500 (610)
(1535)1545 1610
144
FUEL SYSTEM
Speed Lever Angle
353
125
Stop
255
145
MEMO
146
ENGINE ELECTRICALS
SECTION 9
ENGINE ELECTRICALS
TABLE OF CONTENTS
ITEM
PAGE
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
147
ENGINE ELECTRICALS
STARTER
STARTER IDENTIFICATION
3
12V
HITACHI
MADE IN JAPAN
1
2
3
24V
HITACHI
3 Rated voltage
4 Manufacturers 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. Use of the wrong service data will
result in starter damage.
148
ENGINE ELECTRICALS
V
kW
Sec
8-97084-877-0
8-94423-452-0
S13-11
S24-07
12
2.2
24
3.5
30
Clockwise
Roller
V
A
11
160
23
90
rpm
3900
3100
Pinion gear
Modules
Number of teeth
Outside diameter
Travel distance
mm(in.)
mm(in.)
2.75
9
33.0 (4.3)
1.51 (0.059)
mm(in.)
80.0 (3.15)
Number of poles
Magnetic switch (at 20C [68F])
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
mm(in.)
mm(in.)
kgf(lb./N)
mm(in.)
mm(in.)
0.27
1.25
15.0 (0.59)
9.0 (0.35)
15.0 (0.59)
9.0 (0.35)
(3.52/15.74.4/19.6)
(2.5/24.57.7/34.3)
30.0 (1.18)
29.0 (1.14)
36.5 (1.44)
35.5 (1.40)
mm(in.)
0.05 (0.002)
mm(in.)
mm(in.)
mm(in.)
0.10 (0.004)
0.5 0.8 (0.02 0.03)
0.2 (0.008)
149
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
6
2
18
13
12
16
19
15 14
17
20
1
8
9
10
11
Disassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Lead wire
Bolt
Magnetic switch
Torsion spring
Plunger
Shim
Through bolt
Rear cover
Brush holder
Yoke
11.
12.
13.
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.
153
ENGINE ELECTRICALS
ARMATURE
154
ENGINE ELECTRICALS
mm(in.)
Standard
Limit
0.02 (0.0008)
0.05 (0.002)
mm(in.)
Standard
Limit
S13 11
30.0 (1.18)
29.0 (1.14)
S24 07
36.5 (1.44)
35.5 (1.40)
mm(in.)
Standard
Limit
0.5 0.8
(0.02 0.03)
0.2 (0.008)
Bearing Inspection
Visually inspect the bearing.
If the bearing is worn or damaged, it must be replaced.
155
ENGINE ELECTRICALS
YOKE
Field Winding Ground Test
Use a circuit tester to check the field winding ground.
1. Touch one probe to the brush field winding end.
2. Touch the other probe to the bare surface of the
yoke body.
There should be no continuity.
If there is continuity, the field windings are grounded.
Repair or replace the field windings.
156
mm(in.)
Standard
Limit
20.0 (0.79)
13.0 (0.51)
ENGINE ELECTRICALS
PINION CLUTCH
Pinion Inspection
Use your hand to turn the pinion in the direction of starter motor rotation. The pinion should turn freely.
Try to turn the pinion in the opposite direction. The
pinion should lock.
MAGNETIC SWITCH
Check for continuity across the magnetic switch S
terminal and coil case. If no continuity exists, the shunt
coil is open and should be replaced.
157
ENGINE ELECTRICALS
Check for continuity across magnetic switch S terminal and M terminal. If no continuity exists, series coil
are open and should be replaced.
158
ENGINE ELECTRICALS
REASSEMBLY
2
7
8
13
14
10
11 12
19
9
5
20
18
17
16
15
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Magnetic switch
Shim
Plunger
Torsion spring
Shift lever
Dust cover
Bolt
Overrunning clutch
Pinion
Return spring
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Pinion stopper
Snap ring
Bearing retainer
Bolt
Armature
Yoke
Brush holder
Rear cover
Through bolt
Lead wire
159
ENGINE ELECTRICALS
Important Operations
4. Torsion Spring
5. Shift Lever
Set the torsion spring to the hole in magnetic
switch.
Insert the shift lever, via the torsion spring, into
plunger hole in the magnetic switch.
6. Dust Cover
Install the magnetic switch in gear case.
Make sure to install the dust cover.
Dust Cover Bolt Torque
kgfm(lb.ft./Nm)
9. Pinion
Install the pinion after applying grease to the reduction gear.
160
ENGINE ELECTRICALS
19. Through Bolt
Tighten the through bolts to the specified torque a
little at a time.
Through Bolt Torque
kgfm(lb.ft./Nm)
kgfm(lb.ft./Nm)
mm(in.)
0.3 1.5 (0.012 0.060)
161
ENGINE ELECTRICALS
ALTERNATOR
ALTERNATOR IDENTIFICATION
3 Rated output
4 Manufacturers production mark
Note:
Always check the identification number before beginning a service operation.
Applicable service data will vary according to the identification number. Use of the wrong service data will
result alternator damaged.
162
ENGINE ELECTRICALS
A 4J Series
Manufacturers name
HITACHI
V
A
rpm
A/V/rpm
V/rpm
8-94423-756-0
8-94431-560-0
5-81200-335-0
LR135-127
LR215-50
LR200-24
12
35
100013500
33-37/13.5/5000
13.5/1000 or less
24
15
10005000
15/27/5000
27/1000 or less
24
20
100013500
20/27/5000
27/1000 or less
Brush length
Standard
Limit
mm(in.)
mm(in.)
mm(in.)
mm(in.)
Shaft diameter
Front
Rear
mm(in.)
mm(in.)
Regulator(s) applicable
Isuzu Part No.
Manufacturer(s) code No.
Clockwise
Negative
80 (3.15)
3.11
0.13
18.2
0.199
12.72
0.402
14.5 (0.57)
7.5 (0.30)
16.0 (0.63)
7.0 (0.28)
14.5 (0.57)
7.5 (0.30)
31.6 (1.24)
30.6 (1.20)
15.0 (0.59)
12.0 (0.47)
17.0 (0.70)
12.0 (0.47)
15.0 (0.59)
12.0 (0.47)
5-81270-004-0
TR1Z-63
Built-in
5-81251-016-0
TR2Z-47
5-81251-016-0
TR2Z-47
163
ENGINE ELECTRICALS
GENERAL DESCRIPTION
The alternator consists of the front cover, the rotor, the stator, the built-in IC regulator (some engines use a
Tirrell alternator with separate regulator), and the rear cover.
This small size and light weight alternator provides excellent reliability. Its simple construction makes it
very easy to service. The built-in IC regulator minimizes circuit wiring.
164
ENGINE ELECTRICALS
DISASSEMBLY
These disassembly steps are based on the built-in IC regulator type.
5
6
7
3
8
4
12
11
1
10
Disassembly Steps
1.
2.
3.
4.
5.
6.
Through bolt
Rear cover and stator
Pulley and fan
Spacer collar
Rotor with bearing
Bearing retainer
7.
8.
9.
10.
11.
12.
Ball bearing
Front cover
Stator
Rectifier with brush holder
IC regulator
Rear cover
165
ENGINE ELECTRICALS
Important Operations
8. Front Cover
Use screwdrivers to pry the front cover 1 from the
stator 2.
Note:
Do not attempt to pry the coil wires from the stator.
9. Stator
10. Rectifier with Brush Holder
Use a soldering iron 1 and a pair of long nose pliers
2 to remove the rectifiers.
166
Note:
ENGINE ELECTRICALS
Ball Bearing
Check that the ball bearings rotate smoothly.
If the ball bearings are noisy, they must be replaced.
mm(in.)
Standard
Limit
31.6 (1.24)
30.6 (1.20)
167
ENGINE ELECTRICALS
STATOR COIL
Stator Coil Continuity Test
Use an circuit tester to test the stator coil continuity.
1. Touch the circuit tester probes to two of the bare
stator wires.
2. Note the circuit tester reading.
3. Move one of the circuit tester probes to a third wire.
168
ENGINE ELECTRICALS
4. Note the circuit tester reading.
If the two readings (Steps 2 and 4) are identical, the
stator coil has continuity.
If the two circuit tester readings are different, there
is no stator continuity.
5. Check the neutral junction (arrow mark) for breaks.
If breaks are found, repair and repeat the stator coil
continuity test.
If there is still no stator coil continuity, the stator
must be replaced.
