Workshop Manual: Engine

2008-2012MY
2008-2012MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4JB1 model)

ENGINE
(4JB1 model)
No.LG4JB-WE-0871
67537_Maegaki 2011.2.16 3:42 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
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LG4JB-WE-0871.book 1 ページ２０１２年１１月２１日　水曜日　午後８時２４分
Engine Mechanical (4JB1) 1B-1
ENGINE
Engine Mechanical
(4JB1)
TABLE OF CONTENTS
4JB1 Engine.......................................................... 1B-3 Timing Gear.........................................................1B-46
Maintenance Precautions .................................. 1B-3 Component ......................................................1B-46
Reading The Model ........................................... 1B-4 Removal...........................................................1B-46
Description of Function and Operation .............. 1B-5 Installation........................................................1B-49
Functional and Operational Description ............ 1B-6 List of Tightening Torques ...............................1B-53
Functional Inspection:........................................ 1B-7 Valve Spring, Valve Guide Oil Seal, Valve Guide,
Compression Pressure Measure-ment.............. 1B-8 Push Rod.............................................................1B-54
Failure Phenomenon List................................. 1B-11 Component ......................................................1B-54
Hard Starting ................................................... 1B-12 Removal...........................................................1B-54
Unstable Idling................................................. 1B-15 Disassembly.....................................................1B-55
Insufficient Power ............................................ 1B-16 Inspection and Repair ......................................1B-55
Excessive Fuel Consumption .......................... 1B-17 Reassembly .....................................................1B-60
Excessive Oil Consumption............................. 1B-17 Installation........................................................1B-61
Overheating ..................................................... 1B-17 Rocker Arm Assembly .........................................1B-63
White Exhaust Smoke ..................................... 1B-18 Component ......................................................1B-63
Dark Exhaust Smoke....................................... 1B-18 Removal...........................................................1B-63
Oil Pressure Does Not Rise............................. 1B-18 Disassembly.....................................................1B-64
Abnormal Engine Noise................................... 1B-19 Inspection and Repair ......................................1B-64
Engine Cooling Trouble ................................... 1B-20 Reassembly .....................................................1B-65
Primary Specifications ..................................... 1B-21 Installation........................................................1B-65
Special Tools ................................................... 1B-23 Camshaft and Tappet ..........................................1B-68
Engine Assembly ................................................ 1B-26 Component ......................................................1B-68
Component ...................................................... 1B-26 Removal...........................................................1B-68
Removal .......................................................... 1B-26 Disassembly.....................................................1B-70
Installation ....................................................... 1B-30 Inspection and Repair ......................................1B-71
Engine Mount (RH) ............................................. 1B-35 Reassembly .....................................................1B-74
Component ...................................................... 1B-35 Installation........................................................1B-76
Removal .......................................................... 1B-35 List of Tightening Torques ...............................1B-77
Installation ....................................................... 1B-36 Cylinder Head Assembly .....................................1B-78
Engine Mount (LH) .............................................. 1B-37 Component ......................................................1B-78
Component ...................................................... 1B-37 Removal...........................................................1B-78
Removal .......................................................... 1B-37 Disassembly.....................................................1B-80
Installation ....................................................... 1B-37 Clean................................................................1B-81
List of Tightening Torques ............................... 1B-38 Inspection and Repair ......................................1B-81
Cylinder Head Cover ........................................... 1B-39 Reassembly .....................................................1B-83
Component ...................................................... 1B-39 Installation........................................................1B-85
Removal .......................................................... 1B-39 List of Tightening Torques ...............................1B-90
Installation ....................................................... 1B-39 Piston and Connecting Rod.................................1B-91
List of Tightening Torques ............................... 1B-40 Component ......................................................1B-91
Inlet Manifold....................................................... 1B-41 Removal...........................................................1B-91
Component ...................................................... 1B-41 Disassembly.....................................................1B-93
Removal .......................................................... 1B-41 Inspection and Repair ......................................1B-94
Installation ....................................................... 1B-42 Reassembly .....................................................1B-98
List of Tightening Torques ............................... 1B-43 Installation......................................................1B-100
Exhaust Manifold................................................. 1B-44 List of Tightening Torques .............................1B-106
Component ...................................................... 1B-44 Flywheel and Pilot Bearing ................................1B-107
Removal .......................................................... 1B-44 Component ....................................................1B-107
Inspection ........................................................ 1B-45 Removal.........................................................1B-107
Installation ....................................................... 1B-45 Installation......................................................1B-108
List of Tightening Torques ............................... 1B-45 List of Tightening Torques .............................1B-109
1B-2 Engine Mechanical (4JB1)

Crankshaft Front Oil Seal.................................. 1B-110
Component .................................................... 1B-110
Removal ........................................................ 1B-110
Installation ..................................................... 1B-111
List of Tightening Torques ............................. 1B-112
Crankshaft Rear Oil Seal .................................. 1B-113
Component .................................................... 1B-113
Removal ........................................................ 1B-113
Installation ..................................................... 1B-115
Crankshaft......................................................... 1B-119
Component .................................................... 1B-119
Removal ........................................................ 1B-119
Disassembly .................................................. 1B-122
Inspection and Repair.................................... 1B-122
Reassembly................................................... 1B-126
Installation ..................................................... 1B-132
List of Tightening Torques ............................. 1B-136
Cylinder Block ................................................... 1B-137
Component .................................................... 1B-137
Disassembly .................................................. 1B-137
Inspection and Repair.................................... 1B-137
Reassembly................................................... 1B-141
List of tightening Torque ................................ 1B-147
4JB1 Engine
Maintenance Precautions Precautions for work particular to this engine
To prevent damaging the engine and to ensure the reli- Including the inside of the injector, the holes and gaps
ability of engine performance, be careful of the following that are the fuel paths for the fuel system have an ex-
points when performing engine maintenance. tremely precise finish. Therefore, because there is the
When lifting or supporting the engine, do not directly at- possibility of damage if foreign material becomes mixed
tach the jack to the oil pan. in, cover the cap after removing parts, etc., to prevent
• When lowering the engine to the ground, do not let the entry of foreign material.
the oil pan directly contact the ground. Use a
frame, etc. to support it with the engine foot or fly-
wheel housing.
(there is only a small gap between the oil pan and
oil pump strainer, so be careful not to damage the
oil pan and oil pump strainer.)
• When the air intake system, such as the air duct or
air cleaner, etc., has been removed, cover the air
intake to prevent foreign materials from entering
the cylinder.
• To perform maintenance on the engine, always re-
move the battery ground terminals. If the battery
ground terminals remain while performing work,
there is the possibility of damaging the wire har-
ness or electrical components. Take adequate pre-
cautions for safety, such as short circuits, when
inspections require an energized state.
• To protect and lubricate the sliding surfaces when
running for the first time, apply an adequate
amount of engine oil to the sliding surfaces.
• When the valve related parts, injector, pistons, pis-
ton rings, control rod, control rod bearing, crank-
shaft journal bearing, etc. have been removed,
organize them in order for storage.
• When reinstalling them, use the same part and in-
stall it in the same position as when it was re-
moved.
• Whenever disassembling the gasket, oil seals and
O-rings, replace them with new ones.
• Completely wipe off old liquid gasket from the loca-
tions where it is used. After cleaning to completely
remove any oil, moisture and filth, apply the speci-
fied liquid gasket for reassembly.
• After applying the liquid gasket, install within 5 min-
utes. If 5 minutes have passed, remove the liquid
gasket and then apply liquid gasket again.
• When assembling and installing, tighten at the
specified torque value.

Reading The Model
LNW81BMF005301
Legend
1. Engine number stamping

Description of Function and Operation
External appearance of engine
LNW81BXF000101

Functional and Operational Description
Cylinder block
The cylinder block is cast iron, and has a highly rigid
structure with appropriate rib placement.
Piston
The piston is a thermal flow piston made from aluminum
alloy, with graphite coating on the skirt surface.
Cylinder head
The cylinder head is aluminum alloy. It has four valves
per cylinder. Tighten the head bolts using the plastic re-
gion rotational angle tightening method.
Crankshaft
The crankshaft is not to be polished, as it has tufftriding
treatment applied. There is therefore no undersize bear-
ing set.
The main bearing of the crankshaft is selectively assem-
bled, according to the journal outer diameter of the
crankshaft and the inner diameter grade of the crank-
shaft bearing housing.
Connecting rod cap bolt

Tighten the mounting bolt of the connecting rod cap us-
ing the plastic region rotational angle tightening method.
Injection pump
A distribution type injection pump is adopted. Note that
the use of fuel water remover in this pump is prohibited.
Injection nozzle
A 5-hole-type nozzle is used for the injection nozzle.
Fuel filter with sedimenter

This is a fuel filter that has a sedimenter to remove mois-
ture content by using the difference of the relative den-
sity of light diesel oil and water.
Preheat system
The preheat system adopts the QOS-II system.
Lubricating system
This is a full-flow bypass unitized oil filter. Oil flows
through the water cooling oil cooler and around the slid-
ing sections from the oil gallery for lubrication.

Functional Inspection: If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
Inspection and adjustment of valve clearance compression stroke.
Valve Clearance Adjustment If the No. 1 cylinder intake and exhaust valve push
1. Bring the piston in either the No. 1 cylinder or the rods are depressed, the No. 4 piston is at TDC on
No. 4 cylinder to TDC on the compression stroke the compression stroke.
by turning the crankshaft until the crankshaft
damper pulley TDC line is aligned with the timing
pointer.
LNW21BSH043601
Adjust the No. 1 or the No. 4 cylinder valve clear-

LNW81BSH015401
ance while their respective cylinders are at TDC on
the compression stroke.
2. Check the rocker arm shaft bracket nuts for loose-
ness. Valve Clearance (At Cold) mm (in)
Tighten any loose rocker arm shaft bracket nuts 0.4 (0.016)
before adjusting the valve clearance.
4. Loosen each valve clearance adjusting screw as
Tighten:
shown in the illustration.
• Rocker arm shaft bracket nut to 54 N⋅m (5.5 kg⋅m / 40
lb⋅ft) • No.1 Cylinder T.D.C. (Compression stroke)
LNW21BSH043701
LNW81BSH015501
3. Check for play in the No. 1 intake and exhaust 5. Insert a feeler gauge of the appropriate thickness
valve push rods. between the rocker arm and the valve stem end.
6. Turn the valve clearance adjusting screw until a
slight drag can be felt on the feeler gauge.

7. Tighten the lock nut securely.
8. Rotate the crankshaft 360°.
9. Realign the crankshaft damper pulley TDC
notched line with the timing pointer.
10. Adjust the clearance for the remaining valves as
• No.4 Cylinder T.D.C. (Compression stroke)
LNW81BSH016101
4. Turn the engine over with the starter motor and

take the compression gauge reading.
Compression Pressure at 200 rpm kPa (kg/cm2/psi)

Standard Limit
3,038 (31/441) 2,157 (22/313)
LNW21BSH043801
Adjustment table
Cylinder No. 1 2 3 4
Valve arrangement IN EX IN EX IN EX IN EX
First Cylinder
compression top ❍ ❍ ❍ ❍
dead center
Fourth Cylinder
compression top X X X X
dead center
Compression Pressure Measure-ment

1. Start the engine and allow it to idle until the coolant
temperature reaches 70 — 80°C (158 — 176°F).
2. Remove the following parts.
• Glow plugs
HCW31BSH009301
• Fuel cut solenoid connector
• QOS (Quick-On Start System) fusible link wire at 5. Repeat the procedure (Steps 3 and 4) for the re-
the connector. maining cylinders.
3. Set the adapter and compression gauge to the No. If the measured value is less than the specified lim-
1 cylinder glow plug hole. it, refer to “Troubleshooting” in this Manual.
Compression Gauge
(with Adapter): 5-8840-2008-0 (J-29762)
Adapter: 5-8531-7001-0

Injection Timing Adjustment 5. Insert a screwdriver into a hole in the fast idle lever
1. Check that the notched line on the injection pump and turn the lever to release the W-C.S.D. function.
flange is aligned with the front plate or the timing (If so equipped)
gear case notched line. 6. Install the static timing gauge (1).
The probe of the gauge should be depressed in-
ward approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827) (1)
• Use adapter for the 4JB1-TC.
Timing Gauge Adapter: 5-8840-2834-0 (2)
LNW81BSH015601
2. Bring the piston in the No. (2) cylinder to TDC 1 on

the compression stroke by turning the crankshaft 2 1
until the crankshaft pulley TDC line is aligned with
the timing mark (1).
LNW56CSH000501
7. Rotate the crankshaft to bring the piston in the No.

1 cylinder to a point 30 — 40° BTDC.
8. Set the timing gauge needle to zero.
9. Move the crankshaft pulley slightly in both direc-
tions to check that the gauge indication is stable.
LNW81BSH015701
Note:
Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push rods
have play, the No. 1 piston is at TDC on the compres- LNW81BSH015901
sion stroke.
10. Turn the crankshaft clockwise and read the gauge
3. Disconnect the injection pipe from the injection
indication when the crankshaft pulley timing mark
pump.
is aligned with the pointer.
4. Remove one bolt from the distributor head.
4JB1-TC BTDC 4°
4JB1NA BTDC 12°
Standard Reading mm (in) Glow Plug Terminal Voltage V

0.5 (0.02) Approx. 11
LNW81BSH016001 LNW81BSH013901
If the injection timing is outside the specified range,

continue with the following steps.
11. Loosen the injection pump fixing nuts and bracket
Determining the overhaul period
bolts. Increasing engine oil consumption amounts
12. Adjust the injection pump setting angle. If the consumption rate (the traveling distance on con-
sumption of 1L of oil) of a new vehicle is set as 100%,
an overhaul is required when that rate falls below 50%.
Quick-On Start System Inspection Procedure Increasing the fuel consumption rate
1. Disconnect the thermo-sensor connection on the The fuel consumption rate (km/L) of a new vehicle is set
thermostat outlet pipe. as 100%. An overhaul is required when that rate falls be-
low 60%.
Abnormal noises in engine
If the cause of the abnormal noise is inside the engine,
overhaul the engine immediately for repair.
* A variety of causes of abnormal noises are conceiv-
able. However, there are many cases of the parts of the
engine being worn, or foreign material causing chewing
of the engine.
LNW81CSH001901
2. Turn the starter switch to the “ON” position.

If the Quick-On Start II System is operating proper-
ly, the glow relay will make a clicking sound within
15 seconds after the starter switch is turned on.
3. Measure the glow plug terminal voltage with a cir-
cuit tester immediately after turning the starter
switch to the “ON” position.

Failure Phenomenon List
• Hard Starting
1. Starter Inoperative
2. Starter Motor Operates But Engine Does Not
Turn Over
3. Engine Turns Over But Does Not Start
4. Quick-On Start System
• Unstable Idling
• Insufficient Power
• Excessive Fuel Consumption
• Excessive Oil Consumption
• Overheating
• White Exhaust Smoke
• Dark Exhaust Smoke
• Oil Pressure Does Not Rise
• Abnormal Engine Noise
• Engine Cooling Trouble

Hard Starting
1. Starter Inoperative
Checkpoint Possible cause Correction

Battery Loose battery cable terminal poor connec- Clean and/or retighten the battery cable
tions due to rusting terminal
Battery discharged or weak Recharge or replace the battery
Fan belt loose or broken Adjust or replace the fan belt
Fusible link Fusible link shorted Replace the fusible link
Starter switch Defective starter switch or starter relay Replace the starter switch or the starter
relay
Starter motor Defective magnetic switch or starter relay Repair or replace the magnetic switch
Defective starter motor Repair or replace the starter motor
2. Starter Motor Operates But Engine Does Not Turn Over

Battery Loose battery cable terminal Clean and/or retighten the battery cable
terminal
Poor connections due to rusting Recharge or replace the battery
Battery discharged or weak Recharge or replace the battery
Fan belt loose or broken Adjust or replace the fan belt
Starter Defective pinion gear Replace the pinion gear
Defective magnetic switch Repair or replace the magnetic switch
Brush wear, Weak brush spring Replace the brush and/or the brush spring
Engine Piston, crank bearing seizure, or other Repair or replace the related parts
damage

3. Engine Turns Over But Does Not Start

Engine stop mecha- Defective fuel cut solenoid valve Replace the fuel cut solenoid valve
nism
Fuel is not Being Delivered to the Injection Pump
Fuel Fuel tank is empty Fill the fuel tank
Fuel piping Clogged or damaged fuel lines. Loose fuel Repair or replace the fuel lines
line connection Retighten the fuel line connection
Fuel filter Fuel filter overflow valve does not close Repair or replace the fuel filter overflow
valve
Clogged fuel filter element Replace the fuel filter element or the filter
cartridge
Fuel system Air in the fuel system Bleed the air from the fuel system
Fuel feed pump Defective feed pump Repair or replace the feed pump
Fuel is Being Delivered to the Injection Pump
Fuel Use of the wrong fuel Use the correct fuel
Water particles in the fuel Change the fuel
Fuel system Air in the injection pump Bleed the air from the fuel system
Injection nozzle Injection nozzle sticking
Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Improper spray condition
Injection pump Defective fuel injection nozzle resulting in Replace the delivery valve
the fuel drippage after fuel injection
Defective injection pump control rack oper- Repair or replace the injection pump con-
ation trol rack
Injection pump plunger worn or stuck Replace the injection pump plunger
assembly
Injection pump drive shaft seizure or other Replace the injection drive shaft
damage
Injection pump governor spring seizure Replace the injection pump governor
spring
4. Quick-On Start System

Preparation
1. Disconnect the thermoswitch connector.
2. Determine whether or not the glow plugs are receiving power.
a. Make sure that the starter switch is “OFF”.
b. Connect a voltmeter between one of the glow plugs and the cylinder wall.
c. Move the starter switch to the “ON” position.
The voltmeter needle will show the souse voltage (12V) if the glow plugs are receiving power.
If the voltmeter needle does not move, the glow plugs are not receiving power.
3. Perform the troubleshooting procedure.

Glow Plugs are Receiving Power
Glow plug indicator Defective indicator light bulb Replace the indicator light bulb
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
Glow plug indicator Defective quick-on start timer Replace the quick-on start timer
light turns on the 0.3
seconds
Glow plug indicator Return the starter switch to the “ON” posi- Replace the quick-on start timer
light turns on for 3.5 tion from the “START” position after the
seconds engine starts if the glow plug relay remains
on less than 14 seconds, the quick-on start
timer is defective
Move the starter switch from the “OFF” Replace the quick-on start timer
position to the “ON” position if the glow
plug relay remains on less than 14 sec-
onds, the quick-on start timer is defective
Thermo switch Defective thermo switch Replace the thermo switch
Glow plug continuity No glow plug continuity Replace the glow plugs
Glow Plugs are not Receiving Power
Glow plug indicator Broken indicator light fuse Replace the fuse
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
Glow plug indicator Defective glow plug relay Replace the glow plug relay
light turns on for 3.5 The glow plug relay does not turn on after
seconds the starter switch is moved from the “OFF”
position to the “ON” position
Defective quick-on start timer Replace the quick-on start timer
Defective glow plug relay wiring harness Repair or replace the wiring harness
Defective fusible link or wiring harness Replace the fusible link or the wiring har-
The glow plug relay turns on when the ness
starter switch is moved from the “OFF”
position to the “ON” position

Unstable Idling

Idling system Idling improperly adjusted Adjust the idling
Fast idling speed Defective fast idling speed control device Repair or replace the fast idling speed
control device
Accelerator control Accelerator control system improperly Adjust the accelerator control system
system adjusted
Fuel system Fuel system leakage or blockage Repair or replace the fuel system
Air in the fuel system Bleed the air from the fuel system
Water particles in the fuel system Change the fuel
Fuel filter Clogged fuel filter element Replace the fuel filter element or the fuel
filter cartridge
Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump
Injection nozzle Injection nozzle sticking Replace the injection nozzle
too low
Injection pump Defective delivery valve resulting in fuel Replace the delivery valve
drippage after fuel injection
Injection timing improperly adjusted Adjust the injection timing
Insufficient injection volume Adjust the injection volume
Defective idle spring Replace the idle spring
Defective governor lever operation Repair or replace the governor lever
Regulator valve improperly adjustment Adjust or replace the regulator valve
Broken plunger spring Replace the plunger spring
Worn plunger Replace the plunger assembly
Worn cam disc Replace the cam disc
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Compression pressure Blown out cylinder head gasket. Worn cyl- Replace the related parts
inder liner.
Piston ring sticking

Insufficient Power

Air cleaner Clogged air cleaner element Clean or replace the air cleaner element
Fuel Water particle in the fuel Replace fuel
Fuel filter Clogged fuel filter element Replace the fuel filter element or the fuel
filter cartridge
Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump
Injection nozzle Injection nozzle sticking Replace the injection nozzle
too low
Fuel injection pipes Fuel injection pipes damaged or Replace the fuel injection pipes
obstructed
Injection pump Defective regulating valve Repair or replace the regulating valve
Defective delivery valve Replace the delivery valve
Defective timer Repair or replace the timer
Worn cam disc Replace the cam disc
Improper control lever operation Adjust or replace the control lever
Defective injection timing Adjust the injection timing
Repair or replace the injection pump timer
Weak governor spring Replace the governor spring
Worn plunger Replace the plunger assembly
inder liner.
Valve spring Valve spring weak or broken Replace the valve spring
Exhaust system Exhaust pipe clogged Clean the exhaust pipe
Full load adjusting Open and improperly set adjusting screw Adjust and reseal the adjusting screw
screw seal seal

Excessive Fuel Consumption

Fuel system Fuel leakage Repair or replace the fuel system related
parts
Idling speed Poorly adjusted idling speed Adjust the idling speed
Injection nozzle Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing
Injection pump Defective Delivery valve resulting is fuel Replace the delivery valve
inder liner.
Valve spring Valve spring weak or broken Replace the valve spring
Excessive Oil Consumption

Engine oil Engine oil unsuitable Replace the engine oil
Too much engine oil Correct the engine oil level
Oil seal and gasket Oil leakage from the oil seal and/or the Replace the oil seal and/or the gasket
gasket
Air breather Clogged air breather Clean the air breather
Intake and exhaust Worn valve stems and valve guides Replace the intake and exhaust valves
valve and the valve guides
Overheating

Cooling water Insufficient cooling water Replenish the cooling water
Fan clutch Oil leakage from the fan clutch Replace the fan clutch
Fan belt Fan belt loose or cracked causing slippage Replace the fan belt
Radiator Defective radiator cap or clogged radiator Replace the radiator cap or clean the radi-
core ator core
Water pump Defective water pump Repair or replace the water pump
Cylinder head and cyl- Defective sealing cap resulting in water Replace the sealing cap
inder body sealing cap leakage
Thermostat Defective thermostat Replace the thermostat
Cooling system Cooling system clogged by foreign mate- Clean the foreign material from the cooling
rial system
Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing

White Exhaust Smoke

Cooling water Insufficient cooling water Replace the cooling water
Fuel Water particles in the fuel Replace the fuel
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing
inder liner.
Inlet and exhaust valve Defective valve seals. Replace the valve seals, the valves, and
Valves seals Worn valves stems and valve guides the valve guides
Dark Exhaust Smoke

Injection nozzle Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Injection pump Defective delivery valve resulting in fuel Replace the delivery valve
Excessive injection volume Adjust the injection volume
Oil Pressure Does Not Rise

Engine oil Improper viscosity engine oil. Replace the engine oil
Insufficient engine oil Correct the engine oil volume
Oil pressure gauge or Defective oil pressure gauge or unit Repair or replace the oil pressure gauge or
unit unit
Oil pressure indicator Defective indicator light Replace the indicator light
light
Oil filter Clogged oil filter element Replace the oil filter element or the oil filter
cartridge
Relief valve and by- Relief valve sticking and/or weak by-pass Replace the relief valve and/or the by-pass
pass valve valve spring valve spring
Oil pump Clogged oil pump strainer Clean the oil pump strainer
Worn oil pump related parts Replace the oil pump related parts
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing
Camshaft Worn camshaft and camshaft bearing Replace the camshaft and the camshaft
bearing
Crankshaft and bear- Worn crankshaft and bearings Replace the crankshaft and/or the bear-
ings ings

Abnormal Engine Noise
1. Engine Knocking
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

Fuel Fuel unsuitable Replace the fuel
Injection nozzle Improper injection nozzle starting pressure Adjust or replace the injection nozzle
and spray condition
Compression pressure Blown out head gasket Replace the head gasket or the piston ring
Broken piston ring
2. Gas Leakage Noise

Exhaust pipes Loosely connected exhaust pipes. Broken Tighten the exhaust pipe connections
exhaust pipes Replace the exhaust pipes
Injection nozzles and/ Loose injection nozzles and/or glow plugs Replace the washers
or glow plugs Tighten the injection nozzles and/or the
glow plugs
Exhaust manifold Loosely connected exhaust manifold and/ Tighten the exhaust manifold connections
or glow plugs
Cylinder head gasket Damaged cylinder head gasket Replace the cylinder head gasket
3. Continuous Noise

Fan belt Loose fan belt Readjust the fan belt tension
Cooling fan Loose cooling fan Retighten the cooling fan
Water pump bearing Worn or damaged water pump bearing Replace the water pump bearing
Generator or vacuum Defective generator or vacuum pump Repair or replace the generator or the vac-
pump Defective generator or vacuum pump uum pump
Valve clearance Clearance improperly adjust Adjust the valve clearances
4. Slapping Noise

Rocker arm Damaged rocker arm Replace the rocker arm
Flywheel Loose flywheel bolts Retighten the flywheel bolts
Crankshaft and thrust Worn or damaged crankshaft and/or thrust Replace the crankshaft and/or the thrust
bearings bearings bearings
Crankshaft and con- Worn or damaged crankshaft and/or con- Replace the crankshaft and/or the con-
necting rod bearings necting rod bearings necting rod bearings
Connecting rod bush- Worn or damaged connecting rod bushing Replace the connecting rod bushing and/
ing and piston pin and piston pin or the piston pin
Piston and cylinder Worn or damaged piston and cylinder Replace the piston and the cylinder liner.
liner liner.