RECTIFIER
BAD
GOOD
169
ENGINE ELECTRICALS
3. Note the meter reading for each diode terminal.
All of the diode should show continuity.
If a diode shows no continuity, it is open circuit. The
rectifier assembly must be replaced.
BAD
GOOD
BAD
170
ENGINE ELECTRICALS
Note:
1. The stator lead wires must be cut to the proper
length before they are connected to the rectifier
lead wires. If the stator lead wires are too long or
too short, trouble may occur.
Stator Lead Wire Length
mm(in.)
33.5 (1.32)
2. Take care not to damage the rectifier paint surfaces.
BRUSH
Use a vernier caliper to measure the brush.
If the measured value exceeds the limit, the brush must
be replaced.
Brush Length
mm(in.)
Standard
Limit
8-94423-756-0
14.5 (0.57)
7.5 (0.30)
8-94431-560-0
16.0 (0.63)
7.0 (0.28)
5-81200-335-0
14.5 (0.57)
7.5 (0.30)
171
ENGINE ELECTRICALS
REASSEMBLY
9
8
7
11
6
10
1
2
12
Reassembly Steps
1.
2.
3.
4.
5.
6.
172
Rear cover
IC regulator
Rectifier with brush holder
Stator
Rear cover and stator
Front cover
7.
8.
9.
10.
11.
12.
Ball bearing
Bearing retainer
Rotor with bearing
Spacer collar
Pulley and fan
Through bolt
ENGINE ELECTRICALS
Important Operations
kgfm(lb.ft./Nm)
173
MEMO
174
TROUBLESHOOTING
SECTION 10
TROUBLESHOOTING
TABLE OF CONTENTS
ITEM
PAGE
175
TROUBLESHOOTING
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair engine problems.
Each troubleshooting chart has three headings arranged from left to right.
(1)
Checkpoint
(2)
Trouble Cause
(3)
Countermeasure
Hard Starting
1) Starter inoperative
2) Starter operates but engine does not turn over
3) Engine turns over but does not start
2.
Unstable Idling
3.
Insufficient Power
4.
5.
6.
Overheating
7.
8.
9.
10.
176
TROUBLESHOOTING
1.
1.
Checkpoint
Battery
HARD STARTING
STARTER INOPERATIVE
Trouble Cause
NG
NG
NG
NG
Countermeasure
NG
NG
NG
NG
OK
Fusible link
NG
NG
OK
Starter switch
NG
NG
NG
NG
OK
Starter
OK
Starter
NG
Defective starter
NG
177
TROUBLESHOOTING
1.
2.
HARD STARTING
Checkpoint
Battery
Trouble Cause
NG
NG
NG
Countermeasure
NG
NG
NG
OK
Starter
NG
NG
NG
NG
NG
Brush wear
Weak brush spring
NG
NG
NG
OK
Engine
178
TROUBLESHOOTING
1.
3.
HARD STARTING
Checkpoint
Trouble Cause
NG
NG
Countermeasure
NG
NG
Fuel
NG
NG
OK
Fuel piping
NG
NG
NG
NG
NG
OK
Fuel filter
NG
OK
Fuel system
NG
NG
179
TROUBLESHOOTING
1.
3.
HARD STARTING
Trouble Cause
Countermeasure
Injection nozzle
NG
NG
OK
Injection pump
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
OK
180
TROUBLESHOOTING
2.
Checkpoint
Idling system
UNSTABLE IDLING
Trouble Cause
NG
Countermeasure
NG
OK
NG
NG
NG
NG
OK
OK
Fuel system
NG
NG
NG
NG
NG
NG
OK
Fuel filter
NG
NG
181
TROUBLESHOOTING
2.
Checkpoint
UNSTABLE IDLING
Trouble Cause
Countermeasure
Injection pump
NG
NG
NG
NG
NG
NG
NG
182
Worn plunger
NG
NG
NG
NG
NG
NG
NG
TROUBLESHOOTING
2.
Checkpoint
UNSTABLE IDLING
Trouble Cause
Countermeasure
Valve clearance
NG
NG
OK
Compression pressure
NG
NG
183
TROUBLESHOOTING
3.
Checkpoint
Air cleaner
INSUFFICIENT POWER
Trouble Cause
NG
Countermeasure
NG
OK
Fuel
NG
NG
OK
Fuel filter
NG
NG
NG
OK
NG
OK
Injection nozzle
NG
NG
NG
NG
OK
184
NG
NG
TROUBLESHOOTING
3.
Checkpoint
INSUFFICIENT POWER
Trouble Cause
Countermeasure
Injection pump
NG
NG
NG
NG
NG
NG
NG
Defective timer
NG
NG
NG
NG
NG
NG
NG
185
TROUBLESHOOTING
3.
Checkpoint
INSUFFICIENT POWER
Trouble Cause
Countermeasure
Injection pump
NG
NG
NG
NG
Worn plunger
NG
NG
NG
NG
OK
Turbocharger
NG
NG
NG
186
NG
NG
NG
TROUBLESHOOTING
3.
Checkpoint
INSUFFICIENT POWER
Trouble Cause
Countermeasure
Turbocharger
NG
NG
OK
Compression pressure
NG
NG
OK
Valve clearance
NG
NG
OK
Valve spring
NG
NG
OK
Exhaust system
NG
NG
OK
NG
NG
187
TROUBLESHOOTING
4.
Checkpoint
Fuel system
Trouble Cause
NG
Fuel leakage
Countermeasure
NG
NG
OK
Air cleaner
NG
OK
Idling speed
NG
NG
OK
Injection nozzle
NG
NG
OK
NG
NG
OK
Injection pump
NG
NG
OK
Turbocharger
188
NG
NG
TROUBLESHOOTING
4.
Checkpoint
Trouble Cause
Countermeasure
Turbocharger
NG
NG
OK
Valve clearance
NG
NG
OK
Compression pressure
NG
NG
OK
Valve spring
NG
NG
189
TROUBLESHOOTING
5.
Checkpoint
Engine oil
Trouble Cause
Countermeasure
NG
NG
NG
NG
OK
OK
Air breather
NG
NG
OK
NG
NG
OK
Piston rings
NG
NG
NG
NG
OK
Cylinder liners
190
TROUBLESHOOTING
6.
Checkpoint
Cooling water
OVERHEATING
Trouble Cause
NG
Countermeasure
NG
OK
NG
NG
OK
Fan belt
NG
NG
NG
NG
OK
Radiator
OK
Water pump
NG
NG
OK
NG
NG
OK
Thermostat
NG
Defective thermostat
NG
191
TROUBLESHOOTING
6.
Checkpoint
OVERHEATING
Trouble Cause
Countermeasure
Cooling system
NG
NG
NG
NG
OK
192
TROUBLESHOOTING
7.
Checkpoint
Fuel
NG
Countermeasure
NG
OK
NG
NG
OK
Compression pressure
NG
NG
OK
Turbocharger
NG
Defective turbocharger
NG
OK
NG
NG
OK
Piston rings
NG
NG
NG
NG
OK
Cylinder liners
193
TROUBLESHOOTING
8.
Checkpoint
Air cleaner
NG
Countermeasure
NG
NG
OK
Injection nozzle
NG
OK
NG
NG
OK
Injection pump
NG
NG
194
NG
NG
TROUBLESHOOTING
9.
Checkpoint
Engine oil
Trouble Cause
NG
Countermeasure
NG
OK
NG
NG
OK
Oil filter
NG
NG
NG
OK
NG
OK
Oil pump
NG
NG
NG
NG
OK
NG
NG
195
TROUBLESHOOTING
9.
Checkpoint
Trouble Cause
Countermeasure
Camshaft
NG
NG
NG
OK
196
NG
TROUBLESHOOTING
10.
Checkpoint
Engine Knocking
Trouble Cause
Countermeasure
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.
Fuel
NG
Fuel unsuitable
NG
OK
NG
NG
NG
NG
NG
NG
OK
Injection nozzle
OK
Compression pressure
2.
Exhaust pipes
NG
NG
NG
NG
OK
197
TROUBLESHOOTING
10.
Checkpoint
Countermeasure
Exhaust manifold
NG
NG
OK
NG
3.
Fan belt
NG
NG
Continuous Noise
NG
OK
Cooling fan
NG
NG
OK
NG
NG
NG
NG
NG
NG
OK
OK
Valve clearance
198
TROUBLESHOOTING
10.