Engine Cooling Trouble

Engine overheating Low coolant level Replenish
Thermo unit faulty Replace
Faulty thermostat Replace
Faulty coolant unit Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of improper Replenish or change oil
engine oil Replenish
Damaged cylinder head gasket Replace
Clogged exhaust system Clean exhaust system or replace faulty
parts
Loose fan belt Adjust
Excessive fuel injected Adjust
Improper injection timing Adjust
Engine overcooling Faulty thermostat Replace
Too long engine warm- Faulty thermostat Replace
up time Thermo unit faulty Replace

Primary Specifications
Item Engine type 4JB1-TC Engine type 4JB1NA

Engine type Four-cycle, overhead valve,
←
water injection
Combustion chamber type Direct injection ←
Cylinder liner type Dry type, chrome plate,
←
stainless steel tube
Timing train system Gear drive ←
No. of cylinders — Bore × stroke mm (in) 4 — 93 × 102 (3.66 × 4.02) ←
No. of piston rings Compression rings: 2 /
←
Oil ring: 1
Total piston displacement cm3 (in3) 2,771 (169.0) ←
Compression ratio (to 1) 18.1 ←
Compression pressure kPa (kg/cm2 /psi) 3,038 (31/441) ←
Engine weight (Dry) N (kg/lb) Approximately
2,256 (230/507)
2,511 (256/564)
Fuel injection order 1—3—4—2 ←
Fuel injection timing BTDC 4° 12°
Specified fuel type SAE No. 2 diesel fuel ←
Idling speed rpm 725 — 775 ←
Valve clearance (AT cold) Intake: mm (in) 0.40 (0.016) ←
Exhaust: mm (in) 0.40 (0.016) ←
Valve clearance (AT hot) Intake: mm (in) 0.45 (0.018) ←
Exhaust: mm (in) 0.45 (0.018) ←
Intake valves Open at (BTDC) 24.5
←
deg
Close at (BTDC) 55.5
←
deg
Exhaust valves Open at (BTDC) 54
←
deg
Close at (BTDC) 26
←
deg
Lubrication system ←
Lubrication method Pressurized circulation ←
Specified engine oil (API grade) CD ←
Oil pump type Gear ←
Oil filter type Disposable cartridge (Spin-
←
on) Paper element
Oil capacity (Including oil filter) lit (US/lmp gal) 7.0 (1.85/1.54) ←
Oil cooler type Water cooled ←
Item Engine type 4JB1-TC 4JB1NA

Fuel system
Injection pump type Bosch distributor ←
Governor type Mechanical
(Partially variable speed) ←
(For EC Variable speed)
Injection nozzle type Hole ←
Injection nozzle opening pres- MPa (kg/cm2/psi) 1st: 19.5 (199/2,830)
18.1 (185/2,631)
sure 2nd: 26.5 (270/3,840)
Main fuel filter type Cartridge paper element
←
and water separator
Engine cooling
Cooling system Coolant forced circulation
Radiator (2 tube in row) Tube type
←
Corrugated
Coolant capacity lit (lmp.qt.) 3.1 (2.73)
Coolant pump
Pulley type Centrifugal impeller type ←
Thermostat type Wax pellet with jiggle valve.
Valve opening °C (°F) 82 (180) ←
Valve full open °C (°F) 95 (203) ←
Coolant total capacity lit (lmp.qt.) 10 (8.80) ←
Engine electrical
Generator type Alternating current type ←
Output V—A 12 — 50 ←
Regulator type IC ←
Starter type Reduction type ←
Output V — kW 12 — 2.0 ←
Induction system
Air cleaner type Dry paper element ←
Turbocharger IHI RHF4 —

Special Tools
Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks
5-8531-7001-0 / Gauge
5-8840-0200-0 / Oil Filter
Adapter
Wrench (89.0 mm/3.5 in)
5853170010
5884002000
9-8523-1423-0 (J-29760) 5-8840-0145-0 / Measur-

/ Valve Spring Compres- ing Device
sor
5884001450
9852314230
5-8840-2834-0 / Timing
5-8840-2033-0 / Oil Seal
Gauge Adapter
Installer
ST5884028340
5884020330
5-8840-0266-0 / Angle
5-8840-9018-0 / Piston
Gauge
Ring Compressor
5884002660
5884090180
9-8523-1212-0 / Valve 5-8840-9016-0 / Injec-

Guide Replacer tion Nozzle Tester
5884090160
9852312120
5-8840-2034-0 / Nozzle
5-8840-2675-0 / Com- Holder Remover (4JB1
pression gauge only)
5884020340
5884026750
Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks
5-8840-2038-0 / Cam- 5-8840-2000-0 / Pilot

shaft Bearing Replacer Bearing Remover
5884020380 5884020000
5-8840-2036-0 / Front Oil 5-8840-0019-0 / Sliding

Seal Installer Hammer
5884020360 5884000190
5-8840-0253-0 / (J-
5-8522-0024-0 / Pilot
22700) Fuel Filter
Bearing Installer
Wrench
5884002530 5852200240
5-8840-2360-0 / Rear Oil 1-8531-7015-0 / Dial

Seal Remover Gauge
5884023600 1853170150
5-8840-2359-0 / Rear Oil 5-8521-0002-0 / Univer-

Seal Installer sal Puller
5884023590 582100020
5-8840-2040-0 / Cylin- 5-8525-3001-0 / Pilot

der Liner Installer Aligner
5884020400 5852530010
5-8840-2039-0 / Cylin- 5-8840-2057-0 / Crank-

der Liner Remover (4JB1 shaft Timing Gear
only) Remover
5884020390 5884020570
Tool Number /
Illustration
Description / Remarks
9-8522-0020-0 / Crank-
shaft Timing Gear
Installer
9852200200
Engine Assembly
Component
LNW81BMF005201
Legend
1. Radiator assembly 7. Front exhaust pipe
2. Engine control cable 8. Oil pressure switch harness
3. Transmission and clutch assembly 9. Intake air duct
4. Heater hose 10. Support rubber
5. Power steering pump & bracket assembly (Power 11. Fuel hose
steering model) 12. Glow plug harness
6. Engine assembly 13. Vacuum pump hose
Removal
Preparation
• Disconnect battery ground cable.
• Drain coolant.
1. Transmission and Clutch Assembly
• Raise vehicle and support with suitable safely.
1) Propeller Shaft
• Reference mark the flange yoke to the parking
brake drum.
• Disconnect the propeller shaft at flange yoke.
• Put aside the propeller shaft and tie it to the
frame so that it does not interface with servicing
work.
Legend Legend
1. Reference mark 1. Shift cable
2. Clip
2) Parking Brake Cable 3. Select cable
• Move the joint cover. 4. Snap pin
• Disconnect the joint bolt. 5. Snap pin
• Remove the clip then disconnect the cable from
5) Clutch Slave Cylinder
the bracket.
• Remove the clutch pipe fixing clips and the clip
bracket (Right hand drive models only).
LNW81BSH011201
3) Wiring Connector LNW81BSH011401
• Disconnect the wiring connectors from the car

speed sensor, the neutral switch and the back- Legend
up light switch. 1. Flexible hose
4) Shift Cable and Select Cable 2. Clutch pipe
• Disconnect the shift cable and select cable on
the transmission side. • Remove the slave cylinder assembly with the
flexible hose attached, and then tie it to the
frame so that it does not interface with servicing
work.
6) Front Exhaust Pipe • Engine and transmission angles may need to

be adjusted for removal.
• Hold the rear section of the engine by the jack
or hoist.
Caution:
When lifting the engine by the jack, use wood blocks to
prevent any possible damage to the oil pan.
• Remove transmission fastening bolts.
• Pull out the transmission assembly rearward.
8) Mounting Bracket
• Raise vehicle and support with suitable safety
stands.
Note:
Do not let clutch fluid remain on a painted surface, wash
it off immediately.
9) Pressure Plate Assembly
LNW81BSH011601 10) Driven Plate Assembly
7) Transmission Assembly • Use the pilot aligner to prevent the driven plate
assembly from falling free.
Note: Pilot Aligner: 5-8525-3001-0
The gear control bracket and the clips are sometimes in-
• Mark the flywheel and pressure plate lug for
stalled in the wrong position or direction confusedly. To
alignment when installing.
prevent incorrect installation of these parts, put a correct
installation mark on them. • Loosen the pressure plate assembly fixing
bolts.
• Support the transmission with mission jack.
Caution:
To prevent the falling of the transmission, tie it firmly to
the jack with a chain or belt.
Do not allow transmission to hang unsupported from
clutch. Damage to the clutch assembly will result.
2. Radiator Assembly 6. Glow Plug Harness

1) Remove the radiator hose upper and lower. 7. Fuel Hose
2) Remove the reservoir tank hose. • Remove the fuel inlet hose and fuel return hose.
3) Remove the cushion rubbers on both sides. 8. Oil Pressure Switch Harness
4) Remove the radiator stay. 9. Power Steering Pump & Bracket Assembly (Power
Steering Model)
1) Loosen the idle pulley lock nut.
2) Loosen the adjust bolt then remove the drive
belt.
3) Remove the pipe bracket fixing bolt and clip.
4) Remove the power steering pump fixing bolts
pump to chassis frame side use the wire.
LNW81BSH012701
3. Intake Air Duct

4. Heater Hose
5. Engine Control Cable
• Loosen the locking nut at the bracket and discon-
nect accelerator cable from injection pump control
lever. LNW81BSH013001
Legend
1. Clip
2. Bracket
3. Lock nut
4. Clip
10. Vacuum Pump Hose (Exhaust Brake Model)


• Disconnect the vacuum hose from vacuum tank • Remove two fixing nuts at the cross member
side and magnetic valve side. side.
13. Engine Assembly
1) Lift engine carefully by using hoist.
LNW81BSH013201
11. Front Exhaust Pipe

LNW81BSH013301
1) Exhaust manifold fixing nuts.
• Remove two fixing nuts from exhaust manifold 2) Lift front part of engine higher than rear part of
and front pipe. it.
2) Front exhaust pipe mounting bracket fixing nut 3) Take out engine assembly taking care not to
and bolt. damage full pipes, brake pipes and so on.
3) Front exhaust pipe fixing nuts and bolts.
Installation
• Remove two bolts fixed from front pipe and
1. Engine Assembly
center pipe.
4) Front exhaust pipe. • Position engine mountings by using hoist.
• Take out the exhaust pipe to another side. 2. Support Rubber
• After all fixing bolts (left: two bolts, right: two bolts)
were inserted to every holes, and engine asm and
tighten fixing bolts to the specified torque.
Tighten:
• 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
1) Front exhaust pipe fixing nuts and bolts.
• Tighten the fixing nuts to the specified torque
(With exhaust brake, without exhaust brake)
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
2) Front exhaust pipe mounting clamp fixing nut
and bolt.
• Tighten the fixing bolt to the specified torque
Tighten:
LNW81BSH014701 • 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
3) Exhaust manifold fixing nuts
12. Support Rubber • Tighten the fixing nuts to the specified torque
1) Right Hand (Engine side)
• Remove two fixing nuts at the cross member
Tighten:
side.
• 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
2) Left Hand
4. Vacuum Pump Hose (Exhaust Brake Model)

Legend
• Connect the vacuum hose to vacuum tank side and
1. Clip
magnetic valve side.
2. Bracket
3. Lock nut
4. Clip
LNW81BSH013201
5. Power Steering Pump & Bracket Assembly (Power

Steering Model)
• Install the power steering pump and pipe bracket
then tighten bolts to the specified torque.
Tighten:
• Pump bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Pipe bracket bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Clip bolt to 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)

• Install Power Steering pump drive belt (1) and ad-
just belt tension.
Check drive belts for wear or damage, and replace
with new ones as necessary.
Check belts for tension, and adjust as necessary.
• Push the middle of belts with a force of 98N (10 kg
/ 22 lb) and check each bolt for deflection.
• Standard deflection
Amount of Frequency
Belt types flex of vibrations
mm (in) Hz
For a new 8 - 11
135 - 165
P/S pump product (0.31 - 0.43)
drive belt 11 - 12
When reused 117 - 135
(0.43 - 0.47)
LNW81BSH013401
10. Heater Hose

• Connect the heater hose then tighten clip securely.
11. Intake Air Duct
• Connect the air duct and tighten clamp securely.
• Use a new hose clamp
Tightening torque: 6.4 N⋅m (0.65 kg⋅m / 56.4 lb⋅in)
LNW81BSH014801
Legend
1. AC generator & fan pulley drive belt
2. P/S pump drive belt
6. Oil Pressure Switch Harness

• Connect the oil pressure switch harness connec-
tor.
LNW81BSH012801
7. Fuel Hose
• Connect the fuel feed hose and return hose then 12. Radiator Assembly
tighten clip securely. 1) Install the cushion rubber on both sides.
8. Glow Plug Harness 2) Install the radiator stay.
• Install the harness connector then tighten bolt se- 3) Connect the radiator hose upper and lower.
curely. 4) Connect the reservoir tank hose.
9. Engine Control Cable
1) Install the control wire to the engine control le-
ver.
2) Hold accelerator lever in the fully closed posi-
tion and stretch the control cable in the direc-
tion indicated by the arrow to remove any slack.
3) Tighten the accelerator cable bracket bolt.
13. Transmission and Clutch Assembly • Remove the pilot aligner.

1) Driven Plate Assembly Note:
• Apply multi-purpose with MOS2 type grease to In case a new pressure plate assembly is mounted, after
the driven plate hub spline. tightening a pressure plate at the specified torque, be
• Use the pilot aligner to install the driven plate sure to remove the wiring for protection of a diaphragm
assembly. spring.
Pilot Aligner: 5-8525-3001-0 3) Mounting Bracket
Tighten:
• Mounting bracket nuts to 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)
4) Transmission Assembly
Caution:
To prevent the falling of the transmission, tie it securely
to the jack with a chain or belt.
LNW81BSH011801

• Tighten pressure plate assembly fixing bolts in
numerical order.
Tighten:
• Pressure plate fixing bolt to 18 N⋅m (1.8 kg⋅m / 13
lb⋅ft)
LNW81BSH011701
• Shift transmission into high gear.

• Align transmission with engine slope.
• Turn output parking brake drum to aid clutch
spring engagement.
Tighten: Tighten:
• Clutch housing to flywheel hosing bolts to • 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
M10: 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft) 6) Clutch Slave Cylinder
M12: 91 N⋅m (9.3 kg⋅m / 67 lb⋅ft) Tighten:
• Raise engine and transmission up into rear • Slave cylinder bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
transmission mount. • Perform slave cylinder adjustment before in-
Tighten: stallation of the return spring.
• Engine rear mounting nuts to a. Loosen the lock nut of the push rod.
M10: 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft) b. Turn the adjust nut until it reaches the shift
M12: 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft) fork.
c. Back off the adjust nut 1.5 turns. (shift fork
free play Approximately 2 mm / 0.1 in).
d. Tighten the lock nut.
Tighten:
• Push rod lock nut to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
7) Shift Cable and Select Cable
8) Wiring Connector
• Color of Connector
Back-up Light Switch: Brown
Neutral Switch: Gray
9) Parking Brake Cable
10) Propeller Shaft
• Line up reference mark.
Tighten:
• Propeller shaft nuts to 66 N⋅m (6.7 kg⋅m / 48 lb⋅ft)
LNW81BSH012001 • Connect battery ground cable
• Pour coolant
Legend • Start the engine and check coolant leakage
1. M12 L=100 mm (3.94 in)
2. M10 L=40 mm (1.57 in)
3. M10 L=35 mm (1.38 in)
4. M10 L=52 mm (2.05 in)
5. M10 L=35 mm (1.38 in)
6. M12 L=35 mm (1.38 in)
7. M12 L=35 mm (1.38 in)
5) Front Exhaust Pipe

(1) Front exhaust pipe fixing nuts and bolts.
• Tighten the fixing nuts to the specified
torque
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(2) Front exhaust pipe mounting bracket fixing
nut and bolt.
Tighten:
• 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(3) Exhaust manifold fixing nuts
torque
(Engine side)
Engine Mount (RH)

Component
LNW81BMF003001
Legend
1. Fan shroud 4. AC generator & fan pulley drive belt
2. Lock bolt 5. Rigid suspension
3. AC generator fixing bolt 6. Support rubber
Removal • Remove two fixing nuts at the crossmember side.

Preparation • Separate the generator from the engine.
• Disconnect battery ground cable. • Remove the support rubber nut from engine foot
1. Fan Shroud side.
• Remove reservoir tank hose and fan shroud. • Remove the support rubber while raising the en-
gine.
LNW81CSH001301
LNW81BSH015101
• Remove adjust plate lock bolt.
• Loosen generator fixing bolt then remove fan belt.
3. Support Rubber

Installation
1. Support Rubber
• Install the support rubber while raising the engine.
• Tighten the fixing nuts to the specified torque.
Tighten:
• Engine foot side to 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
• Crossmember side to 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
• Install the AC generator & fan pulley drive belt.
• Depress the fan belt mid-portion with a 98 N (10 kg/
22 lb) force.
• Tighten the fixing bolt to the specified torque.
Tighten:
• Adjust plate lock bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Generator fixing bolt to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
Amount of Frequency
mm (in) Hz
For a new 7-9
133 - 157
Generator product (0.28-0.35)
drive belt 9-11
(0.35-0.43)
For a new 8 - 11
135 - 165
P/S pump product (0.31-0.43)
drive belt 11 - 12
(0.43-0.47)
LNW81BSH014801
Legend
3. Fan Shroud
• Install the fan shroud and clip the reservoir tank
hose.
Engine Mount (LH)

Component
LNW81BMF001101
Legend
1. Fan shroud 3. Support rubber
2. Air intake duct 4. Rigid suspension
Removal • Remove the support rubber nut from engine foot

side.
Preparation
• Remove the support rubber while raising the en-
gine.
1. Air Intake Duct
• Remove the intake duct.
2. Fan Shroud
• Remove reservoir tank hose and fan shroud.
N6A3229E
Installation
1. Support Rubber
LNW81CSH001301 • Install the support rubber while raising the engine.
3. Support Rubber • Tighten the fixing nuts to the specified torque.
• Remove two fixing bolts at the crossmember side. Tighten:
• Engine foot side to 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

• Crossmember side to 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft) 3. Air Intake Duct
2. Fan shroud • Install the air intake duct.
• Install the fan shroud and clip the reservoir tank • Use a new hose clamp.
hose. Tightening torque: 6.4 N⋅m (0.65 kg⋅m / 56.4 lb⋅in)
• Connect battery ground cable.
LNW81CSH001301
List of Tightening Torques
LNW81BMF005401
(a) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft) (d) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(b) 80 N⋅m (8.4 kg⋅m / 61 lb⋅ft) (e) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(c) 117 N⋅m (11.9 kg⋅m / 86 lb⋅ft) (f) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
Cylinder Head Cover

Component
LNW81BSF000301
Legend
1. Cylinder head cover 2. PCV hose
Removal • Install the cylinder head cover gasket to the cylin-

Preparation der head cover.
• Disconnect battery ground cable. • The gasket must be perfectly smooth with no loose
areas.
1. PCV Hose
• Tighten the cylinder head cover nuts to the speci-
• Disconnect the PCV hose from intake pipe side.
fied torque.
2. Cylinder Head Cover
Tighten:
• 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
2. PCV Hose
• Connect the PCV hose to the intake pipe.
LNW81BSH003301
Installation
• Apply engine oil to the rocker arms and the valve
springs.

LNW81BSF001001
(a) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)

Inlet Manifold
Component
LNW81BMF001201
Legend
1. Injection pipe 5. Inlet manifold
2. Oil level gauge guide tube 6. Oil cooler water pipe (Oil Cooler Model)
3. Vacuum hose 7. Air intake duct
4. PCV hose
Removal
Preparation
• Drain coolant.
1. Vacuum Hose
2. Air Intake Duct
3. PCV Hose
4. Injection Pipe
• Release injection pipe clip.
• Loosen the flare nut on the injection pump side.
• Loosen the flare nut on the injection nozzle side,
disconnect and put a side the pipe.
LNW81BSH003101

5. Oil Level Gauge Guide Tube 3. Oil Level Gauge Guide Tube
• Remove the fixing bolt and remove level gauge • Install the guide tube and tighten the manifold with
guide tube. guide tube.
6. Oil Cooler Water Pipe (Oil Cooler Model) Tighten:
• Remove the water pipe bracket bolt. • Bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Remove the inlet manifold fixing nut. 4. Injection Pipe
• Connect the injection pipe and tighten flare nut to
the specified torque.
Tighten:
• Flare nut to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
• Install the pipe clip to the original position.
LNW81BSH010301
7. Inlet Manifold
• Remove the manifold fixing bolt and nut.
Installation
1. Inlet Manifold
LNW81DSH002701
• Tighten the fixing nuts and bolts to the specified
torque. 5. PCV Hose
Tighten: 6. Air Intake Duct
• Nut & bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft) • Install the air intake duct.
2. Oil Cooler Water Pipe (Oil Cooler Model) • Use a new hose clamp
• Install the water pipe and tighten the manifold with Tightening torque: 6.4 N⋅m (0.65 kg⋅m / 56.4 lb⋅in)
water pipe. 7. Vacuum Hose
• Tighten the pipe bracket bolt of cylinder head rear • Connect the battery ground cable.
side. • Pour coolant.
• Start the engine and check coolant leakage.
LNW21BSH045501

LNW81BMF005601
(a) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)

(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(c) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
Exhaust Manifold
Component
LNW81GMF000301
Legend
1. Front exhaust pipe nut 3. Front exhaust pipe stay bolt
2. Front exhaust pipe 4. Front exhaust fixing washer and nut
Removal
Preparation
• Battery ground cable
1. Exhaust manifold fixing nuts.
• Remove two fixing nuts from exhaust manifold and
front pipe.
2. Front exhaust pipe mounting bracket fixing bolt and
nut.
LNW21BSH045701
3. Front exhaust pipe fixing nuts and bolts.

• Remove two bolts fixed from front pipe and center
pipe.