Checkpoint
Valve clearance
Slapping Noise
Trouble Cause
NG
Countermeasure
NG
OK
Rocker arm
NG
NG
OK
Flywheel
NG
NG
OK
NG
NG
NG
NG
NG
NG
NG
OK
OK
OK
NG
199
MEMO
200
SECTION 11
201
202
ILLUSTRATION
PART NO.
PARTS NAME
PAGE
5-8840-0145-0
Measuring Device
25
5-8840-2675-0
Compression Gauge
26
5-8840-9029-0
26
5-8840-0019-0
Sliding Hammer
35
71
5-8840-2034-0
Nozzle Holder
Remover
35
5-8840-2363-0
38
9-8523-1423-0
42
85
5-8840-0086-0
46
64
9-8523-1212-0
49
50
10
5-8840-2039-0
57
ITEM NO.
ILLUSTRATION
PART NO.
PARTS NAME
PAGE
11
5-8840-2040-0
58
12
5-8840-2038-0
63
64
13
9-8840-2057-0
70
14
9-8522-0020-0
70
15
5-8840-2000-0
71
16
5-8522-0024-0
71
17
5-8840-2061-0
79
18
5-8840-2033-0
85
19
5-8840-0141-0
98
20
5-8840-9057-0
98
203
MEMO
204
REPAIR STANDARDS
SECTION 12
REPAIR STANDARDS
TABLE OF CONTENTS
ITEM
PAGE
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.
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
Major
Category
L/h
Warm engine
engine speed 200
rpm
(varies depending on
altitude)
Comments
5
(71.1/490)
0.05 (0.002)
or less
Difference in liner
projection between
neighboring cylinders
not to exceed 0.02
Disassemble and
repair engine
Repair Procedure
0.20
(0.008)
Dia 93.1
(3.665)
200%
140%
22
(313/2.157)
Limit
Dia. 93
(3.661)
100%
100%
Assembly
Standard Value
0 0.10
(0 0.0039)
Liner projection
20.0
L/h
31
(441/3.04)
Fuel consumption
Nominal
Dimension
Inspection Item
REPAIR STANDARDS
Name
of Part
Cylinder Head
Major
Category
Same for
(Valve)
45
2nd Step
8.2 9.2
(59.4 66.5/
80.4 90.2)
10.0 11.0
(72.4 79.6/
98.1 107.9)
3.0 5.0
(21.7 36.1/
29.4 49.0)
8.0 9.0
(57.9 65.1/
78.4 88.2)
New
bolt
Reused
bolt
5
(71.1 490)
0.2
(0.008)
0.2
(0.008)
2.5
(0.098)
2.2
(0.087)
1.20
(0.047)
1.28
(0.050)
Limit
1st Step
0.05 (0.002)
or less
Exhaust side
2.0
(0.079)
Inlet side
1.7
(0.067)
Assembly
Standard Value
0.05 (0.002)
or less
Nominal
Dimension
Bottom
surface
to cylinder
(Cylinder
head)
(Insert)
Inspection Item
repair
Maximum Allowable
Griding stock 0.3
(0.012)
Replace insert
Repair Procedure
Comments
REPAIR STANDARDS
207
Engine Body
Name
of Part
Pistons
208
Piston Ring
Major
Category
0.15
(0.006)
0.15
(0.006)
0.050 0.075
(0.002 0.003)
0.030 0.070
(0.0012 0.0028)
Oil ring
0.15
(0.006)
1.5
(0.059)
Dia. 30.95
(1.2185)
Limit
2nd
compression ring
0.090 0.125
(0.0035 0.0049)
1st
compression ring
1.11 1.59
(2.45 3.50/
10.9 16.0)
0.10 0.30
(0.004 0.012)
0.20 0.40
(0.008 0.016)
30.992 30.98
(1.2202 1.2197)
4.0 6.0
(8.82 13.2/
39.2 58.8)
Dia. 31.0
(1.2205)
Oil ring
2nd
compression ring
1st
compression ring
Oil ring
2nd
compression ring
1st
compression ring
Clearance
between piston
ring and ring
groove
Tension
kgf (lb/N)
Pin wear
0.002 0.015
(0.00008 0.0006)
Assembly
Standard Value
Clearance with
major axis
0.017 0.055
(0.0007 0.0022)
Nominal
Dimension
Inspection Item
At 120 intervals
Replace rings or
piston
Replace
Replace
Replace rings or
piston
Replace piston or
piston pin
Repair Procedure
When assembling
compression rings on
piston, be sure rings
marked surface is up.
Backwards installation
will result in excessive
oil consumption.
No top/bottom to oil
ring.
Measure with
expander attached
Comments
REPAIR STANDARDS
Name
of Part
Crankshaft
Connecting Rods
Major
Category
Nominal
Dimension
Clearance between
connecting rod
bearing and crankpin
0.029 0.066
(0.0011 0.0026)
16.0 18.0
(115.7 130.2/
156.9 176.5)
0.10
(0.0039)
Replace bearing
Replace crankshaft
0.08
(0.0031)
0.30
(0.0118)
0.05 (0.002)
or less
0.10
(0.0039)
Ring gear
Crankshaft runout
Journal bearing
undersize
0.11
(0.0043)
Replace bearing
Replace
Repair Procedure
Clearance between
journal and bearing
0.094
(0.0037)
0.09
(0.0035)
Limit
Assembly
Standard Value
A-4JA1 Dia.60(2.362)
Uneven Journal
A-4JB1 Dia.70(2.756)
wear on
journal
Dia. 53
and pins Pin
(2.087)
Inspection Item
Measure at crankshafts
No. 1 bearing thrust surface
Comments
REPAIR STANDARDS
209
Name
of Part
Connecting Rods
210
Camshaft
Major
Category
Journal wear
Clearance between
journal and bearing
Dia. 50
(1.969)
49.945 49.975
(1.9663 1.9675)
0.025 0.085
(0.001 0.0033)
8.0 9.0
(57.9 65.1/
78.4 88.2)
0.05 (0.002)
or less
0.175 0.290
(0.007 0.0114)
0.05 (0.002)
or less
Dia. 50
(1.969)
Dia. 53
(2.087)
Dia. 49.60
(1.953)
0.12
(0.0047)
0.05
(0.002)
0.15
(0.006)
0.20
(0.008)
0.35
(0.0138)
0.05
(0.002)
Repair Procedure
Replace camshaft
Replace bearing
Replace camshaft
Repair or replace
Repair or replace
0.008 0.020
(0.0003 0.0008)
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
Comments
REPAIR STANDARDS
Name
of Part
Camshaft
Major
Category
0.20
(0.008)
0.05 0.114
(0.002 0.0045)
41.65
(1.64)
Limit
0.10
(0.004)
42.08
(1.65)
Assembly
Standard Value
0.02 (0.0008)
or less
Nominal
Dimension
Camshaft runout
Cam height:
Inspection Item
Replace camshaft
Replace camshaft
Repair Procedure
Comments
REPAIR STANDARDS
211
212
Name
of Part
Inspection Item
13.0 (0.512)
1.8 (0.071)
mm
Inclination
Dia.
18.85
(0.742)
Dia.
18.98 19.00
(0.747 0.748)
Adjust
0.2
(0.008)
0.40
(0.016)
2.5 (0.098)
48.2 (1.90)
29.0
(63.9/284.4)
0.01 0.05
(0.0004 0.002)
1.5 (0.06)
or less
49.7 (1.96)
32.6
(71.9/319.6)
1.5 (0.059)
0.25
(0.0098)
0.2
(0.008)
Dia. 7.88
(0.3102)
Limit
mm
Inlet
Free length
Height of valve
guide above
cylinder head
Thickness
0.02
(0.0008)
Valve
thickness
0.064 0.096
(0.0025 0.0038)
Assembly
Standard
Value
0.039 0.069
(0.0015 0.0027)
Dia. 8
(0.315)
Nominal
Dimension
Valve spring
Valves
Major
Category
Replace rocker
arm shaft
Replace bushing or
shaft
Replace valve
Repair Procedure
Reference value
Comments
REPAIR STANDARDS
Valve System
Valve
System
Intake
System
Name
of Part
Tappet
Air
cleaner
Major
Category
Out diameter
Tappet wear
Inspection Item
Nominal
Dimension
0.10
(0.0039)
12.95
(0.5098)
12.97 12.99
(0.5106 0.5114)
Limit
0.03
(0.0012)
Assembly
Standard
Value
Replace tappet
Replace tappet
Repair Procedure
Comments
REPAIR STANDARDS
213
Lubricating System
Pumping rate
L/min
1000 rpm, SAE #30,
pumping pressure
4 kgf/cm2 (56.9 psi/392 kPa)
oil temp. 50C (122F)
Inspection Item
Name
of Part
Oil
pressure
214
Oil filter
Major
Category
Nominal
Dimension
0.20
(0.008)
0.14 (0.006)
or less
5.8 6.2
(82.49 88.18
/569 608.2)
13
0.40
(0.016)
0.15
(0.006)
0.02 0.07
(0.0008 0.0026)
0.20 0.27
(0.008 0.011)
2.0
(28.4/196)
Limit
4.0 4.5
(56.89 64.00
/392 441)
Assembly
Standard Value
Replace
Repair or replace
Replace
vane, rotor or cover
Repair Procedure
Comments
REPAIR STANDARDS
Cooling System
Fuel System
Name
of Part
Water pump
Piping, etc.