4. Front exhaust pipe.
Tighten:
• Take out the exhaust pipe to another side. • 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft) 4JB1-TC
Inspection • 37.2 N⋅m (3.8 kg⋅m / 27 lb⋅ft) 4JB1NA
Installation
2. Front exhaust pipe fixing bolts and nuts.
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
3. Front exhaust pipe mounting clamp fixing nut and
bolt.
Tighten:
• 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
4. Exhaust manifold fixing nuts
• Tighten the fixing nuts to the specified torque LNW81GSH002101
(Engine side)
• After assembling each part, start the engine to
check for any leakage of gas at each connection.
LNW81GMF000801
(a) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft) (c) 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft) 4JB1-TC
(b) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft) 37.2 N⋅m (3.8 kg⋅m / 27 lb⋅ft) 4JB1NA
Timing Gear
Component
LNW81BMF005101
Legend
1. Injection pump 8. AC generator drive belt
2. Timing gearcase cover 9. Cooling fan
3. Idle gear 10. Power steering pump drive belt
4. Camshaft timing gear 11. Fan shroud
5. Oil pipe 12. Crankshaft damper pulley
6. Crankshaft gear 13. Noise shield cover
7. Idle gear 14. Noise cover spacer
Removal • Loosen power steering pump mounting bolt and

adjust bolt, and remove the drive belt.
Preparation
3. AC Generator Drive Belt
• Loosen AC Generator mounting bolt (under size)
• Drain coolant.
and adjust plate lock bolt, and remove the drive
1. Fan Shroud belt.
2. Power Steering Pump Drive Belt

4. Cooling Fan Assembly
• Remove clamp nut, and remove cooling fan as-
sembly, distant pipe, and fan pulley.
5. Crankshaft Damper Pulley
6. Noise Shield Cover
7. Noise Cover Spacer
8. Timing Gearcase Cover
9. Oil Pipe
10. Idle Gear
1) Measure the camshaft timing gear backlash
and the crankshaft timing gear backlash before
removing the idle gear.
2) Measure the idle gear end play before remov-
ing the idle gear.
PJW010SH004301
2) Move the gear to be checked as far as possible

to both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified
limit, the timing gear must be replaced.
Timing Gear Backlash mm (in)

Standard Limit
0.010 — 0.17 0.30 (0.012)
(0.0039 — 0.0067)
12. Idle Gear “A” End Play Measurement

Insert a feeler gauge between the idle gear and the
LNW81BSH010501 thrust collar to measure the gap and determine the
idle gear end play.
Note: If the measured value exceeds the specified limit,
Refer to the following items for details on the backlash the thrust collar must be replaced.
and end play measurement procedures.
Idle Gear End Play mm (in)
11. Timing Gear Backlash Measurement
Standard Limit
1) Set a dial indicator to the timing gear to mea-
sured. 0.07 (0.0028) 0.2 (0.0079)
Hold both the gear to be checked and the ad-
joining gear stationary.
PJW010SH004401 LNW81BSH008201
13. Idle Gear 4) Pull the injection pump along with the injection
14. Injection Pump pump timing gear free toward the rear of the en-
1) Remove the six injection pump bracket bolts (1) gine.
from the timing gearcase. Note:
Plug the injection pump delivery holder ports with the
shipping caps (or the equivalent) to prevent the entry of
foreign material.
15. Camshaft Timing Gear
1) Use a dial indicator to measure the camshaft
end play. This must be done before removing
the camshaft gear.
If the camshaft end play exceeds the specified
limit, the thrust plate must be replaced.
Camshaft End Play mm (in)

Standard Limit
0.050 — 0.114 (0.002 — 0.2 (0.008)
0.0044)
LNW81BSH008101
2) Remove the injection pump rear bracket bolts

(1) from the injection pump bracket (4).
3) Remove the injection pump rear bracket bolts
(2) and the bracket (3) from the cylinder body.
LNW21BSH051601

2) Remove the camshaft timing gear bolt from the 2. Camshaft Timing Gear
camshaft. 1) Install the thrust plate to the cylinder body.
Note: 2) Tighten the thrust plate bolts to the specified
Hold the camshaft stationary to prevent the camshaft torque.
from turning. Tighten:
3) Use the universal puller (3) to pull out the cam- • 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
shaft timing gear (2). 3) Install the camshaft timing gear to the cam-
Universal Puller: 5-8521-0002-0 shaft.
4) Remove the thrust plate (1). The timing gear mark (“Y — Y”) must be facing
outward.
4) Tighten the timing gear to the specified torque.
Tighten:
• 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
LNW81BSH015001
16. Crankshaft Gear
Installation
1. Crankshaft Gear LNW81BSH007001
1) Install the crankshaft gear. 3. Injection Pump

2) Use the crankshaft gear installer (2) to install 1) Install the O-ring (3) to the injection pump
the crankshaft gear (1). flange (4).
The crankshaft gear timing mark (“X — X”) or (“⋅
2) Install the injection pump to the timing gear-
— ⋅”) must be facing outward.
case.
Crankshaft Gear Installer: 9-8522-0020-0 Align the idle gear “B” (2) “V — V” mark with the
injection pump timing gear (1) “V” mark.
LNW81BSH007801
LNW81BSH006201
Gear
Crank gear — Idle gear “A” X—X
Idle gear “A” — Cam gear Y—Y
Idle gear “A” — Idle gear “B” Z—Z
Idle gear “B” — Injection pump V—V
LNW81BSH008201
6) Tighten the injection pump nuts to the specified

torque.
Tighten:
• 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
7) Tighten the injection pump bracket bolts to the
specified torque.
N6A3165E
Tighten:
3) Temporarily tighten the six injection pump bolts • 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(1). 4. Idle Gear
The injection pump bolts will be finally tight- 1) Apply engine oil to the idle gear and the idle
ened after the injection pump rear bracket gear shaft.
bolts. The idle gear shaft oil hole must be facing up.
4) Install the injection pump rear bracket (3) and 2) Position the idle gear setting marks “X” and “Y”
the rear bracket bolts (2) to the cylinder block. so that they are facing the front of the engine.
5) Install the rear bracket bolts (1) to the injection 3) Align the idle gear “X” setting mark with the
pump bracket (4). crankshaft timing gear (1) “X — X” setting mark.
Do not tighten the bolts. 4) Align the idle gear “Y” setting mark with the
The rear bracket bolts (2) and (1) will be finally camshaft timing gear (2) “Y — Y” setting mark.
tightened to the specified torque after tighten
the injection pump nuts.

1) Install the oil pipe to the timing gearcase and
idle gear “A”.
2) Tighten the oil pipe eye bolt (2) and bolt (1) to
Tighten:
• Oil pipe eye bolt to 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
LNW81BSH014101
5) Install the thrust collar and bolts to the cylinder

block through the shaft.
The thrust collar oil hole must be facing up, and
the thrust collar chamfered must be outward.
6) Tighten the idle gear bolt to the specified
torque. LNW81BSH008301
Tighten:
• 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
5. Idle Gear
1) Apply engine oil to the idle gear and the idle
gear shaft.
2) Align the idle gear “B” (1) “Z” setting mark with
the idle gear “A” (2) “Z — Z” setting mark.
LNW81BSH008001

torque.
Tighten:
• 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
6. Oil Pipe

7. Timing Gearcase Cover 11. Cooling Fan Assembly
1) Align the gearcase with the timing gearcase • Mount fan pulley, distance piece, and cooling fan
knock pin and then install the timing gearcase assembly (in this order) on the water pump, and
cover. tighten to the specified torque.
2) Tighten the gearcase cover bolts to the speci-
Tighten:
fied torque.
• 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
• Install AC Generator drive belt and adjust belt ten-
sion.
• Depress the drive belt mid-portion with a 98 N (10
kg / 22 lb) force.
Drive Belt Deflection mm (in)

8 (0.31) — 12 (0.47)
• Tighten the idle lock nut to the specified torque.

Tighten:
• Idle lock nut to 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
13. Power Steering Pump Drive Belt (P/S Model)
• Install Power Steering pump drive belt and adjust
belt tension.
LNW81BSH008401 • Depress the drive belt mid-portion with a 98 N (10
kg / 22 lb) force.
9. Noise Shield Cover Drive Belt Deflection mm (in)
10. Crankshaft Damper Pulley 8 (0.31) — 12 (0.47)
Tighten the crankshaft damper pulley bolt to the
specified torque. • Tighten the idle lock nut to the specified torque.
Note: Tighten:
Hold the flywheel ring gear stationary to prevent the • 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
crankshaft from turning when tightening the damper pul- 14. Fan shroud
ley. • Install the fan shroud and reservoir tank hose.
• Pour coolant
Tighten:
• Pulley boss bolt to 206 N⋅m (21 kg⋅m / 152 lb⋅ft) • Start the engine and check coolant leakage.
LNW81BSH008501

LNW81BMF003801
(a) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in) (d) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft) (e) 108 N⋅m (11 kg⋅m / 80 lb⋅ft)
(c) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
Valve Spring, Valve Guide Oil Seal, Valve Guide, Push Rod
Component
LNW81BMF002501
Legend
1. Rock arm assembly 5. Valve guide oil seal
2. Split collar 6. Spring lower seat
3. Spring upper seat 7. Valve guide
4. Valve spring 8. Valve
Removal
Preparation
• Disconnect battery cable.
2. Rocker Arm Shaft Assembly
• Loosen bolts and nuts of rocker shaft bracket by
turns and removal rocker shaft assembly.
3. Valve Spring
• Apply compressed air to cylinder from the glow
plug hole hold the valve in place.
• Using special tool, compress valve spring and re-
moval split cover.
Valve spring compressor: 9-8523-1423-0 (J-
29760)
PJW010SH005501

7. Spring Lower Seat
Note:
Put removed valve spring in the order of cylinder num- 8. Valve Guide
ber. Valve Guide Replacer: 9-8523-1212-0
4. Valve Guide Oil Seal Inspection and Repair

• Remove valve guide oil seal by pliers Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
Valve spring
Caution:
Visually inspect the valve springs and replace them if
damage or abnormal wear is evident.
1. Free height
• Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit.
Free Height mm (in)

Standard Limit
48.0 (1.891) 47.100 (1.8560)
LNW21BSH048201
Note:
Removed oil controller should not be reused.
Disassembly
1. Rocker Arm Assembly
2. Split Collar
Using special Tool, compress valve spring
29760)
3. Spring Upper Seat
LNW21BSH017001
2. Squareness
• Measure the valve spring squareness with a
steel square.
• Replace the valve springs if the measured val-
ue exceeds the specified limit.
Limit mm (in)
1.7 (0.067)
LNW81BSH006801
4. Valve Spring
5. Valve
6. Valve Guide Oil Seal

1. Valve Guide Clearance
• Measure the valve stem diameter with a mi-
crometer.
If the valve stem diameter is less than the spec-
ified limit, the valve and the valve guide must be
replaced as a set.
mm (in)
Standard Limit
7.946 — 7.961
7.880
Inlet (0.3128 —
(0.310.2)
Diameter of 0.3134)
Valve stem 7.921 — 7.936
7.850
Exhaust (0.3118 —
(0.3091)
0.3124)
LNW21BSH017101 • Measure the inside diameter of the valve guide

with a micrometer.
3. Spring tension • Subtract the measured outer diameter of the
• Use spring tester to compress the springs to valve stem from the measured inner diameter
the installed height. Measure the compressed of the valve guide. If the valve exceeds of the
spring tension. valve guide.
Replace the springs if the measured tension is If the valve exceeds the specified limit, the
below the specified limit. valve and the valve guide must be replaced as
a set.
Tension N (kg/lb)
Standard Limit Valve Guide Clearance mm (in)
At installed height Standard Limit
38.9 mm (1.5 in) 296.2 (30.2/ 257.9 (26.3/
66.6) 57.9) 0.039 — 0.069
0.200
Inlet clearance (0.0015 —
(0.0079)
0.0027)
0.064 — 0.096
0.250
Exhaust clearance (0.0025 —
(0.0098)
0.0038)
LNW21BSH056701
Valve Guide
Note:
Taking care not to damage the valve seat contact sur-
face, when removing carbon adhering to the valve head. LNW21BSH017301
Carefully inspect the valve stem for scratching or abnor-

mal wear. If these conditions are present, the valve and
the valve guide must be replaced as a set.

Valve Guide Replacement Valve Thickness
1. Using special tool, drive out the valve guide from 1. Measure the valve thickness
the combustion chamber side. 2. If the measured value is less than the specified lim-
Valve guide replacer: 9-8523-1212-0 it the valve and the valve guide must be replaced
as a set.
Valve Thickness mm (in)

Standard Limit
Inlet 1.79 (0.0705)
1.5 (0.06)
Exhaust 1.83 (0.0720)
LNW21BSH049401
2. Apply engine oil to the outside of the valve guide.

Using special tool, drive in a new valve guide from
cylinder head upper face side, and check the valve
guide height.
Valve guide replacer: 9-8523-1212-0
Height mm (in) LNW21BSH017801
13 (0.51)
Contact Surface Angle on Valve Seat on Valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve guide and valve seat as a set.
Standard Degrees
45°
LNW21BSH050001
Notice:
If the valve guide has been removed, both the valve and
LNW21BSH018101

Valve Depression
1. Install the valve to the cylinder head.
2. Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the cyl-
inder head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Valve Depression (a) mm (in)

Standard Limit
Inlet 0.73 (0.029) 1.28 (0.050)
Exhaust 0.70 (0.028) 1.20 (0.047)
LNW21BSH018001
Valve Seat Insert Replacement

Valve Seat Insert Removal
1. Arc weld the tire inside circumference (3) of the
valve seat insert (1).
2. Allow the valve seat insert to cool for a few min-
utes.
This will invite contraction and make removal of the
valve seat insert easier.
3. Use a screwdriver (2) to pry the valve seat insert
free.
Take care not to damage the cylinder head (4).
4. Carefully remove carbon and other foreign material
HCW51BSH019601 from the cylinder head insert bore.
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact sur-
faces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Contact Width mm (in)

Standard Limit
Inlet 1.7 (0.0670) 2.2 (0.0866)
Exhaust 2.0 (0.0788) 2.5 (0.0984)
LNW81BSH006901
Valve Seat Insert Installation

1. Carefully place the attachment (1) (having a small-
er outside diameter than the valve seat insert) on
the valve seat insert (2).
Note:
The smooth side of the attachment must contact the
valve seat insert.

2. Use a bench press (3) to gradually apply pressure
Note:
to the attachment and press the valve seat insert
Use an adjustable valve cutter pilot.
into place.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
3. Apply abrasive compound to the valve seat insert
surface.
LNW21BSH018601
Note:
Do not apply an excessive amount of pressure with the
LNW21BSH049501
bench press. Damage to the valve seat insert will result.
Valve Seat Insert Correction 4. Insert the valve into the valve guide.
1. Remove the carbon from the valve seat insert sur- 5. Turn the valve while tapping it to fit the valve seat
face. insert.
2. Use a valve cutter (15°, 45°, and 75° blades) to
minimize scratches and other rough areas, this will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do
not cut away too much. Take care not to cut away
unblemished area of the valve seat surface.
Valve Seat Angle degree

45°
LNW81BSH014001
6. Check that the valve contract width is correct.

7. Check that the valve seat insert surface is in con-
tact with the entire circumference of the valve.
Push Rod Curvature

1. Lay the push rod on a surface plate.
2. Roll the push rod along the surface plate and mea-
sure the push rod curvature with a thickness
gauge.
LNW21BSH018201
If the measure value exceeds the specified limit,
the push rod must be replaced.

4. Valve
Push Rod Curvature Limit mm (in)
• Apply engine oil to the outside of the valve
0.4 (0.0157) or less stem.
5. Valve Spring
• Attach the valve seat to the upper spring seat.
The painted area of the valve spring should be
facing downward.
LNW21BSH049901
3. Visually inspect both ends of the push rod for ex-

cessive wear and damage. The push rod must be
replaced if these conditions are discovered during LNW81BSH006501
inspection.
6. Spring Upper Seat
Reassembly 7. Split Collar
1. Valve Guide • Use a spring compressor to push the valve
• Apply engine oil to the outside of the valve spring into position.
guide. • Install the spring seat split collar.
Using special tool, drive in a new valve guide
• Set the split collar by tapping lightly around the
from the rocker arm shaft side.
head of the collar with a rubber hammer.
Valve guide replacer: 9-8523-1212-0
Valve spring compressor: 9-8523-1423-0 (J-29760)
2. Spring Lower Seat
• Using special tool, drive in a new oil seal
Oil special tool, drive in a new oil seal
Oil seal installer: 5-8840-2033-0
MJW21BSH000301
LNW21BSH048301

8. Rocker Arm Assembly
Tighten:
54 N⋅m (5.5 kg⋅m/40 lb⋅ft)
PJW010SH014501
• Apply compressed air to cylinder from the glow

plug hole to hold the valve in place.
LNW21BSH050801 • Install split collar by special tool
Installation Valve spring compressor: 9-8523-1423-0 (J-

29760)
• Install new valve guide oil seal in valve.
• Install rocker arm shaft with larger oil hole φ4) to
• Guide using special tool. the front of engine.
Special tool: 5-8840-2033-0
LNW81BSH006601
LNW21BSH048301
• Align fixing bolt with nut of rocker arm shaft and
2. Valve Spring tighten fixing bolts to the specified torque.
• Attach the new valve spring to the upper spring
seat. Tighten:
• 54 N⋅m (5.5 kg⋅m / 40 lb⋅ft)
Note: • Valve clearance adjustment
• The painted area of the valve spring should be fac-
4. Valve clearance adjustment
ing toward.
Above works refer to “ROCKER ARM SHAFT AS-
SEMBLY” Section in this manual.

spring.
• Install the cylinder head cover gasket to the cylin-
der head cover.
The gasket must be perfectly smooth with no loose
areas.
• Install cylinder head cover and tighten bolt to the
specified torque (a).
Tighten:
• Head cover bolt to 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
LNW81BSH003401
• Connected PCV hose.

Rocker Arm Assembly

Component
LNW81BMF002301
Legend
1. Rocker arm shaft assembly 5. Rocker arm shaft bracket
2. Rocker arm shaft 6. Rocker arm
3. Rocker arm shaft spring 7. Rocker arm shaft snap ring
4. Rocker arm
Removal
Preparation
1. PCV Hose
• Loosen bolts and nuts of rocker shaft bracket by
turns and remove rocker shaft assembly.
LNW21BSH049201

Disassembly
Rocker Arm and Rocker Shaft Clearance
2. Rocker Arm Shaft Snap Ring mm (in)
3. Rocker Arm Standard Limit
4. Rocker Arm Shaft Bracket 0.06 — 0.08 (0.0024 —
0.10 (0.0039)
5. Rocker Arm 0.0031)
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft
Inspection and Repair

Make the necessary adjustment, repairs, and part re-
during inspection.
Use a micrometer to measure the rocker shaft outside

diameter at the point where the rocker arm moves on the
rocker shaft.
Replace the rocker shaft if the diameter exceeds the
specified limit.
mm (in)
Standard Limit
18.98 — 19.00 (0.7472
18.9 (0.744)
— 0.7480) LNW21BSH050601
3. Check that the rocker arm oil port is free is obstruc-

tions.
If necessary, use compressed air to clean the rock-
er arm oil port.
LNW21BSH019101
Oil Clearance
1. Use either a vernier caliper or a dial indicator to
measure the rocker arm inside diameter.
LNW81BSH010101
Rocker Arm Inside Diameter mm (in)

Rocker Arm Correction
Standard Limit Inspection the rocker arm valve stem contact surface for
19.036 — 19.060 (0.7494 — step wear (1) and scoring (2).
19.100 (0.7519) If the contact surfaces have light step wear or scoring,
0.7503)
they may be honed with an oil stone.
2. Measure the rocker arm shaft outside diameter. If the step wear or scoring is severe, the rocker arm
If the measured value exceeds the specified limit, must be replaced.
replace either the rocker arm or the rocker arm
shaft.

• Install the rocker shaft together with the rocker
arm, the rocker arm shaft bracket, and the
spring.
LNW21BSH050701
Rocker Arm Shaft Run-Out

1. Place the rocker arm shaft on a V-block. LNW81BSH006601
2. Use a dial indicator to measure the rocker arm
shaft central portion run-out. 2. Rocker Arm Shaft Spring
If the run-out is very slight, correct the rocker arm 3. Rocker Arm
shaft run-out with a bench press. The rocker arm 4. Rocker Arm Shaft Bracket
must be at cold condition.
5. Rocker Arm
If the measured rocker arm shaft run-out exceeds
6. Rocker Arm Shaft Snap Ring
the specified limit, the rocker arm shaft must be re-
placed. 7. Rocker Arm Shaft Assembly
• Install the rocker arm shaft assembly in cylinder
Rocker Arm Shaft Run-Out mm (in) head.
Limit 0.2 (0.008) • Tighten the rocker arm shaft fixing bolts to the
specified torque.
Reassembly Installation
1. Rocker Arm Shaft 1. Rocker Arm Shaft Assembly
• Apply a light coat of engine oil to the rocker arm • Install rocker arm shaft with larger oil hole φ4) to
shafts. the front of engine.
• Position the rocker arm shaft with the large oil
hole (φ4) facing the front of the engine.
• Align fixing bolt with nut of rocker arm shaft and 3) Check for play in the No.1 intake and exhaust
tighten fixing bolts to the specified torque. valve push rods.
If the No.1 cylinder intake and exhaust valve
Tighten:
push rods have play, the No.1 piston is at TDC
• 54 N⋅m (5.5 kg⋅m / 40 lb⋅ft)
on the compression stroke.
2. Valve clearance adjustment
If the No.1 cylinder intake and exhaust valve
1) Bring the piston in either the No.1 cylinder or push rods are depressed, the No.4 piston is at
the No.4 cylinder to TDC on the compression TDC on the compression stroke.
stroke by turning the crankshaft until the crank-
shaft damper pulley TDC line is aligned with the
timing pointer.
LNW21BSH043601
Adjust the No.1 or the No.4 cylinder valve clear-

LNW81BSH015401 ances while their respective cylinders are at
TDC on the compression stroke.
2) Check the rocker arm shaft bracket nuts for
looseness. Valve Clearance (At Cold) mm (in)
Tighten any loose rocker arm shaft bracket
nuts before adjusting the valve clearance. 0.4 (0.016)
Tighten:
• Rocker arm shaft bracket nut to 54 N⋅m (5.5 kg⋅m / 40
lb⋅ft)

4) Loosen each valve clearance adjusting screw
Tighten:
as shown in the illustration.
• 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
No. 1 Cylinder T.D.C (Compression stroke)
4. PCV Hose
LNW21BSH043701
5) Insert a feeler gauge of the appropriate thick-

ness between the rocker arm and the valve
stem end.
6) Turn the valve clearance adjusting screw until
a slight drag can be felt on the feeler gauge.
7) Tighten the lock nut securely.
8) Rotate the crankshaft 360°.
9) Realign the crankshaft damper pulley TDC
notched line with the timing pointer.
10) Adjust the clearances for the remaining valves
No. 4 Cylinder T.D.C (Compression stroke)
LNW21BSH043801

• Install cylinder head cover and tighten bolts to the
specified torque.
Camshaft and Tappet

Component
LNW81BMF003301
Legend
1. Push rod 4. Camshaft key
2. Camshaft 5. Thrust plate
3. Tappet 6. Camshaft gear
Removal 1. Transmission and Clutch Assembly

Preparation 1) Transmission
• Disconnect battery ground cable. 2) Clutch
2. Engine Assembly
• Drain coolant.
1) Radiator assembly
• Drain engine oil.
2) Intake air duct
Note: 3) Heater hose
Install drain plug with new washer.
4) Engine control cable
Tighten: 5) Glow plug harness
• Drain plug to 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft) 6) Fuel hose

7) Oil pressure switch harness
8) Power steering pump & bracket assembly
(Power steering Model)
9) Actuator vacuum hose (Exhaust Brake Model)
10) Vacuum pump hose (Exhaust Brake Model)
11) Front exhaust pipe
12) Support rubber
13) Engine assembly
Above works refer to “ENGINE ASSEMBLY”
Section in this manual.
3. Cylinder Head Assembly and Gasket
1) Injection pipe
2) Leak off pipe
3) PCV hose
4) Glow plug harness
5) Oil level gauge guide tube
LNW21BSH051601
6) Oil cooler water pipe (Oil Cooler Model)
7) By-pass hose 5. Oil Pan Assembly
8) Cylinder head cover • Disconnect vacuum pump oil hose (1) from oil pan.
9) Rocker arm shaft
10) Push rod
11) Cylinder head assembly
12) Cylinder head gasket
Above works refer to “CYLINDER HEAD AS-
SEMBLY AND GASKET” Section in this manu-
al.
4. Timing Gear
1) Cooling fan assembly
2) Crankshaft damper pulley
3) Noise shield cover
4) Noise cover spacer
5) Timing gearcase cover
6) Camshaft timing gear
Above works refer to “TIMING GEAR” Section
in this manual.
LNW21BSH039201
Camshaft End Play mm (in)
• Remove the stiffener and space rubber from oil
Standard Limit pan both side.
0.08 (0.003) 0.20 (0.008)
• Remove the oil pan bolts and remove oil pan from • Take care not to damage the camshaft bearings.
cylinder body. • Take out the tappets from cylinder body.
6. Oil Pump Assembly
• Remove the oil pump assembly from cylinder body.
LNW21BSH051501
LNW21HSH004601 Disassembly
1. Cylinder Head Assembly
7. Camshaft and Tappets
2. Flywheel
• Remove the camshaft from cylinder body. 3. Cylinder Block Rear Plate
4. Oil Pan Assembly
• Remove the camshaft timing gear bolt from the
camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
• Use the universal puller (3) to pull out the cam-
shaft timing gear (2).
• Universal Puller: 5-8521-0002-0
Remove the thrust plate (1).

2. Camshaft Journal Diameter
• Use a micrometer to measure each camshaft
journal diameter in two directions (1) and (2). If
the measured value is less than the specified
limit, the camshaft must be replaced.
Journal Diameter mm (in)

Standard Limit
49.945 — 49.975
49.60 (1.9528)
(1.9663 — 1.9675)
LNW81BSH015001
7. Camshaft Thrust Plate

8. Camshaft
9. Tappet

Make the necessary adjustment, repairs, and part re-
during inspection.
1. Measure the Camshaft Thrust Clearance
• Use a dial indicator to measure the camshaft LNW81BSH016201
end play.
This must be done before removing the cam- 3. Cam Height
shaft gear. • Measure the cam height H with a micrometer. If
If the camshaft end play exceeds the specified the measured value is less than the specified
limit, the thrust plate must be replaced. limit, the camshaft must be replaced.
Camshaft End Play mm (in) Cam Height mm (in)
Standard Limit Standard Limit
0.08 (0.0031) 0.2 (0.0079) 42.02 (1.6543) 41.65 (1.6398)

4. Camshaft Run-Out
• Mount the camshaft on V-blocks.
• Measure the run-out with a dial indicator.
If the measured value exceeds the specified
limit, the camshaft must be replaced.
Run-Out mm (in)
Standard Limit
0.02 (0.008) or less 0.10 (0.0039)
LNW21BSH051701
Camshaft Bearing Replacement

Camshaft Bearing Removal
1. Remove the cylinder body plug plate.
2. Use the bearing replacer to remove the camshaft
bearing.
Bearing Replacer: 5-8840-2038-0
LNW21BSH020601
5. Camshaft and Camshaft Bearing Clearance

• Use an inside dial indicator to measure the
camshaft bearing inside diameter.
Camshaft Bearing Inside Diameter mm (in)

Standard Limit
50.00 — 50.03 (1.9685 — 1.9696) 50.08 (1.9716)
Camshaft Bearing Clearance mm (in)

Standard Limit
0.025 — 0.085 (0.0010 — 0.0033) 0.12 (0.005)
LNW21BSH051801
• If the clearance between the camshaft bearing
inside diameter and the journal exceeds the Camshaft Bearing Installation
specified limit, the camshaft bearing must be 1. Align the bearing oil holes with the cylinder body oil
replaced. holes.
2. Use the replacer to install the camshaft bearing.
Bearing Replacer: 5-8840-2038-0

Tappet Outside Diameter
1. Measure the tappet outside diameter with a mi-
crometer. If the measured value is less than the
specified limit, the tappet must be replaced.
Tappet Outside Diameter mm (in)

Standard Limit
12.97 — 12.99 (0.510 — 0.511) 12.95 (0.509)
LNW81BSH006701
Tappet
Visually inspect the tappet camshaft contact surfaces
for pitting, cracking, and other abnormal conditions. The
tappet must be replaced if any of these conditions are
present.
LNW21BSH052001
2. Measure the inside diameter tappet on the cylinder

block and calculate the clearance.
If the clearance exceeds the limit, replace tappet
or/and cylinder block.
Tappet and Cylinder Block Clearance mm (in)

Standard Limit
0.03 (0.001) 0.10 (0.004)
LNW21BSH052201
Legend
1. Normal contact
2. Cracking
3. Pitting
4. Irregular contact
5. 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 re-
placed. LNW81BSH007201

Reassembly
1. Tappet
1) Apply a coat of engine oil to the tappet (1) and
the cylinder body tappet insert holes (2).
LNW81BSH007401

1) Install the camshaft timing gear to the cam-
shaft.
LNW81BSH007301 The timing gear mark (“Y — Y”) must be facing
outward.
2) Locate the position mark applies at disassem-
2) Tighten the timing gear to the specified torque
bly (if the tappet is to be reused).
Tighten:
Note:
Timing Gear Bolt to 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
The tappet must be installed before the camshaft.
2. Camshaft
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 damage the camshaft bearings.
LNW81BSH007001

6. Oil Pan Assembly
Above works refer to “OIL PUMP” Section in this
manual.
LNW21BSH051401 7. Cylinder Block Rear Plate
• Tighten cylinder block rear plate fixing bolts to
3. Camshaft Thrust Plate the specified torque.
Install the thrust plate to the cylinder body and
tighten the thrust plate bolts to specified torque. Tighten:
Rear Plate Bolt to 82 N⋅m (8.4 kg⋅m/61 lb⋅ft)
Tighten:
Thrust Plate Bolt to 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)

8. Flywheel
• Apply engine oil to fixing bolts.
• Tighten the flywheel bolts to the specified
torque in two steps using the Angular Tighten-
ing Method.
Follow the numerical order shown in the illus-
tration.
Tighten:
• Flywheel Bolt to
1st Step (Snug torque): 59 N⋅m (6.0 kg⋅m/43 lb⋅ft)
2nd Step (Final torque): 60° — 90°
LNW21BSH018601
Note:
bench press. Damage to the valve seat insert will result.
Measure the height of the valve guide upper
end from the upper face of the cylinder head.
Valve Guide Upper End Height (H) (Reference)

mm (in)
13 (0.51)
LNW21BSH036401

1) Valve Seat Insert Installation
• Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat
insert) on the valve seat insert (2).
Note:
valve seat insert.
• Use the bench press (3) to gradually apply
pressure to the attachment and press the
valve seat insert into place.
LNW21BSH050001
Note:

2) Spring Lower Seat
3) Valve Stem Oil Seal
4) Valve
5) Valve Spring
6) Spring Upper Seat
7) Split Collar
Above works refer to “VALVE” Section in this
manual.
Installation
1. Camshaft and Tappets
• Apply a coat of engine oil to the tappet and the cyl-
inder body tappet insert holes.
• Locate the position mark applied at disassembly (if
the tappet is to be reused).
Note:
LNW21HSH004601
The tappet must be installed before the camshaft.
• Apply a coat of engine oil to the camshaft and the • Tighten sleeve nut to the specified torque.
camshaft bearings. Tighten:
• Install the camshaft to the cylinder body. • Oil pump bolt to 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
Take care not to damage the camshaft bearings. 3. Oil Pan Assembly
Above works refer to “OIL PAN” Section in this
manual.
4. Timing Gear
Above works refer to “TIMING GEAR (Gear
Type)” Section in this manual.
Piston Head Projection Measurement Point
3) Push rod
LNW21BSH051401
4) Rocker arm shaft
2. Oil Pump Assembly Valve Clearance Adjustment
• Prepare a solution of 80% engine oil and 20% mo- 5) Cylinder head cover
lybdenum disulfide. 6) By-pass hose
• Apply and ample coat of the solution to the teeth of 7) Oil cooler water pipe (Oil cooler Model)
the oil pump pinion. 8) Oil level gauge guide tube
• Apply engine oil to oil pipe O-ring and insert the O- 9) Glow plug harness
ring in O-ring hold on cylinder block. 10) PCV hose
• Install oil pump assembly with oil pipe in cylinder 11) Fuel leak off pipe
block and tighten fixing bolts to the specified 12) Injection pipe
torque. Above works refer to “CYLINDER HEAD AS-
Tighten:
al.
• Oil pump bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)

6. Engine Assembly 11) Heater hose
1) Engine assembly 12) Intake air duct
2) Support rubber 13) Radiator assembly
3) Front exhaust pipe 7. Transmission and Clutch Assembly
4) Vacuum pump hose 1) Clutch
5) Actuator vacuum hose 2) Transmission
6) Power steering pump & bracket assembly Above works refer to “ENGINE ASSEMBLY”
(With Power Steering Model) Section in this manual.
7) Oil pressure switch harness • Connect the battery ground cable.
8) Fuel hose • Pour coolant
9) Glow plug harness • Pour engine oil
10) Engine control cable • Start the engine and check coolant leakage.
LNW81BMF004001
(a) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)

(b) 108 N⋅m (11 kg⋅m / 80 lb⋅ft)
Cylinder Head Assembly

Component
LNWB1BLF003301
Legend
1. Rocker arm shaft 8. Valve seat
2. Push rod 9. Thermostat housing
3. Glow plug & plate 10. Valve guide
4a. Injection nozzle assembly (4JB1-TC) 11. Spring lower seat
4b. Injection nozzle assembly (4JB1NA) 12. Valve stem seal
5. Cylinder head assembly 13. Valve spring
6. Cylinder head gasket 14. Spring upper seat
7. Valve 15. Split collar
Removal • Disconnect upper radiator hose from engine side.

Preparation 2. Heater Hose
• Disconnect battery ground cable. • Disconnect heater hose from heater pipe.
• Drain coolant from the radiator and engine. 3. A/C Compressor Drive Belt
1. Radiator Hose Upper • Loosen idle lock nut.

• Loosen adjust bolt and remove drive belt.
4. Engine Harness
• Disconnect harness connectors from units on ther-
mostat housing.
LNW81BSH016501
9. Glow Plug Harness

10. Oil Level Gauge Guide Tube
• Remove the guide tube from cylinder head.
LNW81BSH003501
Legend
1. Thermo-sensor
5. Air Intake Duct

• Remove the clamp and air intake duct.
6. Injection Pipe
• Remove flare nut injection pump side.
• Remove flare nut injection nozzle side and remove
injection pipe.
Note:
Plug the injection nozzle holder and the delivery holder
to prevent the entry of foreign matters into them.
7. Leak Off Pipe
LNW81BSH010601
• Remove the leak off pipe side of leak off hose.
8. PCV Hose 11. Oil Cooler Water Pipe
• Remove the PCV hose from air intake pipe. • Remove the pipe fixing bolt of cylinder head rear
side.
• Remove the oil cooler water pipe fixing nut from in-
let manifold.

Note:
• Remove the exhaust pipe fixing bolts from exhaust Failure to loosen the rocker arm shaft bracket bolts a lit-
manifold. tle at a time in numerical order will adversely effect the
• Remove the exhaust pipe stay bolt. rocker arm shaft.
13. By-pass Hose 16. Push Rod
14. Cylinder Head Cover 17. Cylinder Head Assembly
• Loosen the cylinder head bolts a little at a time in
the numerical order shown in the illustration.
LNW81BSH010801
15. Rocker Arm Shaft

LNW21BSH049301
• Loosen the rocker arm shaft bracket bolts a little at
a time in the numerical order shown in the illustra-
tion. Note:
Failure to loosen the cylinder head bolts a little at a time
in numerical order will adversely effect the cylinder head
lower surface.
18. Cylinder Head gasket
• Remove the cylinder head gasket and dowel.
Disassembly
1. Thermostat Housing Assembly
2. Injection Nozzle Assembly

1) Remove the nozzle assembly clamp bolt.
LNW21BSH049301
LNW81BSH009601
Note:
2) Use the nozzle holder remover and the sliding Failure to loosen the cylinder head bolts a little at a time
hammer to remove the nozzle holder together in numerical order will adversely effect the cylinder head
with the holder bracket. lower surface.
Nozzle Holder Remover: 5-8840-2723-0
Sliding Hammer: 5-8840-0019-0 Clean
• Cylinder head bolts
• Cylinder head
Carefully remove all varnish, soot and carbon to
the bare metal. Do not use a motorized wire brush
on any gasket sealing surface.

Make the necessary adjustments, repairs, and part re-
during inspection.
• Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause;
– Improper installation
– Loose or warped cylinder head
– Insufficient torque on head bolts
LNW81BSH015301 – Warped case surface
1. Cylinder head bolts for damaged threads or
3. Glow Plug and Glow Plug Connector stretching and damaged heads caused by improp-
4. Rocker Arm Shaft and Rocker Arm er use of tools.
5. Push Rod
Caution:
6. Cylinder Head
Suspected bolts must be replaced.
• Loosen the cylinder head bolts a little at a time
in the numerical order shown in the illustration. 2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
Caution:
Do not attempt to weld the cylinder head. Replace it.

4. Cylinder head deck, intake and exhaust manifold
mating surfaces for flatness.
These surfaces may be re-conditioned by milling
(except cylinder head lower face). If the surfaces
are “out of flat” by more than specification, the sur-
face should be ground to within specifications. If
more than limit of specification, it should be re-
placed.
LNW21BSH053101
LNW21BSH053001
Note:
The cylinder head lower face cannot be reground.
mm (in)
Standard Limit
Standard Limit
0.05 (0.002) or
Cylinder Head 0.20 (0.0079)
less
Lower Face
Cylinder Head
92 (3.622) 91.55 (3.6043)
Height
5. Water jacket sealing plugs seating surfaces.

6. Use a straight edge and a feeler gauge to measure
the manifold cylinder head lifting face warpage.
Regrind the exhaust manifold cylinder head lifting
surfaces if the measured values are between the
specified limit and the standard.
If the measured values exceed the specified limit,
the manifold must be replaced.
Exhaust Manifold Warpage mm (in)

Standard Limit
0.05 (0.002) or less 0.20 (0.0079)

Reassembly
Cylinder Head
1. Valve Seat Insert Installation
1) Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat in-
sert) on the valve seat insert (2).
Note:
valve seat insert.
2) Use the bench press (3) to gradually apply
pressure to the attachment and press the valve
seat insert into place.
LNW21BSH050001
Note:
3) Spring lower seat
4) Valve stem oil seal
• Install a new oil controller in the valve.
• Guide using special tool
Oil seal installer: 5-8840-2003-0
LNW21BSH018601
Note:
bench press. Damage to the valve seat will result.
Measure the height of the valve guide upper end from
the upper face of the cylinder head.
Valve Guide Upper End Height (H) (Reference)

mm (in)
13 (0.51)
N6A3068E
5) Valve
• Apply engine oil to the outside of the valve
stem before installing it.

6) Valve Spring
• Attach the valve spring to the upper spring
seat.
Note:
• The painted area (1) of the valve spring should be
facing downward.
• Apply compressed air to cylinder from the
glow plug hole to hold the valve in place.
• Install split collar by special tool.
29760)
MJW21BSH000301
2. Push Rod
3. Rocker Arm Shaft and Rocker Arm
Tighten:
• Rocker arm shaft fixing bolts to 54 N⋅m (5.5 kg⋅m/40
lb⋅ft)
4. Glow Plug and Glow Plug Connector
Tighten:
Glow plugs to 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
LNW81BSH006501 1) Install the injection nozzle gasket (1) and the O-
ring (2) to the injection nozzle assembly (3).
7) Spring Upper Seat Be sure that the O-ring fits snugly in the injec-
8) Split Collar tion nozzle groove.
• Use a spring compressor to push the valve 2) Apply engine oil to the cylinder head injection
spring into position. nozzle assembly hole.
• Install the spring seat split collar. 3) Install the injection nozzle assembly together
• Set the split collar by tapping lightly around with the injection nozzle assembly clamp (5) to
the head of the collar with a rubber hammer. the cylinder head.
Valve spring compressor: 9-8523-1423-0 (J- 4) Tighten the fixing bolt (4) to the specified
29760) torque.
Tighten:
37 N⋅m (3.8 kg⋅m/27 lb⋅ft)

4JB1-TC 1) Use a dial indicator to measure the piston pro-
jection amount.
LNW81BSH009501
LNW81BSH009201
4JB1NA
2) Refer to the illustration for the piston head pro-
jection measuring positions.
All measuring positions should be as close as
possible to the cylinder liner.
LNWB1BSH015001
6. Thermostat Housing Assembly

Tighten:
LNW81BSH009301
Thermostat housing assembly fixing bolt to 19 N⋅m (1.9
kg⋅m/14 lb⋅ft)
3) Measure the points (1), (2), (3) and (4) and ob-
Installation tain two differences (1) — (2) and (3) — (4) on
each cylinder.
1. Cylinder Head Gasket Calculate the average value of the piston head
Cylinder head gasket is determined by the piston projection on each cylinder.
head projection from the cylinder body upper sur-
4) Obtain the maximum value in the four cylinders.
face, in order to improve engine performance.
5) Determine the gasket grade required to the
Three types of gasket are provided by the differ-
maximum value described above in accor-
ence of thickness. Select the adequate one out of
dance with the following table.
three grades of gasket, according to the following
procedure.
Before measurement, clear off carbon from the pis-
ton head and cylinder body surface and also clean
the place where a gasket was installed.
Piston Head Projection Measurement Point

• 2nd step: 60° — 75°
• 3rd step: 60° — 75°
• Angle Gauge: 5-8840-0266-0
LNW81BSH014601
Note:
The difference between the highest measured piston LNW21BSH050401
head projection and the lowest measured piston head
projection must not exceed 1.0 mm (0.039 in). 3. Push Rod
• Apply engine oil to push rod and in to the cylinder
head.
4. Rocker Arm shaft
1) Loosen all adjusting screws.
2) Position the rocker arm shaft with the large oil
hole (φ4) facing the front of the engine.
LNW81BSH009401

1) Install the dowel in cylinder block.
2) Install the cylinder head gasket with top mark
up.
3) Clean up cylinder head lower surface and cylin-
LNW81BSH006601
der body upper surface.
4) Install the cylinder head as softly. 3) Tighten the rocker arm shaft bracket bolts to
5) Apply engine oil to screw and seat of cylinder the specified torque in the numerical order
head bolts. shown in the illustration.
6) Tighten the cylinder head bolts to the specified Tighten:
torque in three steps following the numerical or- • Rocker arm shaft bracket bolt to 54 N⋅m (5.5kg⋅m / 40
der shown in the illustration. lb⋅ft)
Tighten:
Cylinder head bolts to
• 1st step: 49 N⋅m (5kg⋅m / 36 lb⋅ft)
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
2) Front exhaust pipe mounting clamp fixing nut
and bolt.
Tighten:
• 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
3) Exhaust manifold fixing nuts
Tighten:
• 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
LNW21BSH050801
• Valve clearance adjustment.

Above works refer to “ROCKER ARM SHAFT AS-
SEMBLY” Section in this manual.
spring.
• Install the cylinder head cover gasket to the cylin-
der head cover.
• The gasket must be perfectly smooth with no loose
areas.
• Tighten the cylinder head cover nuts to the speci-
fied torque (a) in the numerical order shown in the LNW81BSH014701
illustration.
8. Oil Cooler Water Pipe
Tighten: • Install the water pipe bolt and tighten bolt to the
• Cylinder head cover to 13 N⋅m (1.3kg⋅m / 113 lb⋅in) specified torque.
Tighten:
• Water pipe nut to 19 N⋅m (1.9 kg⋅m / 1.4 lb⋅ft)
• Pipe bracket bolt to 40 N⋅m (4.1kg⋅m / 30 lb⋅ft)
LNW81BSH003401
6. By-Pass Hose
1) Front exhaust pipe fixing nuts and bolts. LNW21BSH048601

9. Oil Level Gauge Guide Tube

• Install the guide tube bolt and tighten bolt to the
specified torque.
Tighten:
• Guide tube bolt to 19 N⋅m (1.9 kg⋅m / 1.4 lb⋅ft)
LNW81DSH002701
• Fit pipe clip in specified torque.

Tighten:
• Sleeve nut to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
LNW21BSH052801
14. Air Intake Duct
10. Glow Plug Harness • Install the air intake duct
11. PCV Hose • Use a new hose clamp
15. Engine Harness
• Connect the thermo-sensor harness and thermo-
meter unit harness.
LNW81BSH016501
12. Leak Off Pipe

• Mount using a new copper washer.
13. Injection Pipe LNW81BSH003501
• Install the flare nut to injection pump side.
• Install the flare nut to injection nozzle side. Legend
• Tighten the flare nut to the specified torque. 1. Thermo-sensor
Tighten:
• Flare nut to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)

16. Cooling Fan Pulley and Power Steering Pump Pul-
ley Drive Belt
with new ones as necessary. Check belts for ten-
sion, and adjust as necessary.
• Check drive belts tension.
• Push the middle of belts with a force of 98 N
(10 kg / 22 lb) and check each bolt for deflec-
tion.
Amount of Frequency
mm (in) Hz
For a new 7-9
133 - 157
drive belt 9-11
(0.35-0.43) LNW81BSH014901
For a new 8 - 11
135 - 165
P/S pump product (0.31-0.43) Legend
drive belt 11 - 12 1. Adjust plate
(0.43-0.47) 2. Fan pulley
3. P/S pump pulley
4. Idle pulley
5. Adjust pulley
6. Crank pulley
7. ACG bolt
8. AC generator
Tighten:
• AC generator fixing bolt to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
• Adjust plate fixing bolt to 19 N⋅m (1.9kg⋅m / 1.4 lb⋅ft)
• Adjust plate lock bolt to 19 N⋅m (1.9 kg⋅m / 1.4 lb⋅ft)
17. Heater Core
• Connect the heater hose them tighten the clip se-
curely.
18. Radiator Hose Upper
• Connect the radiator hose them tighten clip secure-
LNW81BSH014801 ly.
• Pour coolant.
Legend • Connect the battery ground cable.
1. AC generator &fan pulley drive belt • Start the engine and check coolant leakage.
Tension Adjustment
P/S oil pump and A/C compressor pulley belt
• With P/S pump lock bolt loose, adjust belt tension
with adjust belt.
Cooling fan pulley belt
• With AC Generator mounting and lock bolts loose,
adjust belt tension with adjuster’s adjust bolt.

LNWB1BLF003201
(a) 54 N⋅m (5.5 kg⋅m / 40 lb⋅ft) (c) 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)
(b) 1st step 49 N⋅m (5.0 kg⋅m / 36 lb⋅ft) (d) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
2nd step 65° - 75° (e) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
3rd step 65° - 75° (f) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
Piston and Connecting Rod

Component
LNW81BMF002801
Legend
1. Piston ring 6. Connecting rod bearing
2. Piston pin snap ring 7. Connecting rod nut
3. Piston 8. Connecting rod bearing cap
4. Connecting rod 9. Piston pin snap ring
5. Connecting rod bolt 10. Piston pin
Removal 6) Injection pipe

Preparation 7) Leak off pipe
• Disconnect battery ground cable 8) PCV hose
• Drain coolant 9) Glow plug harness
• Drain engine oil
11) Oil cooler water pipe
Note: 12) Vacuum actuator hose (Exhaust Brake Model)
Tighten: 14) By-pass hose
• 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft) 15) Cylinder head cover
1. Cylinder Head Assembly 16) Rocker arm shaft
1) Radiator hose upper 17) Push rod
2) Heater hose 18) Cylinder head assembly
3) A/C compressor drive belt 19) Cylinder head gasket
4) Engine harness Above works refer to “CYLINDER HEAD AS-
5) Air intake duct
al.

2. Oil Pan Assembly
1) Vacuum pump oil hose
2) Engine mount bolt
3) Stiffener and spacer rubber
4) Oil pan
manual.
4. Piston Cooling Oil Pipe
• Remove the relief valve and oil pipe.
LNW21BSH005001
2) Move the piston to the top of the cylinder and

tap it with a hammer grip or similar object from
the connecting rod lower side to drive it out.
LNW21BSH036101
5. Connecting Rod Bearing Cap

• If the connecting rod lower bearings are to be rein-
stalled, mark their fitting positions by tagging each
bearing with the cylinder number from which it was
removed.
LNW21BSH034401
3) If the connecting rod upper bearings are to be

reinstalled, mark their fitting positions by tag-
ging each bearing with the cylinder number
from which it was removed.
LNW21BSH004901
6. Piston and Connecting Rod Assembly

1) Remove carbon deposits from the upper por-
tion of the cylinder wall with a scraper before re-
moving the piston and connecting rod.
4) Clamp the connecting rod in a vise. 6) Tap the piston pin out with a hammer and a
Take care not to damage the connecting rod. brass bar. If the pistons and piston pins are to
Use a piston ring replacer to remove the piston be reinstalled, mark their installation positions
rings. by tagging each piston and piston pin with the
Piston Ring Replacer cylinder number from which it was removed.
Do not attempt to use some other tool to re-
move the piston rings. Piston ring stretching will
result in reduced piston ring tension.
LNW21BSH005201
Disassembly
LNW21BSH005101
2. Oil Pan Assembly
5) Use a pair of pliers to remove the piston pin 3. Oil Pump Assembly
snap rings. 4. Piston Cooling Oil Pipe
5. Connecting Rod Bearing Cap
6. Piston and Connecting Rod
• Remove carbon deposits from the upper por-
tion of the cylinder wall with a scraper before re-
moving the piston and connecting rod.
7. Piston Ring
Remove the piston rings with a piston ring expand-
er.
Arrange the removed piston rings in the cylinder
number order.

Visually check each piston for cracking, scoring, and
other signs of excessive wear.
If any of the above conditions are present, the piston
must be replaced.
Piston Diameter
1. Measure the piston outside diameter with mi-
crometer at the piston grading position.
Piston Grading Position (1) mm (in)

74 (2.913)
LNW21BSH005101
8. Piston Pin Snap Ring

• Use a pair of pliers to remove the piston pin
snap rings.
RTW56A023101
Size Mark Outside Diameter mm (in)
A 92.985 — 92.994 (3.6608 — 3.6612)

B 92.995 — 93.004 (3.6612 — 3.6616)
C 93.005 — 93.014 (3.6616 — 3.6620)
D 93.015 — 93.024 (3.6620 — 3.6624)
LNW71BSH007401
9. Piston Pin
Note:
Keep the parts removed from each cylinder separate.
All parts must be reinstalled in their original positions.
10. Piston
11. Connecting Rod

Piston and Piston Ring
Pistons
Carefully clean away all the carbon adhering to the pis-
ton head and the piston ring grooves.
Note:
Never use a wire brush to clean the pistons. Damage
will result.
Note:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will result
in engine failure. Always measure the cylinder bore and
select the correct piston grade.
Piston Rings
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
• Insert the piston ring into the bore.
• Push the ring by the piston, at a right angle to
the wall, into the point ring at which the cylinder
bore diameter is the smallest.
LNW81BSH014401
Legend
1. G-mark
2. Front mark
The grading position for piston outside diameter is rep-

resented by the ‘G’ as shown in Figure.
Measure the cylinder bore inside diameter (refer to “in-
spection of the cylinder Block” in this Section).
If the piston clearance does not conform to the specified
valve, the piston and/or cylinder liners must be replaced.
Piston Clearance mm (in)

0.061 (0.0024) LNW21BSH034801
Selection Method of Piston Grade for Service Parts. • The top mark of the piston ring are shown in the
If you find piston grade A from size mark or piston out- illustration.
side diameter measurement result, you will select AX for
service piston grade.
The stamped piston grade on the head of piston for ser-
vice parts.
Service piston grade

Piston Size Mark Service Parts Grade
A AX
B AX
C CX
D CX
Service piston diameter

mm (in)
Piston Grade
LNW21BSH034901
AX 92.989 — 93.004 (3.6610 — 3.6616)
CX 93.005 — 93.020 (3.6616 — 3.6622) Legend
1. N mark (Top ring) (2nd ring)
Ring end gap mm (in) Piston pin outside diameter mm (in)

Standard Limit Standard Limit
0.20 — 0.40 30.995 — 31.000
1st 30.970 (1.2190)
Compression (0.0079 — 0.0157) (1.2202 — 1.2204)
ring 0.20 — 0.40 1.5
2nd
(0.0079 — 0.0157) (0.059)
0.10 — 0.30
Oil ring
(0.0039 — 0.0118)
2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If
the piston ring groove/piston ring clearance ex-
ceeds the specified limit, the piston must be re-
placed.
Clearance between the piston and ring

mm (in)
groove
Standard Limit
0.090 — 0.125
1st
Compression (0.0035 — 0.0049)
ring 0.050 — 0.075 1.5
2nd LNW21BSH009601
(0.0020 — 0.0030) (0.059)
0.03 — 0.07 2. Measure the inside diameter of the connecting rod
Oil ring small end. If the clearance between the small end
(0.0012 — 0.0028)
and pin does not conform to the specified value,
the connecting rod or bushing and pin must be re-
placed.
Clearance between the connecting

mm (in)
rod small end and out side diameter
Standard Limit
0.008 — 0.020
Clearance 0.05 (0.0020)
(0.0003 — 0.0008)
LNW21BSH009501
Piston Pin
Visually inspect the piston pin for cracks, flaws, and oth-
er damage and replace if necessary.
1. Use a micrometer to measure the piston pin out-
side diameter in both directions at three different
positions.
If the measurement exceed the specified limit the
piston pin must be replaced.
LNW21BSH009801

3. Insert the piston pin into the piston and rotate it. If
the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash or rough-
ness, measure the clearance. If the clearance ex-
ceeds the specified limit, the piston and the piston
pin must be replaced.
Clearance between the piston and

mm (in)
piston pin
Standard Limit
0.002 — 0.004
Clearance 0.04 (0.0016)
(0.00008 — 0.00016)
Bushing Replacement
Removal: Use a suitable bar and bench press or ham-
mer.
Installation: Use a suitable bar and bench press.
LNW21BSH010401
2. Measure the connecting rod thrust clearance.