Major
Category
L/min
Temperature at whic
thermostat lift reaches
8mm(0.315in) or more.
Adjust
Repair or replace if
impeller and pump
body are touching
Replace
Repair Procedure
Replace
0.2
(0.0079)
Limit
95C
(203F)
80 84C
(176 183F)
8 12
(0.31 0.47)
0.3 1.3
(0.0118 0.0512)
100
Assembly
Standard Value
Repair or replace
82C
(180F)
Nominal
Dimension
mm(in)
Press with
finger
Fan belt
deflection
Pumping rate
Inspection Item
Cartridge type
Replace thermostat if
operation is incorrect.
(Reference)
10 kgf (22.0 lb/98N)
each
Comments
REPAIR STANDARDS
215
Electrical
Name
of Part
Charge/
Discharge
indication
Wiring
Inspection Item
Repair
Repair Procedure
Replace
Commutator
Undercut depth
O.D.
Jeries coil
Magnetic
resistance ()
switch
(at 20C [68F]) Shut coil
resistance ()
Dia. 29.0
(1.14)
0.2
(0.008)
Dia. 30.0
(1.18)
0.5 0.8
(0.02 0.03)
0.27
Repair
Replace armature
Replace
9.0 (0.35)
7.5
(0.3)
30.6
(1.20)
Replace bearings
0.1 (0.0039)
Replace rotor
or ress
Limit
Brush length
15.0 (0.59)
Assembly
Standard
Value
Repair
14.5
(0.57)
31.6
(1.24)
Nominal
Dimension
Loose mount
Length
Bearing chatter
Shaft runout
Rotor
216
Brush
Major
Category
Comments
REPAIR STANDARDS
Final Inspection
Electrical
Name
of Part
Preheater
Major
Category
4.0 4.5
(392 441)
90% or more
110% or less
Output check
5% or less
Adjust
Inspect
Inspect
Difference in compression
between cylinders
kgf/ cm2 (psi/MPa)
about 200 rpm
30 minutes or more
Unloaded
characteristics
(11V, 160A or less)
6006 DDU
Dia. 30
(1.811)
6200 Z
Repair Procedure
6204 DDU
22
(313/2.157)
Limit
Dia. 20
(0.7874)
3900 rpm
or more
Assembly
Standard Value
Front (armature)
Dia. 10
(0.3937)
Nominal
Dimension
Glow plug
Performance
Ball
bearings
Rear side
(armature)
Inspection Item
1400 rpm
Oil Temp
About 80C (176F)
Warm engine
Warm engine
Smooth pinion
operation without
noise
Replace if rotation is
not smooth or if
abnormal sounds are
heard.
Comments
REPAIR STANDARDS
217
MEMO
218
CONVERSION TABLE
SECTION 13
CONVERSION TABLES
INDEX
CONTENTS
PAGE
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
LENGTH
MILLIMETERS TO INCHES
INCHES TO MILLIMETERS
mm
in.
mm
in.
mm
in.
mm
in.
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
0.0394
0.0787
0.1181
0.1575
0.1969
0.2362
0.2756
0.3150
0.3543
0.3937
0.4331
0.4724
0.5118
0.5512
0.5906
0.6299
0.6693
0.7087
0.7480
0.7874
0.8268
0.8661
0.9055
0.9449
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
1.0236
1.0630
1.1024
1.1417
1.1811
1.2205
1.2598
1.2992
1.3386
1.3780
1.4173
1.4567
1.4961
1.5354
1.5748
1.6142
1.6535
1.6929
1.7323
1.7717
1.8110
1.8504
1.8898
1.9291
1.9685
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
2.0079
2.0472
2.0866
2.1260
2.1654
2.2047
2.2441
2.2835
2.3228
2.3622
2.4016
2.4409
2.4803
2.5197
2.5591
2.5984
2.6378
2.6772
2.7165
2.7559
2.7953
2.8346
2.8740
2.9134
2.9528
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
2.9921
3.0315
3.0709
3.1102
3.1496
3.1890
3.2283
3.2677
3.3071
3.3465
3.3858
3.4252
3.4646
3.5039
3.5433
3.5827
3.6220
3.6614
3.7008
3.7402
3.7795
3.8189
3.8583
3.8976
3.9370
in.
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
3.9764
4.0157
4.0551
4.0945
4.1339
4.1732
4.2126
4.2520
4.2913
111
112
113
114
115
116
117
118
119
4.3701
4.4094
4.4488
4.4882
4.5276
4.5669
4.6063
4.6457
4.6850
121
122
123
124
125
126
127
128
129
4.7638
4.8031
4.8425
4.8819
4.9213
4.9606
5.0000
5.0394
5.0787
131
132
133
134
135
136
137
138
139
5.1575
5.1968
5.2362
5.2756
5.3150
5.3543
5.3937
5.4331
5.4724
27/64
7/16
29/64
15/32
31/64
1/2
0.3969
0.7938
1.1906
1.5875
1.9844
2.3813
2.7781
3.1750
3.5719
3.9688
4.3656
4.7625
5.1594
5.5563
5.9531
6.3500
6.7469
7.1438
7.5406
7.9375
8.3344
8.7313
9.1281
9.5250
9.9219
10.3188
10.7156
11.1125
11.5094
11.9063
12.3031
12.7000
in.
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
13.0969
13.4938
13.8906
14.2875
14.6844
15.0813
15.4781
15.8750
16.2719
16.6688
17.0656
17.4625
17.8594
18.2563
18.6531
19.0500
19.4469
19.8438
20.2406
20.6375
21.0344
21.4313
21.8281
22.2250
22.6219
23.0188
23.4156
23.8125
24.2094
24.6063
25.0031
25.4000
219
CONVERSION TABLE
LENGTH
FEET TO METERS
ft.
10
20
30
40
50
60
70
80
90
100
0
3.048
6.096
9.144
12.192
15.240
18.288
21.336
24.384
27.432
30.480
0.305
3.353
6.401
9.449
12.497
15.545
18.593
21.641
24.689
27.737
30.785
0.610
3.658
6.706
9.754
12.802
15.850
18.898
21.946
24.994
28.042
31.090
0.914
3.962
7.010
10.058
13.106
16.154
19.202
22.250
25.298
28.346
31.394
1.219
4.267
7.315
10.363
13.411
16.459
19.507
22.555
25.603
28.651
31.699
1.524
4.572
7.620
10.668
13.716
16.764
19.812
22.860
25.908
28.956
32.004
1.829
4.877
7.925
10.973
14.021
17.069
20.117
23.165
26.213
29.261
32.309
2.134
5.182
8.230
11.278
14.326
17.374
20.422
23.470
26.518
29.566
32.614
2.438
5.486
8.534
11.582
14.630
17.678
20.726
23.774
26.822
29.870
32.918
2.743
5.791
8.839
11.887
14.935
17.983
21.031
24.079
27.127
30.175
33.223
ft.