Use a feeler gauge to measure the thrust clear-
ance at the big end of the connecting rod.
If the clearance exceeds the specified limit, the
connecting rod must be replaced.
Thrust Clearance mm (in)

Standard Limit
0.230 (0.0091) 0.350 (0.0138)
LNW21BSH035201
Note:
Align the bushing with the connecting rod oil port.
After installing a new bushing, finish the bushing bore
with a pin hole grinder.
Connecting Rods
1. Check the connecting rod alignment with a con-
necting rod aligner.
If either the bend or the twist exceeds the specified
limit, the connecting rod must be replaced.
LNW21BSH035301
Connecting rod alignment for 100 mm mm(in)
3. Measure the oil clearance between the connecting
Standard Limit
rod and the crankshaft by:
Degree of 0.20 1) Remove the connecting rod cap nuts and the
0.08 (0.0031) or less
parallelization (0.0079) rod caps.
0.15 Arrange the removed rod caps in the cylinder
Twisting 0.05 (0.0020) or less number order.
(0.0059)
2) Clean the rod bearings and the crankshaft pins.
3) Carefully check the rod bearings.
If even one bearing is found to be damaged or
badly worn, the entire bearing assembly must

be replaced as a set. Reinstall the bearings in
their original positions.
Apply plastigage to the crank pin.
LNW21BSH035501
Reassembly
LNW21BSH035401
1. Connecting Rod
2. Piston
4) Put the plastigage, and reinstall the rod caps to 3. Piston Pin
their original positions. Apply a cost of engine oil to the piston pin and the
5) Tighten the cap nuts in 2 steps, using angular piston pin hole.
tightening method as shown in the following 4. Piston Pin Snap Ring
specifications. Apply a thin coat of engine oil to the piston pin.
Tighten: Try to insert the piston pin into the piston pin hole
• 1st Step: 29 N⋅m (3.0 kg⋅m/22 lb⋅ft) with normal finger pressure.
2nd Step: 45° — 60° Weigh each piston and connecting rod assembly.
Select piston and connecting rod combinations so
Note: that the weight variation of the different assemblies
Do not allow the crankshaft to rotate. a held within the specified limits.
6) Remove the rod caps.
7) Measure the width of the plastigage and deter- g (oz)
mine the oil clearance. If the oil clearance ex- Variance in weight after
ceeds the limit, replace the rod bearings as a Less than 3 (0.1058)
assembly
set.
8) Remove the plastigage from the bearings and
Note:
the crankshaft pins.
When changing piston/connecting rod combinations, do
Crankshaft Journal and Bearing Clearance not change the piston/piston pin combination
mm (in) • Attach the piston to the connecting rod with the

piston front mark and the connecting rod ISU-
Standard Limit ZU mark on the same side.
0.029 — 0.066
0.100 (0.0039)
(0.0011 — 0.0026)
Legend Legend
1. Front mark 1. 1st compression ring
2. ISUZU mark 2. 2nd compression ring
3. Oil ring
5. Piston Ring
• Install the piston rings with the piston ring ex- 2) 2nd compression ring
pander. 3) 1st compression ring
The compression ring must be set with the N • 1st compression ring: N
mark facing up.
• 2nd compression ring: N
• Discrimination mark is painted as shown in the
• After installation, apply engine oil to the en-
illustration.
tire circumference of the piston rings.
Check to see that all the rings rotate smooth-
ly.
• Insert the bearings into the connecting rods
and caps.
Apply new engine oil to the bearing faces.
Cap side bearings have no oil hole.
Connecting rod side bearings oil hole should
be aligned with oil hole on the connecting
rod.
• Apply engine oil to the cylinder bores, the con-
necting rod bearings and the crankshaft pins.
• Check to see that the piston ring end gaps are
correctly positioned.
• Insert the piston/connecting rod assemblies
into each cylinder with the piston ring compres-
LNW21BSH034901 sor.
• The front marks must be facing the front of the
Legend engine.
• Install piston rings in the following sequence.

1) Oil ring
Legend Note:
1. Lower side rail Check that there is no interference between the piston
2. Upper side rail and the oiling jet pipe by slowly rotating the crankshaft.
3. Expander ring 9. Oil Pump Assembly
4. Expander ring 10. Oil Pan Assembly
7. Connecting Rod Bearing Cap manual.
• Tighten the cap nuts in 2 steps, using angular 11. Cylinder Head Assembly
tightening method as shown in the following • Piston Head Projection Measurement Point
specifications.
• Cylinder Head Assembly
Tighten: • Push Rod
• 1st Step: 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
• Rocker Arm Shaft Assembly
2nd Step: 45° — 60°
Valve clearance adjustment.
After tightening the cap nuts, check to see that the
Above works refer to “CYLINDER BLOCK” Section
crankshaft rotates smoothly.
in this manual.
• Install the piston cooling oil pipe to the cylinder Installation
body. 1. Piston and Connecting Rod Assembly
• Tighten the oil pipe bolts and relief valve to the 1) Try to insert the piston pin into the piston pin
specified torque. hole with normal finger pressure.
Weigh each piston and connecting rod assem-
Tighten:
bly.
Oil Pipe Bolt to
Select piston and connecting rod combinations
• M8 × 1.25: 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
so that the weight variation of the different as-
• M6 × 1.00: 8 N⋅m (0.8 kg⋅m/69 lb⋅in) semblies is held within the specified limits.
Oil Pressure Regulating Valve to
• M16 × 1.5: 29 N⋅m (3.0 kg⋅m/22 lb⋅ft) g (oz)
Variance in weight Less than
after assembly 3 (0.1058)
2) Clamp the connecting rod in a vise.

Take care not to damage the connecting rod.
3) Use a pair of pliers to install the piston pin snap
ring to the piston.
6) Use your fingers to force the piston pin snap

Note:
ring into the piston snap ring groove.
Check that the connecting rod moves smoothly
not change the piston/piston pin combination.
on the piston pin.
4) Install the piston to the connecting rod.
The piston head front mark (1) and the connect-
ing rod “ISUZU” casting mark (2) must be fac-
ing the same direction.
LNW61ASH004601
7) Install the piston rings with the piston ring ex-

pander.
LNW71BSH012201 The compression ring must be set with the N
mark facing up.
5) Apply a coat of engine oil to the piston pin and Discrimination mark is painted as shown in the
the piston pin hole. illustration.
Use your fingers to force the piston pin into the
piston until it makes contact with the snap ring.

9) Apply engine oil to the piston ring surfaces.
10) Check that the piston rings rotate smoothly in
the piston ring grooves.
11) Position the piston ring gaps as shown in the il-
lustration.
LNW21BSH034901
Legend
8) Use a piston ring replacer to install the three LNW81BSH009101

piston rings.
Piston Ring Replacer
Legend
Install the piston rings in the numerical order
1. Expand ring
2. No. 1 compression ring
3. Oil ring
4. Front mark
12) Carefully wipe any oil or other foreign material

from the connecting rod bearing back face and
the connecting rod bearing fitting surface.
LNW81BSH014301
Legend
1. 1st compression ring
2. 2nd compression ring
3. Oil ring
Note: LNW81BSH012201
Install the compression rings with the stamped side fac-
ing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil before
installing the oil ring.

13) Apply a coat of engine oil to the upper bearing 3) Apply a coat of engine oil to the threads and
surfaces. setting faces of each connecting rod cap bolt.
Apply a coat of engine oil the cylinder wall.
14) Position the piston head front mark so that it is
facing the front of the engine.
Use the piston ring compressor to compress
the piston rings.
Piston Ring Compressor: 5-8840-9018-0(J-
8037)
15) 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.
LNW61ASH004801
4) Tighten the connecting rod bearing cap bolts to

the specified torque in two steps using the An-
gular Tightening Method.
Tighten:
Connecting rod bearing cap bolt to
4JB1-TC
• 1st step: 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
2nd step: 45° — 60°
4JB1NA
LNW21BSH072201
• 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
2. Connecting Rod Bearing Cap Note:

Check to see that the crankshaft turns smoothly by ro-
1) Position the bearing cap front mark (1) so that
tating it manually.
it is facing the front of the engine.
1) Install the piston cooling oil pipe to the cylinder
body.
2) Tighten the oil pipe bolts and relief valve to the
specified torque.
Tighten:
• Oil pipe bolt to
M8 × 1.25: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M6 × 1.00: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
• Oil pressure regulating valve to
M6 × 1.5: 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
LNW21BSH036001
2) Install the connecting rod bearing caps.

Align the bearing cap cylinder number marks
and the connecting rod cylinder number marks.
LNW21BSH036101 LNW21HSH004001
3) Install the oil pan to the cylinder body.

Note:
Check that there is no interference between the piston • Tighten the oil pan bolts to the specified torque.
and the oiling jet pipe by slowly rotating the crankshaft. Tighten:
4. Oil Pump Assembly • Oil pan bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
Above works refer to “OIL PUMP” Section in this 4) Install the space rubber and stiffener (right &
manual. left side) then tighten bolts to the specified
5. Oil Pan Assembly torque.
1) Apply the recommended liquid gasket or its Tighten:
equivalent to the No.5 bearing cap arches, the • Engine body side stiffener bolts to 37 N⋅m (3.8 kg⋅m /
grooves, and the timing gearcase arches at the 27 lb⋅ft)
positions shown in the illustration. • Clutch housing side stiffener bolts to 78 N⋅m (8.0
kg⋅m / 58 lb⋅ft)
LNW81BSH009901
LNW21HSH004701
2) Fit the gasket rear lipped portion into the No.5
groove. Be absolutely sure that the lipped por- 5) Install the exhaust pipe bracket.
tion is fitted snugly into the groove.
6) Install the support rubber and tighten nuts to
Tighten:
• Support rubber nut to 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

7) Install the vacuum pump oil hose (1) to oil pan.
LNW21BSH039201

3) Push rod
4) Rocker arm shaft
5) Valve clearance adjustment
6) Cylinder head cover
7) By-pass hoses
9) Vacuum actuator hose (Exhaust Brake Model)
13) PCV hose
14) Leak off pipe
15) Injection pipe
16) Air intake duct
17) Engine harness
18) Heater hose
Above works refer to “CYLINDER HEAD AS-
al.

LNW81BMF003901
4JB1-TC
(a) 1st step: 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
2nd step: 45° - 60°
4JB1NA
(a) 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
Flywheel and Pilot Bearing

Component
LNW81BMF004201
Legend
1. Flywheel 3. Transmission and clutch assembly
2. Pilot bearing
Removal
Preparation
1) Transmission
2) Clutch
2. Pilot Bearing
• Remove pilot bearing using remover.
Pilot Bearing Puller: 5-8840-2000-0
Sliding hammer: 5-8840-0019-0
LNW81BSH012301
3. Flywheel
• Set the flywheel stopper.
• Loosen flywheel fixing bolts then remove the fly-
wheel.

Installation
1. Flywheel
• Tighten the flywheel bolts to the specified torque in
two steps using the Angular Tightening Method.
Follow the numerical order shown in the illustra-
tion.
Tighten:
• Flywheel bolt to
1st step: 59 N⋅m (6.0 kg⋅m / 43 lb⋅ft)
2nd step: 60° — 90°
LNW21BSH036401
2. Pilot Bearing
• Install the pilot bearing using installer.
Pilot bearing Installer: 5-8522-0024-0
LNW21BSH036501

1) Clutch
2) Transmission

LNW81BMF004301
(a) 1st step: 59 N⋅m (6.0 kg⋅m / 43 lb⋅ft)

2nd step: 60° - 90°
Crankshaft Front Oil Seal

Component
LNW81BMF003101
Legend
1. Crankshaft damper pulley 3. Gearcase cover
2. Front oil seal
Removal 6. Front Oil Seal

Preparation • Use a plastic hammer and a screwdriver to top
• Disconnect battery ground cable. around the oil seal to free it from the gearcase cov-
er.
• Drain coolant. Take care not to damage the oil seal fitting surfac-
1. Fan Shroud es.
• Loosen power steering pump mounting bolt and
• Loosen AC Generator mounting bolt (under side)
belt.
Installation 3. Cooling Fan Assembly

1. Front Oil Seal • Mount fan pulley, distance piece, and cooling fan
asm (in this order) on the water pump, and tighten
• Use the installer to install the front oil seal (1) to the
to the specified torque.
gearcase cover (2).
Oil Seal Installer: 5-8840-2061-0 Tighten:
Note the oil seal installation depth (a) shown in the • Pulley boss bolt to 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
illustration. 4. AC Generator Drive Belt
Depth (3) = 1 mm (0.039 in.)
• Install AC Generator drive belt and adjust belt ten-
sion.
• Refer to Drive Belt Adjustment in this section.
• Install power steering pump drive belt and adjust
belt tension.
• Refer to “Drive Belt Adjustment” in this section.
6. Fan Shroud
• Install the fan shroud and reservoir tank hose.
• Pour coolant
LNW81BSH007701

Tighten the crankshaft damper pulley bolt to the
specified torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper pul-
ley.
Tighten:
• Pulley boss bolt to 206 N⋅m (21 kg⋅m / 152 lb⋅ft)

LNW81BMF004101
(a) 206 N⋅m (21 kg⋅m / 152 lb⋅ft)

Crankshaft Rear Oil Seal

Component
LNW81BMF003201
Legend
1. Rear oil seal 3. Transmission and clutch assembly
2. Flywheel
Removal 2) Parking Brake Cable

Preparation • Move the joint cover.
• Disconnect battery ground cable • Disconnect the joint bolt.
1. Transmission and Clutch Assembly • Remove the clip then disconnect the cable from
• Raise vehicle and support with suitable safely. the bracket.
1) Transmission
• Reference mark (1) the flange yoke to the park-
ing brake drum.
LNW81BSH011201
3) Wiring Connector
• Disconnect the wiring connectors from the car
LNW81BSH011101 speed sensor, the neutral switch and the back-
up light switch.
• Disconnect the propeller shaft at flange yoke.
• Put aside the propeller shaft and tie it to the frame
so that it does not interface with servicing work.

4) Shift Cable and Select Cable frame so that it does not interface with servicing
• Disconnect the shift cable and select cable on work.
the transmission side.
LNW81BSH011501
LNW81BSH011301
Legend
1. Shift cable
2. Clip
3. Select cable
4. Snap pin
5. Snap pin

• Remove the clutch pipe fixing clips and the clip
bracket (Right hand drive models only).
LNW81BSH011601
7) Transmission Assembly
Note:
The gear control bracket and the clips are sometimes in-
stalled in the wrong position or direction confusedly. To
prevent incorrect installation of these parts, put a correct
installation mark on them.
Caution:
LNW81BSH011401 To prevent the falling of the transmission, tie it firmly to
the jack with a chain or belt.
Do not allow transmission to hang unsupported from
Legend
clutch. Damage to the clutch assembly will result.
1. Flexible hose
2. Clutch pipe
• Remove the slave cylinder assembly with the

flexible hose attached, and then tie it to the
• Remove the nuts of the transmission mounting • Mark the flywheel and pressure plate lug for
bracket on the crossmember side. alignment when installing.
• Engine and transmission angles may need to • Loosen the pressure plate assembly fixing
be adjusted for removal. bolts.
• Hold the rear section of the engine by the jack 2. Flywheel
or hoist. 3. Rear Oil Seal
Caution: • With the oil seal pushed in deep, install the special
When lifting the engine by the jack, use wood blocks to tool as shown in the illustration to remove the oil
prevent any possible damage to the oil pan. seal.
• Remove transmission fastening bolts. • Rear oil seal Remove: 5-8840-2360-0
• Pull out the transmission assembly rearward.
8) Mounting Bracket
• Raise vehicle and support with suitable safety
stands.
Note:
Do not let clutch fluid remain on a painted surface, wash
it off immediately.
10) Driven Plate Assembly
• Use the pilot aligner to prevent the driven plate
assembly from falling free.
Pilot Aligner: 5-8525-3001-0
LNW21BSH036901
Note:
Take care not to damage the crankshaft or oil seal re-
tainer when removing oil seal.
Installation
1. Rear Oil Seal
• Use the oil seal installer the oil seal to the cylinder
body.
Rear oil seal Install: 5-8840-2359-0
Note:
Wipe off rust and scraps clean from the press-in portion
of the oil seal.
1) Take note of the press-in direction of the oil
seal.
2) Install the adapter of the special tool to the rear
end of the crankshaft with two bolts.
3) Install the oil seal to the outer circumference of
the adapter.
4) Insert the sleeve into the adapter portion, and
tighten it in with the bolt (M12 × 1.75 L = 70) un-
til the adapter section hits the sleeve.
5) Remove the adapter and the sleeve.
6) After installing the oil seal, check the measure-
ment of the oil seal.
Standard mm (in) LNW21BSH036401
12.2 — 12.8 (0.48 — 0.50) 3. Transmission and Clutch Assembly

1) Driven Plate Assembly
• Apply multi-purpose with MOS2 type grease to
the driven plate hub spline.
• Use the pilot aligner to install the driven plate
assembly.
Pilot Aligner: 5-8525-3001-0
LNW21BSH037001
2. Flywheel
two steps using the Angular Tightening Method.
Follow the numerical order shown in the illustra- LNW81BSH011801
tion.
Tighten:
• Tighten pressure plate assembly fixing bolts in
• Flywheel bolt to numerical order.
2nd step: 60° — 90° Tighten:
• Pressure plate fixing bolt to 18 N⋅m (1.8 kg⋅m / 13
lb⋅ft)
Tighten:
• Clutch housing to flywheel hosing bolts to
M10: 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
M12: 91 N⋅m (9.3 kg⋅m / 67 lb⋅ft)
• Raise engine and transmission up into rear
transmission mount.
Tighten:
• Engine rear mounting nuts and bolts to
M10: 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
M12: 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)
LNW81BSH011901
• Remove the pilot aligner.

Note:
In case a new pressure plate assembly is mounted, after
tightening a pressure plate at the specified torque, be
sure to remove the wiring for protection of a diaphragm
spring.
3) Mounting Bracket
Tighten:
• Mounting bracket nuts to 69 N⋅m (7.0 kg⋅m / 51 lb⋅ft)
4) Transmission Assembly LNW81BSH012001

Legend
Caution:
To prevent the falling of the transmission, tie it securely 1. M12 L=100 mm (3.94 in)
to the jack with a chain or belt. 2. M10 L=40 mm (1.57 in)
3. M10 L=35 mm (1.38 in)
4. M10 L=52 mm (2.05 in)
5. M10 L=35 mm (1.38 in)
6. M12 L=35 mm (1.38 in)
7. M12 L=35 mm (1.38 in)

(1) Front exhaust pipe fixing nuts and bolts.
torque
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(2) Front exhaust pipe mounting bracket fixing
nuts and bolts.
Tighten:
N6A3338E • 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(3) Exhaust manifold fixing nuts
• Shift transmission into high gear.
• Align transmission with engine slope.
torque
• Turn output parking brake drum to aid clutch
spring engagement.
Tighten:
• 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
Tighten:
• Slave cylinder bolts to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Perform slave cylinder adjustment before in-
stallation of the return spring.
a. Loosen the lock nut of the push rod.
b. Turn the adjust nut until it reaches the shift
fork.
c. Back off the adjust nut 1.5 turns. (shift fork
free play Approximately 2 mm / 0.1 in).
d. Tighten the lock nut.
Tighten:
• Push rod lock nut to 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
7) Shift Cable and Select Cable
8) Wiring Connector
• Color of Connector
Back-up Light Switch: Brown
Neutral Switch: Gray
9) Parking Brake Cable
10) Propeller Shaft
• Line up reference mark.
Tighten:
• Propeller shaft nuts to 66 N⋅m (6.7 kg⋅m / 48 lb⋅ft)
Crankshaft
Component
LNW81BMF002601
Legend
1. Cylinder block 4. Crankshaft
2. Thrust washer 5. Main bearing lower
3. Main bearing upper 6. Main bearing cap
Removal 1) Radiator assembly

Preparation 2) Intake air duct
• Disconnect battery ground cable. 3) Heater hose
• Drain coolant from the radiator and engine.
1. Transmission and Clutch Assembly 5) Glow plug harness
6) Fuel hose
1) Transmission
2) Clutch
Above works refer to “ENGINE ASSEMBLY” 8) Power steering pump bracket assembly (Power
Section in this manual. Steering Model)
2. Engine Assembly 9) Actuator vacuum hose (Exhaust Brake Model)

10) Vacuum pump hose (Exhaust Brake Model)
12) Support rubber
13) Engine assembly
1) Injection pipe
2) Leak off pipe
3) PCV hose
7) By-pass hose
9) Rocker arm shaft LNW81BSH012401
10) Push rod
11) Cylinder head assembly 5. Oil Pan Assembly
12) Cylinder head gasket 6. Oil Pump Assembly
Above works refer to “CYLINDER HEAD AS- Above works refer to “CAMSHAFT AND TAPPET”
SEMBLY AND GASKET” Section in this manu- Section in this manual.
al. 7. Piston Cooling Oil Pipe
4. Timing Gear • Remove the oil pipe from cylinder block.
6) Oil pipe
7) Idle gear
8) Idle gear “B” and shaft
9) Injection pump
in this manual.
11) Crankshaft gear
• Use the crankshaft timing gear remover (1) to re-
move the crankshaft gear (2).
Crankshaft Timing Gear Remover: 5-8840-2057-0
LNW21BSH036101

• If the connecting rod lower bearings are to be rein-
removed.
• Remove carbon deposits from the upper portion of 9. Timing Gearcase

the cylinder wall with a scraper before removing 10. Water Pump Assembly
the piston and connecting rod. 11. Flywheel and Cylinder Block Rear Plate
Move the piston to the top of the cylinder and tap it
with a hammer grip or similar object from the con- • Set the flywheel stopper.
necting rod lower side to drive it out. • Loosen the flywheel fixing bolts then remove the
flywheel.
• Remove the cylinder block rear plate.
12. Rear Oil Seal
• With the oil seal pushed in deep, install the special
tool as shown in the illustration to remove the oil
seal.
Rear Oil Seal Remover: 5-8840-2360-0
LNW21BSH034401
• If the connecting rod upper bearings are to be rein-

removed.
LNW21BSH036901
Note:
Take care not to damage sealing surface of front plate
and crankshaft when removing oil seal.
13. Crankshaft and Main Bearing
1) Remove the main bearing caps and thrust
washer.
Note:
Take care not to damage sealing surface of rear plate
and crankshaft when removing oil seal.
12. Main Bearing Cap
13. Crankshaft

during inspection.
1. Crankshaft
Thrust clearance
Set the dial indicator as shown in the illustration
and measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified limit,
replace the thrust bearing as a set.
LNW21BSH037401
Thrust clearance mm (in)

2) Remover the crankshaft with care.
3) Remove the crankshaft upper bearing. Standard Limit
0.10 (0.0039) 0.30 (0.0118)
Disassembly
2. Oil Pan Ambly
3. Timing Gear
4. Front Oil Seal
5. Timing Gear Housing
9. Flywheel
10. Cylinder Block Rear Plate
11. Crankshaft Rear Oil Seal
• With the oil seal pushed in deep, install the spe-
cial tool as shown in the illustration to remove
the oil seal.
Remover: Rear Oil Seal 5-8840-2360-0
LNW21BSH037501
2. Main bearing clearance

1) Remove the main bearing caps in the se-
quence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
LNW81BSH007501
Tighten:
167 N⋅m (17 kg⋅m/123 lb⋅ft)
Note:
Do not allow the crankshaft to rotate.
9) Remove the main bearing caps.
10) Measure the plastigage width and determine
the oil clearance. If the oil clearance exceeds
the specified limit, replace the main bearings as
a set and/or replace the crankshaft.
11) Clean the plastigage from the bearings and the
crankshaft.
12) Remove the crankshaft and the bearings.
Oil Clearance mm (in)

Standard Limit
LNW21BSH037601
0.035 — 0.080
0.11 (0.0043)
2) Remove the crankshaft. Remove the main (0.0014 — 0.0036)
bearings.
3) Clean the upper and lower bearings as well as
the crankshaft main journal.
4) Check the bearings for damage or excessive
wear.
The bearings must be replace as a set if dam-
age or excessive wear is discovered during in-
spection.
5) Set the upper bearings and the thrust washers
to their original positions. Carefully install the
crankshaft.
6) Set the lower bearings to the bearing cap origi-
nal position.
7) Apply plastigage to the crankshaft journal unit
LNW81BSH037801
3. Run-out
1) Carefully set the crankshaft on the V-blocks.
Slowly rotate the crankshaft and measure the
runout.
If the crankshaft runout exceeds the specified
limit, the crankshaft must be replaced.
Run-Out mm (in)
Standard Limit
0.05 (0.0020) or less 0.08 (0.0031)
LNW21BSH037701
8) Install the main bearing caps. Apply engine oil

to the bolt threads and the seats. Tighten the
bolts to the specified torque.