10
20
30
40
50
60
70
80
90
100
METERS TO FEET
m
10
20
30
40
50
60
70
80
90
100
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
00
32.8084
65.6168
98.4252
131.2336
164.0420
196.8504
229.6588
262.4672
295.2756
328.0840
3.2808
36.0892
68.8976
101.7060
134.5144
167.3228
200.1312
232.9396
265.7480
298.5564
331.3648
6.5617
39.3701
72.1785
104.9869
137.7953
170.6037
203.4121
236.2205
269.0289
301.8373
334.6457
9.8425
42.6509
75.4593
108.2677
141.0761
173.8845
206.6929
239.5013
272.3097
305.1181
337.9265
13.1234
45.9318
78.7402
111.5486
144.3570
177.1654
209.9738
242.7822
275.5906
308.3990
341.2074
16.4042
49.2126
82.0210
114.8294
147.6378
180.4462
213.2546
246.0630
278.8714
311.6798
344.4882
19.6850
52.4934
85.3018
118.1102
150.9186
183.7270
216.5354
249.3438
282.1522
314.9606
347.7690
22.9659
55.7743
88.5827
121.3911
154.1995
187.0079
219.8163
252.6247
285.4331
318.2415
351.0499
26.2467
59.0551
91.8635
124.6719
157.4803
190.2887
223.0971
255.9055
288.7139
321.5223
354.3307
29.5276
62.3360
95.1444
127.9528
160.7612
193.5696
226.3780
259.1864
291.9948
324.8032
357.6116
10
20
30
40
50
60
70
80
90
100
MILES TO KILOMETERS
miles
10
20
30
40
50
60
70
80
90
100
km
km
km
km
km
km
km
km
km
km
00
16.093
32.187
48.280
64.374
80.467
96.561
112.654
128.748
144.841
160.934
1.609
17.703
33.796
49.890
65.983
82.077
98.170
114.263
130.357
146.450
162.544
3.219
19.312
35.406
51.499
67.592
83.686
99.779
115.873
131.966
148.060
164.153
4.828
20.921
37.015
53.108
69.202
85.295
101.389
117.482
133.576
149.669
165.762
6.437
22.531
38.624
54.718
70.811
86.905
102.998
119.091
135.185
151.278
167.372
8.047
24.140
40.234
56.327
72.420
88.514
104.607
120.701
136.794
152.888
168.981
9.656
25.750
41.843
57.936
74.030
90.123
106.217
122.310
138.404
154.497
170.590
11.265
27.359
43.452
59.546
75.639
91.733
107.826
123.919
140.013
156.106
172.200
12.875
28.968
45.062
61.155
77.249
93.342
109.435
125.529
141.622
157.716
173.809
14.484
30.578
46.671
62.764
78.858
94.951
111.045
127.138
143.232
159.325
175.418
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
miles
miles
miles
miles
miles
miles
miles
miles
miles
miles
0
6.214
12.427
18.641
24.855
31.069
37.282
43.496
49.710
55.923
62.137
0.621
6.835
13.049
19.262
25.476
31.690
37.904
44.117
50.331
56.545
62.758
1.243
7.456
13.670
19.884
26.098
32.311
38.525
44.739
50.952
57.166
63.380
1.864
8.078
14.292
20.505
26.719
32.933
39.146
45.360
51.574
57.787
64.001
2.485
8.699
14.913
21.127
27.340
33.554
39.768
45.981
52.195
58.409
64.622
3.107
9.321
15.534
21.748
27.962
34.175
40.389
46.603
52.816
59.030
65.244
3.728
9.942
16.156
22.369
28.583
34.797
41.010
47.224
53.438
59.652
65.865
4.350
10.563
16.777
22.991
29.204
35.418
41.632
47.845
54.059
60.273
66.487
4.971
11.185
17.398
23.612
29.826
36.039
42.253
48.467
54.681
60.894
67.108
5.592
11.806
18.020
24.233
30.447
36.661
42.875
49.088
55.302
61.516
67.729
10
20
30
40
50
60
70
80
90
100
CONVERSION TABLE
AREA
SQUARE INCHES TO SQUARE CENTIMETERS
in2
10
20
30
40
50
60
70
80
90
100
in2
cm2
cm2
cm2
cm2
cm2
cm2
cm2
cm2
cm2
cm2
00
64.516
129.032
193.548
258.064
322.580
387.096
451.612
516.128
580.644
645.160
6.452
70.968
135.484
200.000
264.516
329.032
393.548
458.064
522.580
587.096
651.612
12.903
77.419
141.935
206.451
270.967
335.483
399.999
464.515
529.031
593.547
658.063
19.355
83.871
148.387
212.903
277.419
341.935
406.451
470.967
535.483
599.999
664.515
25.806
90.322
154.838
219.354
283.870
348.386
412.902
477.418
541.934
606.450
670.966
32.258
96.774
161.290
225.806
290.322
354.838
419.354
483.870
548.386
612.902
677.418
38.710
103.226
167.742
232.258
296.774
361.290
425.806
490.322
554.838
619.354
683.870
45.161
109.677
174.193
238.709
303.225
367.741
432.257
496.773
561.289
625.805
690.321
51.613
116.129
180.645
245.161
309.677
374.193
438.709
503.225
567.741
632.257
696.773
58.064
122.580
187.096
251.612
316.128
380.644
445.160
509.676
574.192
638.708
703.224
10
20
30
40
50
60
70
80
90
100
cm2
10
20
30
40
50
60
70
80
90
100
in2
in2
in2
in2
in2
in2
in2
in2
in2
in2
0
1.550
3.100
4.650
6.200
7.750
9.300
10.850
12.400
13.950
15.500
0.155
1.705
3.255
4.805
6.355
7.905
9.455
11.005
12.555
14.105
15.655
0.310
1.860
3.410
4.960
6.510
8.060
9.610
11.160
12.710
14.260
15.810
0.465
2.015
3.565
5.115
6.665
8.215
9.765
11.315
12.865
14.415
15.965
0.620
2.170
3.720
5.270
6.820
8.370
9.920
11.470
13.020
14.570
16.120
0.775
2.325
3.875
5.425
6.975
8.525
10.075
11.625
13.175
14.725
16.275
0.930
2.480
4.030
5.580
7.130
8.680
10.230
11.780
13.330
14.880
16.430
1.085
2.635
4.185
5.735
7.285
8.835
10.385
11.935
13.485
15.035
16.585
1.240
2.790
4.340
5.890
7.440
8.990
10.540
12.090
13.640
15.190
16.740
1.395
2.945
4.495
6.045
7.595
9.145
10.695
12.245
13.795
15.345
16.895
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
cm3(cc)
cm3(cc)
cm3(cc)
cm3(cc)
cm3(cc)
cm3(cc)
cm3(cc)
cm3(cc)
cm3(cc)
cm3(cc)
00
163.871
327.741
491.612
655.483
819.353
983.224
1147.094
1310.965
1474.836
1638.706
16.387
180.258
344.128
507.999
671.870
835.740
999.611
1163.482
1327.352
1491.223
1655.093
32.774
196.645
360.515
524.386
688.257
852.127
1015.998
1179.869
1343.739
1507.610
1671.481
49.161
213.032
376.902
540.773
704.644
868.514
1032.385
1196.256
1360.126
1523.997
1687.868
65.548
229.419
393.290
557.160
721.031
884.901
1048.772
1212.643
1376.513
1540.384
1704.255
81.935
245.806
409.677
573.547
737.418
901.289
1065.159
1229.030
1392.900
1556.771
1720.642
98.322
262.193
426.064
589.934
753.805
917.676
1081.546
1245.417
1409.288
1573.158
1737.029
114.709
278.580
442.451
606.321
770.192
934.063
1097.933
1261.804
1425.675
1589.545
1753.416
131.097
294.967
458.838
622.708
786.579
950.450
1114.320
1278.191
1442.062
1605.932
1769.803
147.484
311.354
475.225
639.095
802.966
966.837
1130.707
1294.578
1458.449
1622.319
1786.190
10
20
30
40
50
60
70
80
90
100
cm3(cc)
10
20
30
40
50
60
70
80
90
100
in3
in3
in3
in3
in3
in3
in3
in3
in3
in3
0
0.6102
1.2205
1.8307
2.4409
3.0512
3.6614
4.2716
4.8818
5.4921
6.1023
0.0610
0.6713
1.2815
1.8917
2.5020
3.1122
3.7224
4.3326
4.9429
5.5531
6.1633
0.1220
0.7323
1.3425
1.9527
2.5630
3.1732
3.7834
4.3937
5.0039
5.6141
6.2243
0.1831
0.7933
1.4035
2.0138
2.6240
3.2342
3.8444
4.4547
5.0649
5.6751
6.2854
0.2441
0.8543
1.4646
2.0748
2.6850
3.2952
3.9055
4.5157
5.1259
5.7362
6.3464
0.3051
0.9153
1.5256
2.1358
2.7460
3.3563
3.9665
4.5767
5.1870
5.7972
6.4074
0.3661
0.9764
1.5866
2.1968
2.8071
3.4173
4.0275
4.6377
5.2480
5.8582
6.4684
0.4272
1.0374
1.6476
2.2579
2.8681
3.4783
4.0885
4.6988
5.3090
5.9192
6.5295
0.4882
1.0984
1.7086
2.3190
2.9291
3.5393
4.1496
4.7598
5.3700
5.9803
6.5905
0.5492
1.1594
1.7697
2.3799
2.9901
3.6004
4.2106
4.8208
5.4310
6.0413
6.6515
10
20
30
40
50
60
70
80
90
100
221
CONVERSION TABLE
VOLUME
GALLONS (U.S.) TO LITERS
U.S. gal.