Crankshaft Tufftriding Inspection
The portion to be tested must be held horizontally so as
not let the test solution flow (1).
Test liquid should not be applied to the area around the
oil port.
Approximately 10 mm (0.39 in) (1)
The sliding surface of the pin or journal (3).
LNW21BSH024501
Measure the diameter and the uneven wear of

main journal and crank pin.
If the crankshaft wear exceeds the specified
limit, crankshaft must be replaced.
mm (in)
LNW21BSH038001
Standard Limit
Main journal 69.917 — 69.932 Note:
69.91 (2.7524)
diameter (2.7526 — 2.7532) To increase crankshaft strength, Tufftride Method (Soft
nitriding) has been applied. Because of this, it is not pos-
Crank pin 52.915 — 52.930
52.90 (2.0843) sible to regrind the crankshaft surfaces.
diameter (2.0833 — 2.0838)
1. Use an organic cleaner to thoroughly clean the
Uneven 0.05 (0.0020) or
0.08 (0.0031) crankshaft. There must be no traces of oil the sur-
wear limit less
faces to be inspected.
2. Prepare a 5 — 10% solution of ammonium cupric
chloride (dissolved in distilled water).
3. Use a syringe to apply the solution to the surface to
be inspected.
Hold the surface to be inspected perfectly horizon-
tal to prevent the solution from running.
Note:
Do not allow the solution to come in contact with the oil
ports and their surrounding area.
Testing
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty sec-
onds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color copper), the crankshaft must
be replaced.
LNW21BSH037901 2. Steam clean the crankshaft surface immediately
after completing the test.
Crankshaft Inspection
Inspect the surface of the crankshaft journals and crank Note:
pins for excessive wear and damage. The ammonium cupric chloride solution is highly corro-
Inspect the oil seal fitting surfaces for excessive wear sive. Because of this, it is imperative that the surfaces
and damage. being tested be cleaned immediately after completing
Inspect the oil ports for obstructions. the test.

Crankshaft Bearing Selection
When installing new crankshaft bearings or replacing
old bearings, refer to the selection table.
LNW21BSH038301
LNW21BSH038101
Note:
Please note that some Crankshaft No. 4 journals made
during a limited production period have their number
(No. 4) marked on either their front or rear side of webs
as shown below.
LNW21BSH038201
Note:
Although all upper journal bearings (cylinder block side)
have oil grooves and holes, all lower bearings (bearing
cap side) have no groove and hole.
Play close attention to the distinction during the installa-
tion procedure.
mm (in)
Crankshaft Bearing Housing Crankshaft Journal Crankshaft Bearing
Grade Mark Diameter Grade Mark Diameter Size Code
69.927 — 69.932
1 or -
(2.7530 — 2.7532)
4
73.992 — 74.000 69.922 — 69.927
1 2 or - -
(2.9131 — 2.9134) (2.7528 — 2.7530)
69.917 — 69.922
3 or - - - 5
(2.7556 — 2.7528)
69.927 — 69.932
1 or - 2
(2.7530 — 2.7532)
73.983 — 73.992 69.922 — 69.927
2 2 or - - 3
(2.9127 — 2.9131) (2.7528 — 2.7530)
69.917 — 69.922
3 or - - - 4
(2.7556 — 2.7528)
69.927 — 69.932
1 or - 1
(2.7530 — 2.7532)
73.975 — 73.983 69.922 — 69.927
3 2 or - -
(2.9124 — 2.9127) (2.7528 — 2.7530)
2
69.917 — 69.922
3 or - - -
(2.7526 — 2.7528)
Reassembly
1. Crankshaft
• Install the main bearings to the cylinder body
and the main bearing caps.
LNW21BSH037401
2. Main Bearing Cap

• Apply the recommended liquid gasket or its
equivalent to the No. 5 crankshaft bearing cap
LNW21BSH038401 (1) as shown in the illustration.
• Install the arch gasket (2) to the No. 5 bearing
• Be sure that they are positioned correctly.
cap.
• Apply new engine oil to the upper and lower Use your fingers to push the arch gasket into
main bearing faces. the bearing cap groove.
• Carefully mount the crankshaft.
• Apply engine oil to the thrust washer.
• Assemble the thrust washer to the No.3 bear-
ing journal. The oil grooves must face the
crankshaft.
Note: Note:
Be sure that the bearing cap fitting surface is completely Check to see that the crankshaft turns smoothly by ro-
free of oil before applying the liquid gasket. tating it manually.
Do not allow the liquid gasket to obstruct the cylinder 3. Crankshaft Rear Oil Seal
thread holes and bearings. Use the oil seal installer to install the oil seal to the
• Install the bearing caps with the bearing cap cylinder body.
head arrow mark facing the front of the engine. Installer: Rear Oil Seal 5-8840-2359-0
Note:
of the oil seal.
Take note of the press-in direction of the oil seal.
the adapter.
3) Insert the slave into the adapter portion, and
tighten it in with the bolt (M12 × 1.75 L=70) until
the adapter section hits the slave.
4) Remove the adapter and the slave.
Standard mm (in)
LNW21BSH038601
12.2 — 12.8 (0.48 — 0.50)
• Apply engine oil to the crankshaft bearing cap
bolts.
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the se-
quence shown in the illustration.
Tighten:
167 N⋅m (17 kg⋅m/123 lb⋅ft)
4. Cylinder Block Rear Plate 6. Piston and Connecting Rod

Align the rear plate with the cylinder block knock 7. Piston Cooling Oil Pipe
pins. 8. Oil Pump Assembly
Tighten the rear plate to the specified torque Above works refer to “PISTON AND CONNECT-
ING ROD”
Tighten:
82 N⋅m (8.4 kg⋅m/61 lb⋅ft) Section in this manual.
9. Timing Gearcase
5. Flywheel
1) Install the timing gearcase to the cylinder block.
1) Thoroughly clean the remove the oil from the
2) Tighten the timing gearcase bolt together with
threads of crankshaft.
the timing gearcase gasket to the specified
2) Mount the flywheel on the crankshaft and then torque.
install the washer.
3) Apply a coat of engine oil to the threads of the Tighten:
flywheel bolts. 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
4) Align the flywheel with the crankshaft dowel 3) Cut away the gasket protruding above the fit-
pin. ting surface (as shown in the illustration).
5) Tighten the flywheel bolts to the specified
torque in two steps using the Angular Tighten-
ing Method.
Follow the numerical order shown in the illus-
tration.
Tighten:
• Flywheel Bolt to
1st Step: 59 N⋅m (6.0 kg⋅m/43 lb⋅ft)
2nd Step: 60° — 90°
LNW81BSH006101
10. Front Oil Seal

• Install oil seal using special tool.
Installer: 5-8840-2061-0
13. Idle Gear

Legend
1) Apply engine oil to the idle gear and the idle
1. Oil seal
gear shaft.
2. Timing pulley housing The idle gear shaft oil hole must be facing up.
11. Crankshaft Gear 2) Position the idle gear setting marks “X” and “Y”
so that they are facing the front of the engine.
1) Install the crankshaft gear.
2) Use the crankshaft gear installer (2) to install
the crankshaft gear (1).
The crankshaft gear timing mark (“X — X”)
must be facing outward.
Crankshaft Gear Installer: 9-8522-0020-0
LNW81BSH007901
3) Align the idle gear “X” or “⋅” setting mark with

the crankshaft timing gear (2) “X — X” setting
mark.
4) Align the idle gear “Y” setting mark with the
LNW81BSH007801 camshaft timing gear (1) “Y — Y” setting mark.
5) Install the thrust collar and bolts to the cylinder
12. Crankshaft Timing Gear
body through the shaft.
1) Install the camshaft timing gear to the cam- The thrust collar oil hole must be facing up, and
shaft. the thrust collar chamfered must be outward.
The timing gear mark (“Y — Y”) must be facing
outward.
torque.
2) Tighten the timing gear to the specified torque.
Tighten:
Tighten:
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
14. Idle Gear “B” and Shaft

1) Apply engine oil to the idle gear and the idle Gear
gear shaft. Crank gear A — Idle gear “A” X—X
2) Align the idle gear “B” (1) “Z” setting mark with Idle gear “A” — Cam gear Y—Y
the idle gear “A” (2) “Z — Z” setting mark.
Idle gear “A” — Idle gear “B” Z—Z
torque. Idle gear “B” — Injection pump V—V
Tighten:
76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
LNW81BSH006301
LNW81BSH008001 3) Temporarily tighten the six injection pump bolts

(1).
15. Injection Pump The injection pump bolts will be finally tight-
1) Install the O-ring (3) to the injection pump ened after the injection pump rear bracket
flange (4). bolts.
2) Install the injection pump to the timing gear
case.
Align the idle gear “B” (2) “V — V” mark.
4) Install the injection pump rear bracket (3) and 17. Timing Gearcase Cover
the rear bracket bolts (2) to the cylinder body. 1) Align the gearcase with the timing gearcase
5) Install the rear bracket bolts (1) to the injection knock pin and then install the timing gearcase
pump bracket (4). cover.
Do not tighten the bolts. 2) Tighten the gearcase cover bolts to the speci-
The rear bracket bolts (2) and (1) will be finally fied torque.
tightened to the specified torque.
Tighten:
Tighten: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
LNW81BSH008401
LNW81BSH008201
16. Timing Gear Oil Pipe Tighten the crankshaft damper pulley bolt to the
1) Install the oil pipe to the timing gear case and specified torque.
idle gear “A”. Note:
2) Tighten the oil pipe eye bolt (2) and bolt (1) to Hold the flywheel ring gear stationary to prevent the
the specified torque. crankshaft from turning when tightening the damper pul-
Tighten: ley.
13 N⋅m (1.3 kg⋅m/113 lb⋅in)
Tighten:
206 N⋅m (21 kg⋅m/152 lb⋅ft)

• The crankshaft upper bearings (2) have an oil hole
and an oil groove. The lower bearings do not.
• Install main bearings in the cylinder block and main
bearing cap (1) respectively.
• Apply new engine oil to upper (2) and lower (3)
main bearings.
LNW81BSH008501

1) Mount fan pulley, distance piece, and cooling
fan asm (in this order) on the water pump, and
tighten to the specified torque.
Tighten: LNW21BSH038401
8 N⋅m (0.8 kg⋅m/69 lb⋅in)
20. AC Generator, Power Steering Pump Drive Belt • Make sure that main bearing are in correct posi-
tion.
1) Install AC Generator, Power Steering pump
drive belt and adjust belt tension. • Carefully wipe any foreign material from the upper
2) Depress the drive belt mid-portion with a 98 N bearing.
(10 kg/22 lb) force. • Install the main bearings to the cylinder body and
the main bearing caps.
Drive Belt Deflection mm (in)
8 (0.31) — 12 (0.47)
3) Tighten the idle lock nut to the specified torque.

Tighten:
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
21. Fan Shroud (Gear Drive model)
1) Install the fan shroud and reservoir tank hose.
2) Pour coolant
3) Start the engine and check coolant leakage.
22. Oil Pan Assembly
manual.
• Piston Head Projection Measurement Point
• Cylinder Head Assembly LNW21BSH038301
• Push Rod
• Rocker Arm Shaft Assembly Note:
Valve clearance adjustment. Do not apply engine oil to the bearing back faces and
Above works refer to “CYLINDER BLOCK” Section the cylinder body bearing fitting surfaces.
in this manual. • Be sure that they are positioned correctly.
Installation • Apply new engine oil to the upper and lower main
bearing faces.
1. Crankshaft and Main Bearings
• Carefully mount the crankshaft.

• Apply engine oil to the thrust washer.
Tighten:
• Install thrust washer on No.3 journal. • 167 N⋅m (17.0 kg⋅m / 123 lb⋅ft)
Oil grooves in thrust washer must face the crank-
shaft.
LNW21BSH038701
LNW21BSH037401
Note:
• Apply the recommended liquid gasket or its equiv- Check to see that the crankshaft turns smoothly by ro-
alent to the No.5 crankshaft bearing cap cylinder tating it manually.
block fitting surfaces at points and shown in the il- 2. Crankshaft Rear Oil Seal
lustration. Use the oil seal installer to install the oil seal to the
cylinder body.
Rear Oil Seal Installer: 5-8840-2361-0
Note:
of the oil seal.
Take note of the press-in direction of the oil seal.
the adapter.
3) Insert the slave into the adapter portion, and
tighten it in with the bolt (M12 × 1.75 L = 70) un-
til the adapter section hits the slave.
4) Remove the adapter and the slave.
LNW81BSH007601
Standard mm (in)
Note:
12.2 — 12.8 (0.48 — 0.50)
Be sure that the bearing cap fitting surface is completely
free of oil before applying the liquid gasket.
Do not allow the liquid gasket to obstruct the cylinder
thread holes and bearings.
• Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.
• Apply engine oil to the front of the engine.
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
Tighten:
• Flywheel bolt to
2nd step: 60° — 90°
LNW21BSH037001
3. Flywheel and Cylinder Block Rear Plate

• Align the rear plate with the cylinder block knock
pins.
• Tighten the rear plate to the specified torque. LNW21BSH036401
Tighten: 4. Water Pump Assembly

• Rear plate bolts to 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
• Fit the O-ring to the water pump body.
• Remove the water pump assembly and tighten
Tighten:
• Water pump bolts to 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
LNW81BSH012501
• Block the crankshaft with a piece of hard wood to

prevent the flywheel form turning.
• Apply a coat of engine oil to the threads of the fly-
wheel bolts. LNW81BSH012601
• Align the flywheel with the crankshaft dowel pin.
5. Timing Gearcase
two steps using the Angular Tightening Method. • Install the timing gearcase the cylinder block.
• Follow the numerical order shown in the illustra- • Tighten the timing gearcase together with the tim-
tion. ing gearcase gasket to the specified torque.
Tighten:
• Timing gearcase bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Cut away the flash from the gasket.

7. Piston Cooling Oil Pipe 8) Oil level gauge guide tube
Above works refer to “PISTON” Section in this 9) Glow plug harness connector
manual. 10) PCV hose
8. Oil Pump Assembly 11) Fuel leak off pipe
9. Oil Pan Assembly 12) Injection pipe
Above works refer to “OIL PUMP AND OIL PAN” Above works refer to “CYLINDER HEAD AS-
Section in this manual. SEMBLY AND GASKET” Section in this manu-
10. Timing Gear al.
1) Crankshaft gear 12. Engine Assembly
• Install the crankshaft gear. 1) Support rubber
• Use the crankshaft gear installer (1) to install 2) Front exhaust pipe
the crankshaft gear (2). 3) Vacuum pump hose
• The crankshaft gear timing mark (“X — X”) or (“⋅ 4) Actuator vacuum hose (Exhaust Brake Model)
— ⋅”) must be facing outward. 5) Power steering pump & bracket assembly
Crankshaft Gear Installer: 9-8522-0020-0 (Power Steering Model)
7) Fuel hose
10) Heater hose
11) Intake air duct
12) Radiator assembly
1) Clutch
2) Transmission
LNW81BSH007801

3) Injection pump
4) Idle gear “B” and shaft
5) Idle gear
6) Timing gear oil pipe
in this manual.
3) Push rod
4) Rocker arm shaft assembly
Valve Clearance Adjustment
6) By-pass hose

LNW81BMF004501
(a) 167 N⋅m (17.0 kg⋅m / 123 lb⋅ft)

Cylinder Block
Component
LNW81BMF002701
Legend
1. Cylinder liner 2. Cylinder block
Disassembly Inspection and Repair

1. Cylinder Head Assembly and Gasket Make the necessary adjustments, repairs, and part re-
2. Oil Pan Assembly placements if excessive wear or damage is discovered
3. Timing Gear during inspection.
4. Timing Gearcase 1. Remove the gasket and any other material adher-
ing the upper surface of the cylinder block.
Be very careful not to allow any material to acci-
6. Piston Cooling Oil Pipe dental drop into the cylinder block.
7. Piston and Connecting Rod Be very careful not to scratch the cylinder block.
8. Flywheel 2. Carefully remove the oil pump, Rear Seal retainer
9. Cylinder Block Rear Plate and oil pan installation surface seal.
10. Crankshaft Rear Oil Seal 3. Wipe the cylinder block clean.
11. Main Bearing Cap
12. Crankshaft
Cylinder Liner Projection Inspection
13. Camshaft 1. Hold a straight edge along the top edge of the cyl-
inder liner to be measured.
14. Tappet
2. Use a feeler gauge to measure each cylinder line
15. Cylinder Block
projection.
The difference in the cylinder liner projection height
between any two adjacent cylinders must not ex-
ceed 0.03 mm (0.0012 in).

If the measured values exceeds the limit, the cylin-
Standard mm (in) der block must be replaced.
0.0 — 0.1 (0.0000 — 0.0039)
LNW81BSH008701
LNW21BSH039601 Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder liner
Flatness bore at measuring point (1) in the thrust (2) — (2) and
1. Remove the cylinder block dowel. axial (3) direction of the crankshaft.
2. Set the cylinder liner remover to the cylinder liner. Measuring Point (1) 20mm (0.79 in)
3. Check that the remover shaft ankle is firmly grip- If the measured value exceeds the specified limit, the
ping the cylinder liner bottom edge. cylinder liner must be replaced.
4. Slowly turn the remover shaft handle counterclock-
wise to pull the cylinder liner free.
Cylinder Liner Remover Ankle:
5-8840-2039-0
LNW21BSH039801
Note:
The inside of the dry type cylinder liner is chrome plated.
LNW81BSH008801 It cannot be rebored or honed.
If the inside of the cylinder liner is scored or scorched,
Note: the cylinder liner must be replaced.
Take care not to damage the cylinder body upper during
the cylinder liner removal procedure. Cylinder Liner Grade Selection
Measure the cylinder block inside diameter and select
5. Use a straight edge and a feeler gauge to measure
the appropriate cylinder liner grade.
the four sides and the two diagonals of the cylinder
block upper face.
Standard Lifting Interference mm (in)

0.01 — 0.019 (0.0004 — 0.0007)
If the cylinder liner fitting interference (1) is too small, en-

gine cooling efficiency will be adversely effected.
If the cylinder liner fitting interference is too large, it will
be difficult to insert the cylinder liner into the cylinder
block.
LNW21BSH040201
2. Calculate the average value of the four measure-

ments to determine the correct cylinder grade.
3. Consult the following table with the resultant diam-
eter for the correct liner application.
Selection method of cylinder liner and piston grade
for service parts.
The production line stamped cylinder liner grade on the
top of cylinder block, the cylinder liner outside diameter
LNW21BSH04001
grade 1, 2, 3, 4.
Cylinder Block Bore Measurement If you find cylinder liner outside diameter grade 1 and
piston outside diameter B on the cylinder block or result
1. Take measurements at measuring point (A) across of measurement for each parts, you will select service
positions (1) — (1), (2) — (2), (3) — (3), and (4) — parts grade for cylinder liner 1, AX grade and for piston
(4). AX grade.
Measuring Point (A) 98mm (3.86 in). The stamping grade code on the service parts are;
For cylinder liner grade stamped on the outside of cylin-
der liner.
For piston grade stamped on the head of piston.
Cylinder block inner diameter, liner grade mm (in)

Liner
Cylinder bore diameter Liner bore
outside Liner outside diameter Service liner bore measurement
average Grade
Grade
95.001 — 95.010 95.011 — 95.020 AX 93.035 (3.6628) — 93.050 (3.6634)
1
(3.7402 — 3.7406) (3.7406 — 3.7409) CX 93.051 (3.6634) — 93.066 (3.6640)
95.011 — 95.020 95.021 — 95.030 AX 93.035 (3.6628) — 93.050 (3.6634)
2
(3.7406 — 3.7409) (3.7410 — 3.7413) CX 93.051 (3.6634) — 93.066 (3.6640)
95.021 — 95.030 95.031 — 95.040 AX 93.035 (3.6628) — 93.050 (3.6634)
3
(3.7410 — 3.7413) (3.7414 — 3.7417) CX 93.051 (3.6634) — 93.066 (3.6640)
95.031 — 95.040 95.041 — 95.050 AX 93.035 (3.6628) — 93.050 (3.6634)
4
(3.7414 — 3.7417) (3.7418 — 3.7421) CX 93.051 (3.6634) — 93.066 (3.6640)
Note:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will result
in engine failure. Always measure the cylinder bore and
select the correct piston grade.
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in slight
decreases in cylinder liner clearances. Always measure
the cylinder liner clearance after installation to be sure
that it is correct.
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 lin-
er and bore surfaces. LNW21BSH040301
Note: 4) Set the cylinder liner installer (1) to the top of

All foreign material must be carefully removed from the the cylinder liner.
cylinder liner and the cylinder bore before installation. Position the cylinder block so that the installer
3) Insert the cylinder liner (3) into the cylinder center is directly beneath the bench press shaft
block (2) from the top of the cylinder block. center (1).
Cylinder Liner Installer (1) Cylinder Liner Installer
: 5-8840-2040-0 : 5-8840-2040-0
4. Crankshaft
Note:
Check that the cylinder liner is set perpendicular to the 5. Main Bearing Cap
bench press and that there is no wobble. 6. Crankshaft Rear Oil Seal
7. Cylinder Block Rear Plate
5) Use the bench press to apply a seating force of
500 kg (1,102.5 lb/4,900 N) to the cylinder liner. 8. Flywheel
Above works refer to “CRANKSHAFT” Section in
6) Apply a force 2,500 kg (5,512.5 lb/24,500 N) to
this manual.
fully seat the cylinder liner.
7) After installing the cylinder liner, measure the
cylinder liner projection. 1) Try to insert the piston pin into the piston pin
hole with normal finger pressure.
8) After installing the cylinder liner, measure the
Weigh each piston and connecting rod assem-
cylinder liner projection.
bly.
Refer to “Cylinder Liner Projection Inspection”
in this Section. Select piston and connecting rod combinations
so that the weight variation of the different as-
Measure the cylinder liner bore inside diameter
semblies is held within the specified limits.
and select the appropriate piston grade.
Reassembly g (oz)
1. Cylinder Block Variance in weight after
Less than 3 (0.1058)
2. Tappet assembly
3. Camshaft
2) Clamp the connecting rod in a vise.
• Apply a coat of engine oil to the tappet and the Take care not to damage the connecting rod.
cylinder body tappet insert holes. 3) Use a pair of pliers to install the piston pin snap
• Locate the position mark applied at disassem- ring to the piston.
bly (if the tappet is to be reused).
• Apply a coat of engine oil to the camshaft and
the camshaft bearings.
• Install the camshaft to the cylinder block.
Take care not to damage the camshaft bear-
ings.
6) Use your fingers to force the piston pin snap

Note:
ring into the piston snap ring groove.
Check that the connecting rod moves smoothly
not change the piston/piston pin combination.
on the piston pin.
4) Install the piston to the connecting rod.
The piston head front mark (1) and the connect-
ing rod “ISUZU” casting mark (2) must be fac-
ing the same direction.
LNW61ASH004601
7) Install the piston rings with the piston ring ex-

pander.
LNW81BSH014501 The compression ring must be set with the N,
mark facing up.
5) Apply a coat of engine oil to the piston pin and Discrimination mark is painted as shown in the
the piston pin hole. illustration.
Use your fingers to force the piston pin into the
piston until it makes contact with the snap ring.

9) Apply engine oil to the piston ring surfaces.
10) Check that the piston rings rotate smoothly in
the piston ring grooves.
11) Position the piston ring gaps as shown in the il-
lustration.
LNW21BSH034901
Legend
8) Use a piston ring replacer to install the three LNW81BSH009101

piston rings.
Piston Ring Replacer:
Legend
Install the piston rings in the numerical order
1. Expand ring
3. Oil ring
4. Front mark
12) Carefully wipe any oil or other foreign material

from connect rod bearing back face and the
connecting rod bearing fitting surface.
13) Apply a coat of engine oil to the upper bearing
surfaces.
Apply a coat of engine oil to the cylinder wall.
LNW81BSH014301
Legend
1. 1st compression ring
2. 2nd compression ring
3. Oil ring
Note:
Install the compression rings with the stamped side fac-
ing up.
LNW81BSH009001
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil before
installing the oil ring.

14) Position the piston head from mark so that it is 18) Apply a coat of engine oil to the threads and
facing the front of engine. setting faces of each connecting rod cap bolt.
Use the piston ring compressor to compress 19) Tighten the connecting rod bearing cap bolts to
the piston rings. the specified torque in two steps using the An-
Piston Ring Compressor: 5-8840-9018-0 (J- gular Tightening Method.
8037)
Tighten:
15) Use a hammer grip to push the piston in until Connecting Rod Bearing Cap Bolt to
the connecting rod makes contact with the
4JB1-TC
crankpin.
At the same time, rotate the crankshaft until the • 1st Step: 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
crankpin is at BDC. 2nd Step: 45° — 60°
4JB1NA
• 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
LNW21BSH072201
16) Position the bearing cap front mark so that it is

LNW81BSH016301
facing the front of the engine.
17) Install the connecting rod bearing caps.
Align the bearing cap cylinder number marks Note:
and the connecting rod cylinder number marks. Check to see that the crankshaft turns smoothly by ro-
tating it manually.
1) Fix the oil jet pipes with knock pins on the cylin-
der block.
2) Install the oil pipe for piston cooling in the cylin-
der block, tightening a relief valve and four joint
Tighten:
• Oil pipe fixing bolts to
M8: 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
M6: 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
• Relief valve fixing bolt to 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
LNW21BSH036001
Legend
1. Front mark

Before measurement, clear off carbon from the
piston head and cylinder body surface and also
clean the place where a gasket was installed.
LNW21BSH036101
Note:
After installed the piston assembly. Check and see that LNW81BSH009201
there is appropriate clearance between pistons and oil
jet pipes by rotating crankshaft slowly. Piston Head Projection Measurement Point
2) Use a dial indicator to measure the piston pro-
jection amount.
manual. 3) Refer to the illustration for the piston head pro-
jection measuring positions.
12. Timing Gearcase
All measuring positions should be as close as
13. Timing Gear possible to the cylinder liner.
1) Crankshaft Gear 4) Measure the points (1) (2) (3) (4) and obtain
2) Crankshaft Timing Gear two difference (1) — (2) and (3) — (4) on each
3) Idle Gear cylinder.
4) Idle Gear “B” and Shaft Calculate the average value of the piston head
5) Injection Pump projection on each cylinder.
6) Timing Gear Oil Pipe 5) Obtain the maximum value in the four cylinders.
7) Timing Gearcase Cover 6) Determine the gasket grade required to the
maximum value described above in accor-
8) Crankshaft Damper Pulley
dance with the following table.
9) Cooling Fan Assembly
10) AC Generator, Power Steering Pump Drive
Belt
11) Fan Shroud
Above works refer to “CRANKSHAFT” Section
in this manual.
14. Oil Pan Assembly
manual.
1) Cylinder head gasket is determined by the pis-
ton head projection from the cylinder body up-
per surface, in order to improve engine
performance.
Three types of gasket are provided by the dif-
ference of thickness. Select the adequate one
out of three grades of gasket, according to the
following procedure. LNW81BSH009301

Cylinder Head Gasket Thickness 6. Tighten the cylinder head bolts to the specific
torque in three step following the numerical and
Tighten:
Cylinder Head Bolts to
• 1st Step: 49 N⋅m (5 kg⋅m/36 lb⋅ft)
• 2rd Step: 60° — 75°
• 3rd Step: 60° — 75°
LNW81BSH014601
Legend
1. Gasket grade mark
2. Piston projection
3. Gasket thickness (Reference)
LNW21BSH050401
Push Rod
• Apply engine oil to push rod and into the cylinder
head.
Rocker Arm Shaft Assembly
1. Loosen all adjusting screws.
2. Position the rocker arm shaft with the large oil hole
(φ4) facing the front of the engine.
LNW81BSH009401
Note:
The difference between the highest measured piston
head projection and the lowest measured piston head
projection must not exceed 1.0mm (0.039 in).
Cylinder Head Assembly
1. Install the dowel in cylinder block.
2. Install the cylinder head gasket with top mark up.
3. Clean up cylinder head lower surface and cylinder LNW81BSH006601
body upper surface.

4. Install the cylinder head as softly.
5. Apply molybdenum disulfide grease to screw and
seat of cylinder head bolts.

3. Tighten the rocker arm shaft bracket bolts to the
specified torque in the numerical order shown in
the illustration.
Tighten:
Rocker Arm Shaft Bracket Bolt to 54 N⋅m (5.5 kg⋅m/40
lb⋅ft)
LNW21BSH050801
• Valve clearance adjustment.
List of tightening Torque
LNW81BSF000201
(a) 29 N⋅m (3.0 kg⋅m/ 22 lb⋅ft)

(b) 8 N⋅m (0.8 kg⋅m/ 69 lb⋅in)
(c) 19 N⋅m (1.9 kg⋅m/ 14 lb⋅ft)
MEMO
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Engine Cooling (4JB1) 1C-1
ENGINE
Engine Cooling
(4JB1)
TABLE OF CONTENTS
General Description ..............................................1C-2
Component ........................................................1C-2
Coolant Flow......................................................1C-2
Water Pump.......................................................1C-2
Thermostat ........................................................1C-3
Radiator .............................................................1C-3
Engine Coolant Change Procedure...................1C-3
Specified Coolant Solution ................................1C-4
Water Pump ..........................................................1C-6
Component ........................................................1C-6
Removal ............................................................1C-6
Inspection ..........................................................1C-7
Installation .........................................................1C-7
List of Tightening Torques .................................1C-9
Thermostat ..........................................................1C-10
Component ......................................................1C-10
Removal ..........................................................1C-10
Inspection ........................................................1C-10
Installation .......................................................1C-11
Radiator...............................................................1C-12
Component ......................................................1C-12
Removal ..........................................................1C-12
Inspection ........................................................1C-12
Installation .......................................................1C-13
Drive Belt Adjustment..........................................1C-15
Component ......................................................1C-15
Inspection ........................................................1C-16
Tension Adjustment.........................................1C-16
1C-2 Engine Cooling (4JB1)
General Description
Component
Coolant Flow
LNW81CMF000601
Legend
1. Radiator cap 7. Injection pump
2. Reservoir tank 8. Car heater
3. Air bleeding plug 9. Water pump
4. Cylinder head 10. Thermostat
5. Oil cooler 11. Cooling fan
6. C.S.D 12. Radiator
The cooling system is a pressurized coolant forced cir-

culation type which consists of water pump, thermostat
cooling fan, radiator and other components. The circu-
lating coolant cools the lubricating oil in the oil filter and
turbocharger.
Water Pump
The coolant pump is a centrifugal impeller type and is
driven by V type drive belt.
The water pump is not disassembled type.
LNW21CSH002601 LNW81CSH001001
Thermostat Engine Coolant Change Procedure

The thermostat is a wax pellet type with a juggle valve 1. To change engine coolant, make sure that the en-
and is installed in the thermostat housing. gine is cool.
WARNING:
Warning:
WHEN THE COOLANT IS HEATED TO A HIGH TEM-
PERATURE, BE SURE NOT TO LOOSEN OR RE-
MOVE THE RADIATOR CAP.
OTHERWISE YOU MIGHT GET SCALDED BY HOT
VAPOR OR BOILING WATER. TO OPEN THE RADI-
ATOR CAP, PUT A PIECE OF THICK CLOTH ON THE
CAP AND LOOSEN THE CAP SLOWLY TO REDUCE
THE PRESSURE WHEN THE COOLANT HAS BE-
COME COOLER.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
Note:
For best result it is suggested that the engine cooling
system be flushed at least once a year. It is advisable to
LNW81CSH001801
flush the interior of the cooling system including the ra-
diator before using specified coolant.
Replace damaged rubber hoses as the engine specified
Legend
coolant. Coolant is liable to leak out even minor cracks.
1. Jiggle valve
Isuzu recommends to use Isuzu genuine specified cool-
ant or equivalent, for the cooling system and not add any
Radiator inhibitors or additives.
The radiator is a tube type with corrugated fins. In order Caution:
to raise the boiling point of coolant a pressurized radia- A failure to correctly fill the engine cooling system in
tor is attached. changing or topping up coolant may sometimes cause
the coolant to overflow from the filler neck even before
the engine and radiator are completely full.
If the engine runs under this condition, shortage of cool-
ant may possibly result in engine overheating. To avoid
such trouble, the following precautions should be taken
in filling the system.
3. To refill engine coolant, pour coolant up to filler
neck using a filling hose which is smaller in outside
diameter of the filler neck.

Otherwise air between the filler neck and the filling
hose will block entry, preventing the system from
completely filling up.
4. It pour slowly so that coolant should not spill.
And also, the coolant overflow will increase, mak-
ing it difficult to determine, whether or not the sys-
tem is completely full.
5. After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system
is dislodged and the coolant level goes down.
Should the coolant level go down, repeat topping-
up until there is no more drop in the coolant level.
6. After directly filling the radiator, fill the reservoir to
the maximum level.
7. Install and tighten radiator cap and start the en-
gine. After idling for 2 to 3 minutes, stop the engine
and reopen radiator cap. If the water level is lower,
replenish. LNW81CSH001101
WARNING:
Warning: • Calculation of mixing ratio
WHEN THE COOLANT IS HEATED TO A HIGH TEM-
PERATURE, BE SURE NOT TO LOOSEN OR RE- Mixing ratio
MOVE THE RADIATOR CAP. Specified coolant solution (Lit/qt.)
OTHERWISE YOU MIGHT GET SCALDED BY HOT = Specified coolant solution (Lit/qt.) + Water (Lit/
VAPOR OR BOILING WATER. TO OPEN THE RADI-
qt.)
ATOR CAP, PUT A PIECE OF THICK CLOTH ON THE
CAP AND LOOSEN THE CAP SLOWLY TO REDUCE
THE PRESSURE WHEN THE COOLANT HAS BE- Note:
COME COOLER. Specified coolant solution + Water = 10 lit
8. After tightening radiator cap, warm up the engine at Total cooling system capacity.
about 2,000 r/min. In case of 6.8 lit total cooling system capacity
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into heat- Specified coolant
er water system. Mixing Water:
solution:
ratio (%) lit. (imp. qt.)
9. Check to see the thermostat has opened through lit. (imp. qt.)
the needle position of water thermometer, conduct 0 0 0 10 (8.80)
a 5 minutes idling again and stop the engine.
10. When the engine has been cooled, check filler 5 0.5 (0.44) 9.5 (8.36)
neck for water level and replenish if required. 10 1.0 (0.88) 9.0 (7.92)
Should extreme shortage of coolant is found,
15 1.5 (1.32) 8.5 (7.48)
check the coolant system and reservoir tank hose
for leakage. 20 2.0 (1.76) 8.0 (7.04)
11. Fill the coolant into the reservoir tank up to “MAX” 25 2.5 (2.20) 7.5 (6.60)
line.
30 3.0 (2.64) 7.0 (6.16)
Specified Coolant Solution 35 3.5 (3.08) 6.5 (5.72)
• Relation between Mixing ratio and Freezing point 40 4.0 (3.52) 6.0 (5.28)
Freezing temperature of the engine coolant varies
with the ratio of specified coolant solution in water. 45 4.5 (3.96) 5.5 (4.84)
Proper mixing ratio can be determined by referring 50 5.0 (4.40) 5.0 (4.40)
to the chart. Supplemental inhibitors or additives
claiming to increase cooling capability that have
not been specifically approved by Isuzu are not
recommended for addition to the cooling system.

• Mixing ratio
Check the specific gravity of engine coolant in the
cooling system in temperature ranges from 0° to
50°C using a suction type hydrometer, then deter-
mine the mixing ratio of the coolant by referring to
the table.
LNW71CSH004601
Water Pump
Component
LNW81CMF000301
Legend
1. Cooling fan assembly 4. O-ring: Water pump
2. AC generator drive belt 5. Cooling fan pulley
3. Water pump assembly
Removal
Preparation:
• Drain coolant.
1. Fan Shroud
• Remove the reservoir tank hose, bypass hose and
fan guide.
LNW81CSH001301

2. Cooling Fan Assembly Inspection
• Remove lock nut and take out cooling fan assem- Make necessary parts replacement if extreme wear or
bly. damage is found during inspection. Should any of the
3. Power Steering Pump Drive Belt following problems occur, the entire water pump assem-
• Loosen the idler pulley lock nut and loosen adjust bly must be replaced.
bolt, and remove the drive belt. • Cracks in the coolant pump body
4. AC Generator Drive Belt • Coolant leakage from the seal unit
• Loosen AC Generator mounting bolt (under side) • Play or abnormal noise in the bearing
and adjust plate lock bolt, and remove the drive • Cracks or corrosion in the impeller
belt.
Installation
1. Water Pump Assembly
• Set O-ring in water pump body groove.
LNW81BSH005701
Legend
1. Lock bolt LNW81BSH012601
5. Crankshaft Damper Pulley • Install water pump assembly, and tighten to speci-
fied torque.
Tighten:
Pump Fixing Bolt to 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
• Install crankshaft damper pulley, and tighten to
specified torque.
Tighten:
Pulley Bolt to 206 N⋅m (21 kg⋅m/152 lb⋅ft)
LNW81BSH008501
6. Water Pump Assembly

• Remove the O-ring.
Legend
Tighten:
• Generator Fixing Belt to 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
• Adjust Plate Fixing Belt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• P/S Idler Pulley Lock Nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
• Mount fan pulley and cooling fan assembly on the
water pump and tighten to the specified torque.
Tighten:
Fan Pulley Nut to 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
6. Fan Shroud
LNW81BSH008501
• Install the fan shroud and reservoir tank hose and
bypass hose.
• Install the drive belts and adjust belt.
with new ones as necessary. Check belts for ten-
sion, and adjust as necessary.
• Push the middle of belts with a force of 98 N (10 kg/
22 lb) and check each bolt for deflection.
Amount of Frequency
mm (in) Hz
For a new 7-9
133 - 157
drive belt 9-11
(0.35-0.43)
For a new 8 - 11 LNW81CSH001301
135 - 165
drive belt • Connect the battery ground cable.
11 - 12
When reused 117 - 135 • Pour coolant.
(0.43-0.47)
LNW81BSH014801

LNW81CMF000401
(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) (c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(b) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) (d) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
Thermostat
Component
LNW81CMF000701
Legend
1. Switch harness 3. Thermostat
2. Gasket 4. Outlet pipe
Removal
Valve Opening Temperature °C(°F)
Preparation:
82 (180)
• Drain coolant from the radiator and engine. • Make sure that secondary valve opens fully at the
1. Switch Harness specified temperature.
2. Outlet Pipe
Valve Full Open Temperature °C(°F)
• Remove mounting bolt and remove outlet pipe to-
gether with radiator hose. 95 (203)
3. Gasket
4. Thermostat
Inspection
Submerge the thermostat assembly in the water.
Place wooden blocks on the bottom of the water con-
tainer.
Not to directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
• Make sure that primary valve begins to open at the
specified temperature.
LNW21CSH003101
Make necessary repair and parts replacement if ex-

treme wear or damage is found during inspection.
Installation
1. Thermostat
2. Gasket
3. Outlet Pipe
• Connect outlet pipe and tighten bolts to the speci-
fied torque.
Tighten:
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
4. Switch Harness
• Install switch harness.
LNW81CSH001901
• Install battery ground cable.

• Pour coolant.
Radiator
Component
LNW81CMF000201
Legend
1. Radiator assembly 4. Air intake duct
2. Reservoir tank hose & Bypass hose 5. Radiator stay
3. Radiator hose 6. Cushion rubber
Removal Inspection
Preparation: Radiator cap
• Disconnect battery ground cable. 1. Use the radiator cap tester to inspect the open
• Loosen drain plug to drain coolant. valve pressure. Replace the radiator cap if the
open valve pressure is not at the standard value.
1. Reservoir Tank Hose & Bypass Hose
Open valve pressure
• Disconnect the hose from radiator.
2. Radiator Hose Tighten:
93 - 123 kPa (0.95 - 1.25 kg/cm2/13.5 - 17.8 psi)
• Disconnect lower hose and upper hose from the
engine.
3. Air Intake Duct
4. Radiator Stay
5. Cushion Rubber
• Remove cushion rubbers on both sides of the bot-
tom.
6. Radiator Assembly
• Remove upward the radiator assembly with hose,
taking care not to damage the radiator core by fan
blade.

5. Rinse off the mild detergent using a high-pressure
washer.
• Start washing from the engine side of the radiator.
Note:
• Apply the high-pressure water in a direction per-
pendicular to the fins.
• Do not bring the high-pressure water too close to
the fins.
• Be careful not to deform the fins.
LNW21BSH000201
2. Inspect the condition of the negative pressure

valve in the center of the cap valve seat side. If the
valve seat is not operating smoothly because of
rust or foreign matter, clean or replace the radiator
cap.
Radiator Core
3. Remove dirt or other foreign matter.
Also, if the radiator fins are deformed, this can lead
to a drop in heat dissipation and cause overheat-
ing. Repair the fins. When repairing, be careful not MFWA1CSH001101
to damage the base of the fins.
Cleaning the radiator Legend
• Clean the inside of the radiator and coolant path 1. Radiator
with water. Clean away all scales and rust.
Washing the radiator core 6. After washing is finished, inspect the fins to confirm
that the dirt is removed sufficiently.
Caution:
Do not perform high-pressure washing onto the radiator, • If washing is not sufficient, wash them again.
intercooler and surrounding parts when they are still in- Note:
stalled on the vehicle. If some dirt is still left, fine black particles attached on
1. Seal the hose connecting section with a cap or fab- the fins can be seen.
ric tape. 7. Rinse off the detergent constituents on the fins and
2. Sufficiently wet the front and back surfaces of the resin parts using the tap water.
radiator. 8. Remove the seal on the hose connecting section.
• Adhering matter which easily comes off with a 9. Clean and dry the hose connecting section suffi-
splash of tap water should be washed off sufficient- ciently.
ly in advance.
Installation
Note:
Do not use a high-pressure washer or brush. 1. Radiator Assembly
• Install the radiator.
3. Prepare a mild detergent.
2. Cushion Rubber
• Use a type which contains approx. 8% of surface
• Install cushion rubbers on both sides of radiator
acting agent.
bottom.
Note: • Install radiator assembly with hose, taking care not
Do not use anything other than a mild detergent. Use of to damage the radiator core by a fan blade.
any product other than a mild detergent may cause cor-
3. Radiator Stay
rosion.
4. Air Intake Duct
4. Spray the mild detergent onto both sides of the
• Connect the air duct and tighten clamp securely.
fins, and leave them as is for 10 minutes.

• Use a new hose clamp
5. Radiator Hose
• Connect inlet hose and outlet hose to the engine.
• Pour coolant up to filler neck of radiator, and up to
MAX mark of reservoir tank.
6. Reservoir Tank Hose
• Start engine to warm up, and check for coolant lev-
el.
LNW81CSH000901
Legend
1. Reservoir tank
2. Maximum
3. Minimum
Drive Belt Adjustment

Component
LNW81BLF002901
Legend
1. Adjust plate 6. Crank pulley
2. Cooling fan pulley 7. Belt position: Generator, cooling fan
3. P/S oil pump 8. Belt position: P/S oil pump
4. Idle pulley 9. AC generator fixing bolt
5. Adjust bolt 10. AC generator

Inspection 2. P/S Oil Pump Pulley Belt
Check drive belts for wear or damage, and replace with • With P/S pump lock bolt loose, adjust belt tension
new ones as necessary. Check belts for tension, and with adjust belt.
adjust as necessary. Tighten lock nut to the specified torque.
• Check drive belts tension. Tighten:
• Push the middle of belts with a force of 98 N (10 kg/ Lock Nut to 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
22 lb) and check each bolt for deflection.
Amount of Frequency
mm (in) Hz
For a new 7-9
133 - 157
drive belt 9-11
(0.35-0.43)
For a new 8 - 11
135 - 165
drive belt 11 - 12
(0.43-0.47)
LNW81BSH014801
Legend
Tension Adjustment
1. Cooling Fan Pulley Belt
• With AC Generator mounting and lock bolts loose,
adjust belt tension with adjuster’s adjust bolt.
Tighten bolt to the specified torque.
Tighten:
• Generator Fixing Bolt to 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
• Adjust Plate Fixing Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
Engine Fuel (4JB1) 1D-1
ENGINE
Engine Fuel
(4JB1)
TABLE OF CONTENTS
General Description ..............................................1D-2
Fuel Flow ...........................................................1D-3
Injection Pump...................................................1D-4
Fuel Filter and Water Separator ........................1D-5
Injection Nozzle .................................................1D-6
Fuel Filter Assembly..............................................1D-8
Components ......................................................1D-8
Removal ............................................................1D-8
Installation .........................................................1D-8
Fuel Filter Cartridge ..............................................1D-9
Removal ............................................................1D-9
Installation .........................................................1D-8
Injection Nozzle (4JB1-TC) .................................1D-11
Component ......................................................1D-11
Removal ..........................................................1D-12
Disassembly ....................................................1D-12
Reassembly and Opening Pressure
Adjustment.......................................................1D-13
Reassembly and Adjustment Procedure .........1D-14
List of Tightening Torques ...............................1D-24
Injection Nozzle (4JB1NA) ..................................1D-25
Component ......................................................1D-25
Removal ..........................................................1D-26
Disassembly ....................................................1D-26
Inspection and Repair......................................1D-26
Reassembly.....................................................1D-27
Installation .......................................................1D-28
Injection Pump Assembly ....................................1D-30
Component ......................................................1D-30
Removal ..........................................................1D-31
Installation .......................................................1D-32
Injection Pump Data............................................1D-36
Test Conditions................................................1D-36
Identification Plate and Number ......................1D-37
Injection Volume and Governor Performance
Diagram...............................................................1D-38
Governor Performance Diagram .....................1D-38
Fuel Tank ............................................................1D-43
Component ......................................................1D-43
Removal ..........................................................1D-44
Installation .......................................................1D-44
Fuel Gauge Unit ..................................................1D-46
Component ......................................................1D-46
Removal ..........................................................1D-46
Installation .......................................................1D-46
1D-2 Engine Fuel (4JB1)
General Description
When working on the fuel system, there are several
things to keep in mind:
• Any time the fuel system is being worked on, dis-
connect the negative battery cable except for those
tests where battery voltage is required.
• Always keep a dry chemical (Class B) fire extin-
guisher near the work area.
• Replace all pipes with the same pipe and fittings
that were removed.
Clean and inspect O-rings. Replace where re-
quired.
• Always relieve the line pressure before servicing
any fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pic-
tures relating to that repairs.
• For information on fuel injection pump mainte-
nance and/or part replacement, contact the Bosch
Automotive Systems Corporation.
• Contact the Bosch Automotive Systems Corpora-
tion for information on 4JB1-TC and 4JB1NA en-
gine fuel injection nozzle maintenance.

Fuel Flow
LNW81DLF001201
Legend
1. CSD solenoid valve 4. Fuel tank
2. Nozzle 5. Fuel filter & Water separator
3. Fuel cut solenoid valve 6. VE type injection pump
The fuel system consists of the fuel tank, the water separator & 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 for-
eign 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.

Injection Pump
LNW81DMF001101
Legend
1. Control lever shaft 10. Delivery valve
2. Control lever 11. Control sleeve
3. Governor spring 12. Plunger spring
4. Aneroid compensator 13. Timer
5. Collector lever 14. Driver disc
6. Tension lever 15. Feed pump gear
7. Fuel cut solenoid valve 16. Drive shaft
8. Plunger 17. From fuel filter
9. To nozzle
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing.
The injection pump is compact, light weight, and provides reliable high-speed operation.
An aneroid compensator is available as an option for vehicles to be operated at high altitudes. It adjusts the fuel and
air mixing ratio.

Fuel Filter and Water Separator
Fuel Filter With Built-in Water Separator
LNW81DMF000401
Legend
1. Priming pump 5. Drain plug
2. PTC heater assembly 6. Float
3. Filter cartridge 7. Filter element
4. Level sensor assembly
A fuel filter with a built-in water separator is used along with the VE type injection pump.
As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The
fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches the
injection pump.
The water separator has an internal float. When the float reaches the specified level, a warning light comes on to
remind you to drain the water from the water separator.
A diaphragm type priming pump is installed at the top of the water separator. It is used during the water draining and
the air bleeding procedures.

Injection Nozzle
4JB1-TC
LNW8DMF000501
Legend
1. Nozzle holder body 7. Spacer
2. Shim 8. Injection nozzle
3. Spring 9. Retaining nut
4. Spring seat 10. Spring seat
5. Push rod 11. Spring
6. Collar
4JB1-TC engines employ a hole type nozzle with five in-

jection orifices. The nozzle is made up of the nozzle
body and the needle valve assembly.
Pressurized fuel from the injection pump is sprayed by
the injection nozzle into the combustion chamber
through the nozzle body orifices.
The two-spring nozzle holder has been developed to re-
duce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.

4JB1NA
LNWB1DLF000101
Legend
1. Spring 4. Nozzle holder
2. Spring seat 5. Adjusting shim
3. Injection nozzle 6. Retaining nut
4JB1NA engines employ a hole type nozzle with four in-

jec-tion orifices. The nozzle is made up of the nozzle
body and the needle valve assembly.
Pressurized fuel from the injection pump is sprayed by
the injection nozzle into the combustion chamber
through the nozzle body orifices.
Fuel Filter Assembly

Components
LNW81DMF001201
Legend
1. Fuel filter assembly 2. Fuel filler cap
Removal
Preparation
1. Fuel Filler Cap
2. Fuel Hose
• Disconnect fuel hose from filter body.
Plug the hose ends to prevent fuel spillage.
3. Fuel Filter Assembly
• Remove the fixing bolts on fuel filter bracket.
Installation
1. Fuel Filter Assembly
• Install the fuel filter bracket, then tighten fixing bolt.
2. Fuel Hose
• Connect hoses to filter body.
3. Fuel Filler Cap
• Connect the battery ground cable.
• Feed fuel to the injection pump by means of the
priming, and bleed the fuel system.
Fuel Filter Cartridge

Removal
• Remove the cartridge using a filter wrench.
Filter wrench: 5-8840-0253-0 (J-22700)
Remove the sediment sensor.
Installation
• Install the sediment sensor (3) on the new car-
tridge.
• Clean the cartridge (2) mounting surface of the fil-
ter body to ensure tight seating of the cartridge.
• Lightly coat the O-ring (1) of the cartridge with en-
gine oil.
LNW81DSH002901
Air Bleeding
• Loosen the drain plug at the bottom of the fuel filter,
and then move the priming pump up and down by
hand 10 to 20 times.
• Tighten the drain plug securely, and then operate
the priming pump once again several times.
• Confirm that no fuel leaks from the drain plug and
also that the warning light goes out after the engine
starts.
Caution:
LNW21DSH000401 • Clean off any fuel that has adhered to the vehicle
body.
• To facilitate bleeding of the fuel system, fill the new • Starting the engine immediately after draining the
cartridge with diesel fuel. water from the fuel filter requires a little more time
• Install the cartridge by tightening it until the O-ring than usual. If the engine doesn't start in 10 sec-
touches the sealing surface. Do this work extreme- onds, wait for awhile and try again.
ly carefully not to spill the diesel fuel from the car- • Fuel will be mixed in the drained water. Dispose of
tridge. it in a method conforming to the regulatory require-
• Using the special filter wrench, tighten the cartridge ments in your country.
an additional 1/3 to 2/3 of a turn.
Filter wrench: 5-8840-0253-0 (J-22700)

Draining
• When the water in the sedimentor reaches the
specified volume, warning light is actuated.
In this case, follow the draining steps below.
• Set a vinyl hose over the drain plug.
• Loosen the drain plug.
• To drain the water, operate the priming pump sev-
eral times.
• After draining, tighten the drain plug.
• Operate the priming pump several times to check
for fuel leakage.
• Check and see the warning light is off.
LNW81DSH002801
Injection Nozzle (4JB1-TC)

Component
LNW81DMF000801
Legend
1. Eye bolt 6. Clamp bolt
2. Gasket 7. Clamp
3. Leak off pipe 8. O-ring
4. Clip 9. Injection nozzle gasket
5. Fuel hose 10. Injection nozzle assembly

Removal
Preparation:
1. Injection Pipe
disconnect and put aside the pipe.
2. Leak off Pipe or Hose
Injection Nozzle Assembly (Two Spring Nozzle
Holder)
The two-spring nozzle holder has been developed to re-
duce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Disassembly
1. Retaining nut (7)
2. Nozzle & kit (6)
3. Spring seat (5)
4. Shim (Second nozzle opening pressure adjust-
ment) (4)
5. Second spring (3)
6. Push rod (2)
7. Spacer (1) LNW81DMH000101
8. Spring seat (8)
1) Before disassembly, remove carbon deposit
9. First spring (9)
from nozzle and nozzle holder using a wire
10. Shim (First nozzle opening pressure adjustment) brush and wash the outside nozzle holder as-
(10) sembly.
11. Nozzle holder body (11)
Note:
12. Eye bolt (12)
Do not touch nozzle holes with the wire brush during
13. Gasket (15)
cleaning it.
2) Disassemble the nozzle holder assembly to nu-
merical order.