10
20
30
40
50
60
70
80
90
100
liters
liters
liters
liters
liters
liters
liters
liters
liters
liters
U.S.gal.
00
37.8543
75.7085
113.5628
151.4171
189.2713
227.1256
264.9799
302.8342
340.6884
378.5427
3.7854
41.6397
79.4940
117.3482
155.2025
193.0568
230.9110
268.7653
306.6196
344.4738
382.3281
7.5709
45.4251
83.2794
121.1337
158.9879
196.8422
234.6965
272.5507
310.4050
348.2593
386.1135
11.3563
49.2105
87.0648
124.9191
162.7734
200.6276
238.4819
276.3362
314.1904
352.0447
389.8990
15.1417
52.9960
90.8502
128.7045
166.5588
204.4131
242.2673
280.1216
317.9759
355.8301
393.6844
18.9271
56.7814
94.6357
132.4899
170.3442
208.1985
246.0527
283.9070
321.7613
359.6156
397.4698
22.7126
60.5668
98.4211
136.2754
174.1296
211.9839
249.8382
287.6924
325.5467
363.4010
401.2553
26.4980
64.3523
102.2065
140.0608
177.9151
215.7693
253.6236
291.4779
329.3321
367.1864
405.0407
30.2834
68.1377
105.9920
143.8462
181.7005
219.5548
257.4090
295.2633
333.1176
370.9718
408.8261
34.0688
71.9231
109.7774
147.6316
185.4859
223.3402
261.1945
299.0487
336.9030
374.7573
412.6115
10
20
30
40
50
60
70
80
90
100
liters
10
20
30
40
50
60
70
80
90
100
gal.
gal.
gal.
gal.
gal.
gal.
gal.
gal.
gal.
gal.
00
2.6417
5.2834
7.9252
10.5669
13.2086
15.8503
18.4920
21.1338
23.7755
26.4172
0.2642
2.9059
5.5476
8.1893
10.8311
13.4728
16.1145
18.7562
21.3979
24.0397
26.6814
0.5283
3.1701
5.8118
8.4535
11.0952
13.7369
16.3787
19.0204
21.6621
24.3038
26.9455
0.7925
3.4342
6.0760
8.7177
11.3594
14.0011
16.6428
19.2846
21.9263
24.5680
27.2097
1.0567
3.6984
6.3401
8.9818
11.6236
14.2653
16.9070
19.5487
22.1904
24.8322
27.4739
1.3209
3.9626
6.6043
9.2460
11.8877
14.5295
17.1712
19.8129
22.4546
25.0963
27.7381
1.5850
4.2268
6.8685
9.5102
12.1519
14.7936
17.4354
20.0771
22.7188
25.3605
28.0022
1.8492
4.4909
7.1326
9.7744
12.4161
15.0578
17.6995
20.3412
22.9830
25.6247
28.2664
2.1134
4.7551
7.3968
10.0385
12.6803
15.3220
17.9637
20.6054
23.2471
25.8889
28.5306
2.3775
5.0193
7.6610
10.3027
12.9444
15.5861
18.2279
20.8696
23.5113
26.1530
28.7947
10
20
30
40
50
60
70
80
90
100
Imp gal.
10
20
30
40
50
60
70
80
90
100
liters
liters
liters
liters
liters
liters
liters
liters
liters
liters
00
45.4590
90.9180
136.3770
181.8360
227.2950
272.7540
318.2130
363.6720
409.1310
454.5900
4.5459
50.0049
95.4639
140.9229
186.3819
231.8409
277.2999
322.7589
368.2179
413.6769
459.1359
9.0918
54.5508
100.0098
145.4688
190.9278
236.3868
281.8458
327.3048
372.7638
418.2228
463.6818
13.6377
59.0967
104.5557
150.0147
195.4737
240.9327
286.3917
331.8507
377.3097
422.7687
468.2277
18.1836
63.6426
109.1016
154.5606
200.0196
245.4786
290.9376
336.3966
381.8556
427.3146
472.7736
22.7295
68.1885
113.6475
159.1065
204.5655
250.0245
295.4835
340.9425
386.4015
431.8605
477.3195
27.2754
72.7344
118.1934
163.6524
209.1114
254.5704
300.0294
345.4884
390.9474
436.4064
481.8654
31.8213
77.2803
122.7393
168.1983
213.6573
259.1163
304.5753
350.0343
395.4933
440.9523
486.4113
36.3672
81.8262
127.2852
172.7442
218.2032
263.6622
309.1212
354.5802
400.0392
445.4982
490.9572
40.9131
86.3721
131.8311
177.2901
222.7491
268.2081
313.6671
359.1261
404.5851
450.0441
495.5031
10
20
30
40
50
60
70
80
90
100
liters
10
20
30
40
50
60
70
80
90
100
222
gal.
gal.
gal.
gal.
gal.
gal.
gal.
gal.
gal.
gal.
00
2.1998
4.3996
6.5994
8.7992
10.9990
13.1988
15.3986
17.5984
19.7982
21.9980
0.2200
2.4198
4.6196
6.8194
9.0192
11.2190
13.4188
15.6186
17.8184
20.0182
22.2180
0.4400
2.6398
4.8396
7.0394
9.2392
11.4390
13.6388
15.8386
18.0384
20.2382
22.4380
0.6599
2.8597
5.0595
7.2593
9.4591
11.6589
13.8587
16.0585
18.2583
20.4581
22.6579
0.8799
3.0797
5.2795
7.4793
9.6791
11.8789
14.0787
16.2785
18.4783
20.6781
22.8779
1.0999
3.2997
5.4995
7.6993
9.8991
12.0989
14.2987
16.4985
18.6983
20.8981
23.0979
1.3199
3.5197
5.7195
7.9193
10.1191
12.3189
14.5187
16.7185
18.9183
21.1181
23.3179
1.5399
3.7397
5.9395
8.1393
10.3391
12.5389
14.7387
16.9385
19.1383
21.3381
23.5379
1.7598
3.9596
6.1594
8.3592
10.5590
12.7588
14.9586
17.1584
19.3582
21.5580
23.7578
1.9798
4.1796
6.3794
8.5792
10.7790
12.9788
15.1786
17.3784
19.5782
21.7780
23.9778
10
20
30
40
50
60
70
80
90
100
CONVERSION TABLE
MASS
POUNDS TO KILOGRAMS
lbs.
10
20
30
40
50
60
70
80
90
100
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
lbs.
0
4.536
9.072
13.608
18.144
22.680
27.216
31.751
36.287
40.823
45.359
0.454
4.990
9.525
14.061
18.597
23.133
27.669
32.205
36.741
41.277
45.813
0.907
5.443
9.979
14.515
19.051
23.587
28.123
32.659
37.195
41.731
46.267
1.361
5.897
10.433
14.970
19.504
24.040
28.576
33.112
37.648
42.184
46.720
1.814
6.350
10.886
15.422
19.958
24.494
29.030
33.566
38.102
42.638
47.174
2.268
6.804
11.340
15.876
20.412
24.948
29.484
34.019
38.555
43.091
47.627
2.722
7.257
11.793
16.329
20.865
25.401
29.937
34.473
39.009
43.545
48.081
3.175
7.711
12.247
16.783
21.319
25.855
30.391
34.927
39.463
43.998
48.534
3.629
8.165
12.701
17.237
21.772
26.308
30.844
35.380
39.916
44.452
48.988
4.082
8.618
13.154
17.690
22.226
26.762
31.298
35.834
40.370
44.905
49.442
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
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
00
22.046
44.092
66.139
88.185
110.231
132.277
154.324
176.370
198.416
220.462
2.205
24.251
46.297
68.343
90.390
112.436
134.482
156.528
178.574
200.621
222.667
4.409
26.455
48.502
70.548
92.594
114.640
136.687
158.733
180.779
202.825
224.871
6.614
28.660
50.706
72.753
94.799
116.845
138.891
160.937
182.984
205.030
227.076
8.818
30.865
52.911
74.957
97.003
119.050
141.096
163.142
185.188
207.234
229.281
11.023
33.069
55.116
77.162
99.208
121.254
143.300
165.347
187.393
209.439
231.485
13.228
35.274
57.320
79.366
101.413
123.459
145.505
167.551
189.597
211.644
233.690
15.432
37.479
59.525
81.571
103.617
125.663
147.710
169.756
191.802
213.848
235.895
17.637
39.683
61.729
83.776
105.822
127.868
149.914
171.960
194.007
216.053
238.099
19.842
41.888
63.934
85.980
108.026
130.073
152.119
174.165
196.211
218.258
240.304
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
98.07
196.13
294.20
392.27
490.33
588.40
686.47
784.53
882.60
980.67
9.81
107.87
205.94
304.01
402.07
500.14
598.21
696.27
794.34
892.41
990.47
19.61
117.68
215.75
313.81
411.88
509.95
608.01
706.08
804.15
902.21
1000.28
29.42
127.49
225.55
323.62
421.69
519.75
617.82
715.89
813.95
912.02
1010.08
39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.69
823.76
921.83
1019.89
49.03
147.10
245.17
343.23
441.30
539.37
637.43
735.50
833.57
931.63
1029.70
58.84
156.91
254.97
353.04
451.11
549.17
647.24
745.31
843.37
941.44
1039.50
68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.11
853.18
951.25
1049.31
78.45
176.52
274.59
372.65
470.72
568.79
666.85
764.92
862.99
961.05
1059.12
88.26
186.33
284.39
382.46
480.53
578.59
676.66
774.73
872.79
970.86
1068.92
10
20
30
40
50
60
70
80
90
100
NEWTON TO KILOGRAMS
N
100
200
300
400
500
600
700
800
900
1000
10
20
30
40
50
60
70
80
90
kgf
kgf
kgf
kgf
kgf
kgf
kgf
kgf
kgf
kgf
00
10.197
20.394
30.592
40.789
50.986
61.183
71.380
81.578
91.775
101.972
1.020
11.217
21.414
31.611
41.809
52.006
62.203
72.400
82.597
92.795
102.992
2.039
12.237
22.434
32.631
42.828
53.025
63.223
73.420
83.617
93.814
104.011
3.059
13.256
23.454
33.651
43.848
54.045
64.242
74.440
84.637
94.834
105.031
4.079
14.276
24.473
34.670
44.868
55.065
65.262
75.459
85.656
95.854
106.051
5.099
15.296
25.493
35.690
45.887
56.085
66.282
76.479
86.676
96.873
107.071
6.118
16.316
26.513
36.710
46.907
57.104
67.302
77.499
87.696
97.893
108.090
7.138
17.335
27.532
37.730
47.927
58.124
68.321
78.518
88.716
98.913
109.110
8.158
18.355
28.552
38.749
48.947
59.144
69.341
79.538
89.735
99.933
110.130
9.177
19.375
29.572
39.769
49.966
60.163
70.361
80.558
90.755
100.952
111.149
100
200
300
400
500
600
700
800
900
1000
223
CONVERSION TABLE
PRESSURE
POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS
lb/in2
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
0.7031
1.4061
2.1092
2.8123
3.5154
4.2184
4.9215
5.6246
6.3276
7.0307
0.0703
0.7734
1.4764
2.1795
2.8826
3.5857
4.2887
4.9918
5.6949
6.3979
7.1010
0.1406
0.8437
1.5468
2.2498
2.9529
3.6560
4.3590
5.0621
5.7652
6.4682
7.1713
0.2109
0.9140
1.6171
2.3201
3.0232
3.7263
4.4293
5.1324
5.8355
6.5386
7.2416
0.2812
0.9843
1.6874
2.3904
3.0935
3.7966
4.4996
5.2027
5.9058
6.6089
7.3119
0.3515
1.0546
1.7577
2.4607
3.1638
3.8669
4.5700
5.2730
5.9761
6.6792
7.3822
0.4218
1.1249
1.8280
2.5311
3.2341
3.9372
4.6403
5.3433
6.0464
6.7495
7.4525
0.4921
1.1952
1.8983
2.6014
3.3044
4.0075
4.7106
5.4136
6.1167
6.8198
7.5228
0.5625
1.2655
1.9686
2.6717
3.3747
4.0778
4.7809
5.4839
6.1870
6.8901
7.5932
0.6328
1.3358
2.0389
2.7420
3.4450
4.1481
4.8512
5.5543
6.2573
6.9604
7.6635
10
20
30
40
50
60
70
80
90
100
kgf/cm2
10
20
30
40
50
60
70
80
90
100
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)
lb/in2(psi)
00
142.23
284.46
426.69
568.92
711.15
853.38
995.61
1137.84
1280.07
1422.30
14.22
156.45
298.68
440.91
583.14
725.37
867.60
1009.83
1152.06
1294.29
1436.52
28.45
170.68
312.91
455.14
597.37
739.60
881.83
1024.06
1166.29
1308.52
1450.75
42.67
184.90
327.13
469.36
611.59
753.82
896.05
1038.28
1180.51
1322.74
1464.97
56.89
199.12
341.35
483.58
625.81
768.04
910.27
1052.50
1194.73
1336.96
1479.19
71.12
213.35
355.58
497.81
640.04
782.27
924.50
1066.73
1208.96
1351.19
1493.42
85.34
227.57
369.80
512.03
654.26
796.49
938.72
1080.95
1223.18
1365.41
1507.64
99.56
241.79
384.02
526.25
668.48
810.71
952.94
1095.17
1237.40
1379.63
1521.86
113.78
256.01
398.24
540.47
682.70
824.93
967.16
1109.39
1251.62
1393.85
1536.08
128.01
270.24
412.47
554.70
696.93
839.16
981.39
1123.62
1265.85
1408.08
1550.31
10
20
30
40
50
60
70
80
90
100
kgf/cm2
10
20
30
40
50
60
70
80
90
100
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
00
980.7
1961.3
2942.0
3922.7
4903.4
5884.0
6864.7
7845.3
8826.0
9806.7
98.1
1078.7
2059.4
3040.1
4020.7
5001.4
5982.1
6962.7
7943.4
8924.1
9904.7
196.1
1176.8
2157.5
3138.1
4118.8
5099.5
6080.1
7060.8
8041.5
9022.1
10002.8
294.2
1274.9
2255.5
3236.2
4216.9
5197.5
6178.2
7158.9
8139.5
9120.2
10100.8
392.3
1372.9
2353.6
3334.3
4314.9
5295.6
6276.3
7256.9
8237.6
9218.3
10198.9
490.3
1471.0
2451.7
3432.3
4413.0
5393.7
6374.4
7355.0
8335.7
9316.3
10297.0
588.4
1569.1
2549.7
3530.4
4511.1
5491.8
6472.4
7453.1
8433.7
9414.4
10395.1
686.5
1667.1
2647.8
3628.5
4609.1
5589.8
6570.5
7551.1
8531.8
9512.5
10493.1
784.5
1765.2
2745.9
3726.5
4707.2
5687.9
6668.6
7649.2
8629.9
9610.5
10591.2
882.6
1863.3
2843.9
3824.6
4805.3
5785.9
6766.6
7747.3
8727.9
9708.6
10689.2
10
20
30
40
50
60
70
80
90
100
KPa
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
224
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
10.197
20.394
30.592
40.789
50.986
61.183
71.380
81.578
91.775
101.972
1.020
11.217
21.414
31.611
41.809
52.006
62.203
72.400
82.597
92.795
102.992
2.039
12.237
22.434
32.631
42.828
53.025
63.223
73.420
83.617
93.814
104.011
3.059
13.256
23.454
33.651
43.848
54.045
64.242
74.440
84.637
94.834
105.031
4.079
14.276
24.473
34.670
44.868
55.065
65.262
75.459
85.656
95.854
106.051
5.099
15.296
25.493
35.690
45.887
56.085
66.282
76.479
86.676
96.873
107.071
6.118
16.316
26.513
36.710
46.907
57.104
67.302
77.499
87.696
97.893
108.090
7.138
17.335
27.532
37.730
47.927
58.124
68.321
78.518
88.716
98.913
109.110
8.158
18.355
28.552
38.749
48.947
59.144
69.341
79.538
89.735
99.933
110.130
9.177
19.375
29.572
39.769
49.966
60.163
70.361
80.558
90.755
100.952
111.149
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
CONVERSION TABLE
TORQUE
FOOT POUNDS TO KILOGRAMMETERS
ft. lbs.
10
20
30
40
50
60
70
80
90
100
kgf-m
kgf-m
kgf-m
kgf-m
kgf-m
kgf-m
kgf-m
kgf-m
kgf-m
kgf-m
ft lbs.
0
1.383
2.765
4.148
5.530
6.913
8.295
9.678
11.060
12.443
13.826
0.138
1.521
2.903
4.286
5.668
7.051
8.434
9.816
11.199
12.581
13.964
0.277
1.659
3.042
4.424
5.807
7.189
8.572
9.954
11.337
12.719
14.102
0.415
1.797
3.180
4.562
5.945
7.328
8.710
10.093
11.475
12.858
14.240
0.553
1.936
3.318
4.701
6.083
7.466
8.848
10.231
11.613
12.996
14.379
0.691
2.074
3.456
4.839
6.221
7.604
8.987
10.369
11.752
13.134
14.517
0.830
2.212
3.595
4.977
6.360
7.742
9.125
10.507
11.890
13.272
14.655
0.968
2.350
3.733
5.115
6.498
7.881
9.263
10.646
12.028
13.411
14.793
1.106
2.489
3.871
5.254
6.636
8.019
9.401
10.784
12.166
13.549
14.932
1.244
2.627
4.009
5.392
6.774
8.157
9.540
10.922
12.305
13.687
15.070
10
20
30
40
50
60
70
80
90
100
kgf-m
10
20
30
40
50
60
70
80
90
100
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
0
72.33
144.66
216.99
289.32
361.65
433.98
506.31
578.64
650.97
723.30
7.23
79.56
151.89
224.22
296.55
368.88
441.21
513.54
585.87
658.20
730.53
14.47
86.80
159.13
231.46
303.79
376.12
448.45
520.78
593.11
665.44
737.77
21.70
94.03
166.36
238.69
311.02
383.35
455.68
528.01
600.34
672.67
745.00
28.93
101.26
173.59
245.92
318.25
390.58
462.91
535.24
607.57
679.90
752.23
36.17
108.50
180.83
253.16
325.49
397.82
470.15
542.48
614.81
687.14
759.47
43.40
115.73
188.06
260.39
332.72
405.05
477.38
549.71
622.04
694.37
766.70
50.63
122.96
195.29
267.62
339.95
412.28
484.61
556.94
629.27
701.60
773.93
57.86
130.19
202.52
274.85
347.18
419.51
491.84
564.17
636.50
708.83
781.16
65.10
137.43
209.76
282.09
354.42
426.75
499.08
571.41
643.74
716.07
788.40
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
N-m
N-m
N-m
N-m
N-m
N-m
N-m
N-m
N-m
N-m
00
98.07
196.13
294.20
392.27
490.33
588.40
686.47
784.53
882.60
980.67
9.81
107.87
205.94
304.01
402.07
500.14
598.21
696.27
794.34
892.41
990.47
19.61
117.68
215.75
313.81
411.88
509.95
608.01
706.08
804.15
902.21
1000.28
29.42
127.49
225.55
323.62
421.69
519.75
617.82
715.89
813.95
912.02
1010.08
39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.69
823.76
921.83
1019.89
49.03
147.10
245.17
343.23
441.30
539.37
637.43
735.50
833.57
931.63
1029.70
58.84
156.91
254.97
353.04
451.11
549.17
647.24
745.31
843.37
941.44
1039.51
68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.11
853.18
951.25
1049.31
78.45
176.52
274.59
372.65
470.72
568.79
666.85
764.92
862.99
961.05
1059.12
88.26
186.33
284.39
382.46
480.53
578.59
676.66
774.73
872.79
970.86
1068.93
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
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
10.197
20.394
30.591
40.788
50.985
61.182
71.379
81.576
91.773
101.970
1.020
11.217
21.414
31.611
41.808
52.005
62.202
72.399
82.596
92.793
102.990
2.039
12.236
22.433
32.630
42.827
53.024
63.221
73.418
83.615
93.812
104.009
3.059
13.256
23.453
33.650
43.847
54.044
64.241
74.438
84.635
94.832
105.029
4.079
14.276
24.473
34.670
44.867
55.064
65.261
75.458
85.655
95.852
106.049
5.099
15.296
25.493
35.690
45.887
56.084
66.281
76.478
86.675
96.872
107.069
6.118
16.315
26.512
36.709
46.906
57.103
67.300
77.497
87.694
97.891
108.088
7.138
17.335
27.532
37.729
47.926
58.123
68.320
78.517
88.714
98.911
109.108
8.158
18.355
28.552
38.749
48.946
59.143
69.340
79.537
89.734
99.931
110.128
9.177
19.374
29.571
39.768
49.965
60.162
70.359
80.556
90.753
100.950
111.147
100
200
300
400
500
600
700
800
900
1000
225
CONVERSION TABLE
TEMPERATURE
FAHRENHEIT TO CENTIGRADE
F
-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
-51.1
-50.0
-48.9
-47.8
-46.7
-45.6
-44.4
-43.3
-42.2
-41.1
-40.0
-38.9
-37.8
-36.7
-35.6
-34.4
-33.3
-32.2
-31.1
-30.0
-28.9
-27.8
-26.7
-25.6
-24.4
-23.3
-22.2
-21.1
-20.0
-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
-18.9
-17.8
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.6
6.7
7.8
8.9
10.0
11.1
12.2
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
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
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
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6
66.7
67.8
68.9
70.0
71.1
72.2
73.3
74.4
75.6
76.7
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
77.8
78.9
80.0
81.1
82.2
83.3
84.4
85.6
86.7
87.8
88.9
90.0
91.1
92.2
93.3
94.4
95.6
96.7
97.8
98.9
100.0
101.1
102.2
103.3
104.4
105.6
106.7
107.8
108.9
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
111.1
112.2
113.3
114.4
115.6
116.7
117.8
118.9
120.0
121.1
122.2
123.3
124.4
125.6
126.7
127.8
128.9
130.0
131.1
132.2
133.3
134.4
135.6
136.7
137.8
138.9
140.0
141.1
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
142.2
143.3
144.4
145.6
146.7
147.8
148.9
150.0
151.1
152.2
153.3
154.4
155.6
156.7
157.8
158.9
160.0
161.1
162.2
163.3
164.4
165.6
166.7
167.8
168.9
170.0
171.1
172.2
173.3
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
174.4
175.6
176.7
177.8
178.9
180.0
181.1
182.2
183.3
184.4
185.6
186.7
187.8
188.9
190.0
191.1
192.2
193.3
194.4
195.6
196.7
197.8
198.9
200.0
204.4
210.0
215.6
221.1
226.7
CENTIGRADE TO FAHRENHEIT
C
-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
-56.2
-54.4
-52.6
-50.8
-49.0
-47.2
-45.4
-43.6
-41.8
-40.0
-38.2
-36.4
-34.6
-32.8
-31.0
-29.2
-27.4
-25.6
-23.8
-22.0
-20.2
-18.4
-16.6
-14.8
-13.0
-11.2
-9.4
-7.6
-5.8
-4.0
-2.2
-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
-0.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
32.0
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0
51.8
53.6
55.4
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
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0
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
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
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
172.4
174.2
176.0
177.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
213.8
215.6
217.4
219.2
221.0
222.8
224.6
226.4
228.2
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
230.0
231.8
233.6
235.4
237.2
239.0
240.8
242.6
244.4
246.2
248.0
249.8
251.6
253.4
255.2
257.0
258.8
260.6
262.4
264.2
266.0
267.8
269.6
271.4
273.2
275.0
276.8
278.6
280.4
282.2
284.0
285.8
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
287.6
289.4
291.2
293.0
294.8
296.6
298.4
300.2
302.0
303.8
305.6
307.4
309.2
311.0
312.8
314.6
316.4
318.2
320.0
321.8
323.6
325.4
327.2
329.0
330.8
332.6
334.4
336.2
338.0
339.8
341.6
343.4
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
345.2
347.0
348.8
350.6
352.4
354.2
356.0
357.8
359.6
361.4
363.2
365.0
366.8
368.6
370.4
372.2
374.0
375.8
377.6
379.4
381.2
383.0
384.8
386.6
388.4
390.2
392.0
410.0
428.0
446.0
464.0
482.0
226
Issued by
107-03K
IDE-2310
PRINTED IN JAPAN