Reassembly and Opening Pressure Adjust-
ment
1. Nozzle holder body (11)
2. Shim (First opening pressure adjustment) (10)
3. First spring (9)
4. Spring seat (8)
5. Spacer (1)
6. Second spring (3)
7. Push rod (2)
8. Shim (Second opening pressure adjustment) (4)
9. Spring seat (5)
10. Nozzle & kit (6)
11. Retaining nut (7)
12. Eye bolt (12)
LNW81DMH000101
The nozzle holder is adjusted as the components are re-

assembled in the sequence above.
As adjustment of the two-spring nozzle holder is made
in hundredths of a millimeter, clean the parts thoroughly
in light oil to completely remove any dirt or foreign mat-
ter.

Reassembly and Adjustment Procedure
LNW81DMF001301
First Nozzle Opening Pressure Adjustment

1. Claim the nozzle holder in a vise.
LNW81DSH000801
LNW81DSH000701 Legend
1. Spring seat
Legend 2. First spring
1. Nozzle holder body 3. First nozzle opening pressure adjusting shim
2. Install the shim, first spring and spring seat in the 3. Install the collar, second spring, shim, spring seat
nozzle holder. and push rod in the nozzle holder.
LNW81DSH000901 LNW81DSH001101
7. Hand-tighten the adjustment retaining nut together

Legend with the gasket to the nozzle holder.
1. Push rod Retaining nut: 5-8677-7140-0
2. Spring seat Gasket: 5-8677-7139-0
3. Spacer
4. Second spring
5. Second nozzle opening pressure adjusting
shim
4. Install the pins (3), lift piece (2) and spacer (1) in
the nozzle holder.
LNW21DSH012301
Legend
1. Nozzle
2. Gasket (Special tool)
3. Retaining nut (Special tool)
LNW81DSH001001
8. Tighten the adjustment retaining nut to the speci-
5. Install the pins (2) in the spacer. fied torque.
6. Install the nozzle (1) on the spacer. Tighten:
Retaining nut to 29 — 39 N⋅m (3.0 — 4.0 kg⋅m/22 — 29
lb⋅ft)
Parts No. Thickness mm (in)

1-1534-9042-0 0.40 (0.0157)
1-1534-9043-0 0.50 (0.0197)
1-1534-9044-0 0.52 (0.0205)
1-1534-9045-0 0.54 (0.0213)
1-1534-9046-0 0.56 (0.0220)
1-1534-9047-0 0.58 (0.0228)
1-1534-9048-0 0.60 (0.0236)
1-1534-9049-0 0.70 (0.0276)
LNW81DSH001201
Legend
1. Torque wrench
9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first
nozzle opening pressure.
LNW21DSH012601
Legend
1. φ 2.6 mm
2. φ 6.2 mm
3. 3 mm
Full Needle Valve Lift Confirmation

1. Install the gasket (2) and plug (1) on the adjust-
ment retaining nut.
Gasket: 8-9422-7602-0
Plug: 5-8677-7141-0
LNW21DSH012501
Legend
1. Nozzle holder
2. Nozzle tester
11. If the first nozzle opening pressure is not as speci-

fied, disassemble the nozzle holder and replace
the shim until the pressure is as specified.
Note:
Use a micrometer to measure shim thickness.
• First nozzle opening pressure adjusting shims
2. Position the nozzle holder with the nozzle facing 4. Install the pin (1) to the dial gauge (2).
down and install the dial gauge holder on the noz-
Note:
zle holder.
The lengths of the pin do not include the threaded por-
Dial gauge holder: 5-8677-7142-0
tions.
Pin (liter=100 mm): 5-8677-7144-0
Dial gauge: 1-8531-7015-0
LNW21DSH014701
Legend
LNW21DSH013001
1. Dial gauge holder (Special tool)
5. Secure the dial gauge to the nozzle holder using
3. Install the nut (1) on the dial gauge holder (2). the nut so that the pin contacts the tip of the first
Nut: 5-8677-7143-0 spring seat.
Note:
• Secure the dial gauge so that a stroke of 2 mm can
be measured.
• Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)
LNW21DSH012501
8. Operate the nozzle tester and increase the inline

pressure to 34.3 — 44.1 MPa (350 — 450 kg/cm2)
so that the nozzle’s needle valve moves through its
full lift.
Record full lift ‘L’. (Read dial gauge)
Note:
The above operation is used to determine whether the
LNW21DMH000701 nozzle seat is worn and whether the nozzle assembly is
in good condition.
Legend
1. Dial gauge
2. Nut
3. Holder
4. Pin
5. Nozzle holder
6. First spring seat
6. Set the nozzle holder (2) to the nozzle tester (1)

and put needle to zero on the dial gauge.
7. Operate the nozzle tester (1) to bleed any air from
inside the retaining nut and to confirm that no fuel
leaks.
LNW81DSH001801
Legend
1. Needle valve lift
2. First nozzle opening pressure
3. Inline pressure
Pre-lift Confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.
Legend Legend
1. Pressure gauge 1. Needle valve lift
2. Measuring point of pre-lift
3. First nozzle opening pressure
4. Inline pressure
Note:
This point can be found while the pressure is decreas-
ing.
3. Confirm that pre-lift ‘liter’ is as specified.
Pre-lift mm (in)
0.04 (0.002)
LNW81DSH001501
Legend
1. Needle valve lift
2. Inline pressure
Note:
The inline pressure will decrease and needle valve lift
(as indicated on the dial gauge) will also decrease a lit-
tle.
2. Read the needle valve lift ‘liter’ from the dial gauge
indication (once the needle valve has descended
when the second spring has stopped operating).
Refer to the pre-lift measuring point for ‘liter’.
Pre-Lift Measuring Point:
Read the dial gauge at first nozzle opening pressure
+approx 1 MPa (10 kg/cm2/142 psi).
Legend Legend
1. Second spring 1. Pin
2. Adjusting shim 2. Spacer
3. Lift piece 3. Capsule
4. Needle valve 4. Nozzle assembly
5. Spacer 5. Lift piece
6. Spring seat
7. Push rod Second Nozzle Opening Pressure Confirmation
1. After pre-lift confirmation, operate the nozzle tester
4. If pre-lift is not specified, replace the pins, lift piece, to increase inline pressure to 34.3 — 44.1 MPa
spacer and nozzle assembly with the service kit. (350 — 450 kg/cm2/4,977 — 6,399 psi) so that the
nozzle’s needle valve moves through its full lift.
Service kit:
8-9720-3470-1
LNW21DSH012501
Legend
1. Nozzle tester
2. Nozzle holder
2. Release the nozzle tester handle so that inline

pressure decreases.
Legend Legend
1. Needle 1. Pressure gauge
2. Inline pressure
Second Nozzle Opening Pressure Adjustment
3. Second nozzle opening pressure
If the second nozzle opening pressure is not as speci-
fied, disassemble the nozzle from the nozzle holder and
Note:
replace the shim until the pressure is as specified.
The inline pressure will decrease and needle valve lift
(as indicated on the dial gauge) will also decrease a lit- Note:
tle. • Because the second opening pressure changes
3. Then, read the pressure gauge indication (second when the first opening pressure changes, the sec-
nozzle opening pressure) the instant that the dial ond opening pressure must be adjusted when the
gauge indicates the specified needle valve lift (usu- first opening pressure changes.
ally pre-lift liter + 0.05 mm (0.002 in)). • Use a micrometer to measure shim thickness.
LNW81DSH002001
Legend
1. When needle valve lift is L + 0.05 mm (0.002 in)
2. Full needle valve lift
3. Dial gauge
Legend
1. φ 2.6 mm (0.10 in)
2. φ 6.2 mm (0.24 in)
3. Thinkness
Final Inspection
1. Remove the dial gauge (1), nut (2) and dial gauge
holder (3).
LNW81DSH000901
Legend
1. Push rod
2. Spring seat
3. Spacer
4. Second spring
5. Second nozzle opening pressure adjusting
shim LNW21DSH013501
• Second nozzle opening pressure adjusting shims 2. Remove the adjustment retaining nut and gasket.
3. Install the original retaining nut, confirm that the
Part No. Thickness mm (in)
pins are inserted fully into the nozzle, and then
8-9711-6034-0 0.40 (0.0157) hand-tighten the retaining nut. Then, tighten the
8-9711-6035-0 0.50 (0.0197) original retaining nut to the specified torque.
Torque: 59 — 79 N⋅m (6.0 — 8.0 kg⋅m/43.5 — 58.2
8-9711-6037-0 0.52 (0.0205) lb⋅ft)
8-9711-6039-0 0.54 (0.0213)
8-9711-6041-0 0.56 (0.0220)
8-9711-6043-0 0.58 (0.0228)
8-9711-6044-0 0.59 (0.0276)
LNW21DSH012401
Legend
LNW21DSH012601

4. Set the nozzle holder to the nozzle tester and
check first nozzle opening pressure, spray condi-
tion, seat oil tightness and each part for oil leaks.
LNW81BSH009501
Legend
LNW21DSH012501 1. Gasket
2. O-ring
Legend 3. Injection nozzle assembly
1. Nozzle tester 4. Bolt
2. Nozzle holder 5. Bracket
5. When replacing the nozzle, replace the nozzle, lift 2. Leak Off Hose
piece, pins and spacer as a set with the nozzle ser- 3. Injection Pipe
vice kit.
Note:
Pre-lift will not be as specified if only the nozzle is re-
placed.
Installation
1. Injection nozzle
1) Install the injection nozzle gasket (1) and the O-
ring (2) to the injection nozzle holder (3).
Be sure that the O-ring fits snugly in the injec-
tion nozzle groove.
2) Apply engine oil to the cylinder head nozzle
holder hole.
3) Install the nozzle holder together with the noz-
zle holder bracket (5) to the cylinder head.
Tighten:
37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)

LNW81DMF000901
(a) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)

(b) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
Injection Nozzle (4JB1NA)

Component
LNWB1DLF000201
Legend
1. Gasket 5. Clamp bolt
2. O-ring 6. Fuel hose
3. Injection nozzle assembly 7. Clip
4. Clamp 8. Fuel leak rubber hose

Removal
Preparation:
1. Injection Pipe
disconnect and put aside the pipe.
2. Leak off Pipe or Hose
3. Injection Nozzle
Disassembly
1. Retaining Nut (8)
2. Injection Nozzle (7)
1) Remove the nozzle assemblies from the nozzle
holders. LNWB1DSH000601
Tag the nozzle assemblies and the nozzle
holders to ensure that they are reinstalled in Inspection and Repair
their original positions. Make the necessary adjustments, repairs, and part re-
The nozzle assembly and nozzle holder combi- placements if excessive wear or damage is discovered
nations must not be interchanged. during inspection.
2) Immerse the injection nozzle in a tool tray filled
with clean diesel oil to protect them from dust. Inspection Nozzle Needle Inspection
3. Positioning pin (6) 1. Remove the needle from the nozzle body.
4. Spacer (5) • Carefully wash the nozzle needle and the nozzle
body in clean diesel fuel.
5. Spring Seat (4)
6. Spring (3) 2. Check that the nozzle needle moves smoothly in-
side the injection nozzle body.
7. Adjusting Shim (2)
If the nozzle needle does not move smoothly, it
8. Nozzle Holder (1) must be repaired (See “Nozzle Lapping Proce-
dure”).
LNWB1DSH000501
LNWB1DSH000701
Nozzle Lapping Procedure

1. Lap the nozzle needle (1) and the nozzle body (2)
by applying a compound of oxidized chrome and
animal oil (3).

5. Spacer
Note:
Do not apply an excessive amount of the oxidized 6. Injection Nozzle
chrome and animal oil compound to the injection needle 7. Retaining Nut
valve seat area. Applying too much compound will Tighten:
cause the injection nozzle needle and the injection noz- Retaining nut to 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
zle body cavity to wear excessively.
LNWB1DSH001001
LNWB1DSH000801
2. Carefully wash the needle valve and the nozzle Injection Nozzle Adjustment
body in clean diesel fuel after lapping.
1. Attach the injection nozzle holder to the injection
Nozzle Body and Needle Valve Inspection nozzle tester.
Check the nozzle body and the needle valve for damage 2. Apply pressure to the nozzle tester to check that
and deformation. the injection nozzle opens at the specified pres-
The nozzle and body assembly must be replaced if ei- sure.
ther of these two conditions are discovered during in-
spection. kPa (kg/cm2/psi)
18,142 (185/2,630)
LNWB1DSH000901
Reassembly LNWB1BSH001101
1. Nozzle Holder
2. Adjusting Shim If the injection nozzle does not open at the specified
3. Spring pressure, install or remove the appropriate number of
4. Spring Seat adjusting shims to adjust it.
Adjusting Shim Availability mm (in)

Range 0.50 — 1.50 (0.02 — 0.06)
Increment 0.025 (0.001)
Total number of Shims 40
Removing or installing one shim will increase or de-

crease the nozzle opening pressure approximately
369.46 kPa (3.77 kg/cm2 /53.6 psi).
WARNING:
Warning:
TEST FLUID FROM THE INJECTION NOZZLE WILL
SPRAY OUT UNDER GREAT PRESSURE. IT CAN
EASILY PUNCTURE A PRESONÅfS SKIN. KEEP
YOUR HANDS AWAY FROM THE INJECTION NOZ-
ZLE TESTER AT ALL THE TIMES.
Installation
1. Injection Nozzle
1) Install the injection nozzle gasket (1) and the O-
ring (2) to the injection nozzle holder (3).
Be sure that the O-ring fits snugly in the injec-
tion nozzle groove.
2) Apply engine oil to the cylinder head nozzle
holder hole.
3) Install the nozzle holder together with the noz-
zle holder bracket (5) to the cylinder head.
Tighten:
37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
LNWB1BSH015001
Legend
1. Gasket
2. O-ring
3. Injection nozzle assembly
4. Bolt
5. Bracket
2. Leak Off Hose

3. Injection Pipe

LNWB1DMF000101
(a) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)

Injection Pump Assembly

Component
LNW81DLF001001
Legend
1. Injection pipe
2. Injection pump assembly
3. Injection pump bracket

Removal
Preparation:
• Drain coolant.
2. Fan Shroud
3. Power Steering Pump Drive Belt (P/S Model)
• Loosen power steering pump mounting bolt and
4. A/C Compressor Drive Belt (A/C Model)
• Loosen A/C compressor idler pulley lock nut, ad-
just bolt and remove the drive belt.
• Loosen AC generator mounting bolt (under side) LNW81DSH003001

12. Injection Pump Harness
belt.
• Remove the tachometer sensor (with tachometer),
CSD solenoid, fuel cut solenoid.
LNW81BSH005701
6. Noise Shield Cover LNW81DSH003101

8. Air Intake Duct Legend
9. Injection Pump Control Cable 1. CSD solenoid
• Remove the control cable bracket bolt and remove 2. Injection pump
the control lever side. 3. Fuel cut solenoid
10. Fuel Hose 4. Tachometer sensor
• Disconnect the fuel feed hose and fuel return hose.
13. Injection Pipe
11. CSD (Cold Starting Device) Water Hose
• Release pipe clip.
• Disconnect the water hose from injection pump
• Remove the flare nut on the pump side.
side.
• Remove the flare nut on the injection nozzle side,
and remove the injection pipe.
Note:
• Be sure to plug the injection nozzle holder and de-
livery holder to prevent the entry of foreign matter.
14. Injection Pump Assembly
• Remove pump mounting nut.

• Loosen injection pump rear bracket adjuster lock 3) Look in through the check hole on the crank-
bolt. shaft timing gear side and check to see if the
• Remove the mounting bolt on the engine side, and “O” mark on the timing gear is in line with the
pull out the pump from the engine. pointer of the check hole.
4) In the condition above with the injection pump
gear mark “O” set to the pointer of the check
hole, install the injection pump assembly.
• Install the injection pump fixing bolts and tighten
them to the specified torque.
Tighten:
Pump Bolts to 15 N⋅m (1.5 kg⋅m/11 lb⋅ft)
LNW81BSH008201
Note:
Plug the injection pump delivery holder parts with the
shipping caps (or the equivalent) to prevent the entry of
foreign materials.
Installation
LNW81BSH005801
1. Injection Pump Assembly
1) Timing gearcase a camshaft timing gear side c
injection pump timing gear side check hold cov- Legend
er. 1. Camshaft gear
2. Injection pump gear
2. Injection Pipe
• Connect the pump side and nozzle side of the pipe,
and tighten securely.
• Install clip where it was.
Tighten:
Sleeve Nut to 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
LNW81DSH003201
2) Turn the crankshaft clockwise to see the TDC

mark of the crank pulley to the pointer, and then
bring the No. 1 cylinder to the TDC on the com-
pression stroke.
LNW81DSH002701 LNW81BSH013401
3. Injection Pump Harness 7. Air Intake Duct

• Mount engine harness and connect it to switches. 8. Noise Cover Spacer
4. CSD Water Hose 9. Noise Shield Cover
• Connect the water hose and tighten clip securely.
LNW81BSH008401
LNW81DSH003301
5. Fuel Hose • Install AC generator drive belt and adjust belt ten-
• Connect the fuel feed hose and fuel return hose. sion.
• Connect the leak off hose. • Depress the drive belt mid-portion with a 98 N (10
kg/22 lb) force.
6. Injection Pump Control Cable
1) Install the control wire to the engine control le- Amount of Frequency
ver. Belt types flex of vibrations
2) Hold the accelerator lever in the fully closed po- mm (in) Hz
sition and stretch the control cable in the direc- For a new 7-9
133 - 157
tion indicated by the arrow to remove any slack. Generator product (0.28-0.35)
3) Tighten the accelerator cable bracket bolt. drive belt 9-11
(0.35-0.43)
Legend
• Install fixing bolt and tighten bolts to the specified

torque.
Tighten:
• Generator Fixing Bolt to 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
• Adjust Plate Fixing Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• Install P/S pump drive belt and adjust belt tension.
• Depress the drive belt mid-portion with a 98 N (10
kg/ 22 lb) force.
Amount of Frequency
mm (in) Hz
For a new 8 - 11
135 - 165
drive belt 11 - 12
(0.43-0.47)
• Tighten the idler lock nut to the specified torque.

Tighten:
27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
12. Fan Shroud
• Install the fan shroud and reservoir tank hose.
• Mount fan pulley, distance piece, and cooling fan
assembly (in this order) on the water pump, and
tighten to the specified torque.
Tighten:
8 N⋅m (0.8 kg⋅m/69 lb⋅in)
• Pour coolant.

LNW81DLF001101
(a) 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft) (c) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(b) 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft) (d) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
Injection Pump Data

Test Conditions
Items Conditions
Engine Type 4JB1-TC 4JB1NA
Injection Nozzle
Bosch Part Number 105017-2380 105017-1780
Bosch Type Number
Injection Nozzle holder
Bosch Part Number 10548-2201 105048-3251
First nozzle opening pressure
2 19.5 (199/ 2,830)
Injection Nozzle MPa (kg/cm /psi) 18.1 (185/ 2,631)
Second nozzle opening pres-
sure 26.5 (270/ 3,839)
Opening Pressure
Injection Line dimensions mm (in)
Inside Diameter 1.8 (0.071) 2 (0.0787)
Outside Diameter 6.35 (0.250) 6 (0.2362)
Length 435 (17.1) 415 (16.3386)
2
Fuel delivery Pressure kPa (kg/cm /psi) 20 (0.2 / 2.84) ←
SAE Standard Test Diesel
←
Fuel (SAE967D)
Test Fuel
ISO Standard Test Diesel Fuel
←
(ISO4113)
Test Fuel Temperature °C(°F) 48 — 52 (118 — 126) ←
104742-1471
Identification Numbers 104746-6627 104742-1461
104742-1451

Identification Plate and Number
Use the data following the injection pump identification
number to adjust the injection volume.
LNW81DSH000301
LNW81DSH00401
Injection Volume and Governor Performance Diagram

Governor Performance Diagram
Engine ; 4JB1-TC
Injection pump identification No. ; 104746-5113
Adjustment specification of injection volume
Average Uneven
Pump rotation Boost pressure Oil temperature
injection quantity amplitude Remarks
(r/min) (kPa (kg/cm2)) (°C)
(mm3/ST) (mm3/ST)
500 57.6±1.0 5.0 0 48±2 Standard
800 63.1±1.0 5.5 52.0 (0.531) 50±2 Standard
800 68.6±1.0 6.0 80.0 (0.821) 50±2 Standard
1000 (79.7±6.5) 80.0 (0.821) 50±2
1250 (87.9±6.5) 80.0 (0.821) 50±2
1700 (98.5±6.5) 80.0 (0.821) 50±2
2075 34.0±3.0 7.0 80.0 (0.821) 52±2 Standard
375 13.9±2.0 2.0 0 48±2 Standard
100 60 +40-0 0 48±2
LNW81DSH000501

Adjustment specification of timer and pump case pressure
Pump rotation Timer piston stroke At pressure of pump Boost Pressure

Remarks
(r/min) (mm) (kPa (kg/cm2)) (kPa (kg/cm2))
1020 Below 0.5 80.0 (0.82)
1350 1.8±0.2 471±29 (4.8±0.3) 80.0 (0.82) Standard
1500 (3.0±0.4) 80.0 (0.82)
1800 4.5 +0.4 80.0 (0.82)
-0.3
LNW81DSH000601
Potentiometer adjustment
Average injection
Pump speed Out-put voltage BoostPressure
quantity Remarks
(r/min) (V) (kPa (kg/cm2))
(mm3/st)
1080 3.56±0.03 27.5±2.0 0 Standard
375 (0.93±0.45) 13.9±2.0 0 Standard
LNW81DSH003401

Engine ; 4JB1NA (Gear drive)
Injection pump identification No. ; 104742-1451, 1461, 1471 Adjustment specification of injection volume
Pump rotation Average injection Uneven amplitude Oil temperature

Remarks
(rpm) quantity (mm3/ST) (mm3/ST) (°C)
500 (29.7±4.5) — 48±2
1000 (46.4±3.5) — 50±2
1150 47.6±1.0 3.5 50±2 Standard
1800 (55.5+0.4-6.0) — 50±2
2100 14.9±3.0 4.0 52±2 Standard
375 7.3±2.0 2.0 48±2 Standard
LNWB1DSH001201

Adjustment specification of timer and pump case pressure
Timer piston stroke At of pressure pump

Pump rotation (mm) (MPa(kg/cm2))
Remarks
(rpm) Solenoid timer Solenoid timer
ON OFF ON OFF
700 Over 0.5 — — —
1400 — 1.5±0.4 — —
0.53±0.02
1600 — 3.0±0.2 — Standard
(5.4±0.2)
2100 — 5.7+0.4-0.3 — —
LNWB1DSH001301

Adjustment specification of aneroid compensator (For 104742-1471)
Air pressure differ-

Pump rotation Altitude Amount of reduction Rate of reduction
ence
(rpm) (m) (mm3/ST) (%)
(kPa (mmHg))
0 0 0 0
-5.9±3.3
(500) Inflation point Inflation point
1150 (-44±25)
-21.9
2000 (-5.2±1.3) (-11±3)
(-164)
LNWB1DSH001401
Fuel Tank
Component
LNW81DMF000601
Legend
1. Frame 4. Fuel return hose
2. Fuel gauge unit connector 5. Fuel tank
3. Fuel feed hose 6. Band

Removal
Preparation:
• Loosen fuel filler cap.
• Drain fuel from drain plug.
• After the drain fuel, tighten the drain plug to the
specified torque.
Tighten:
M8: 20 N⋅m(2.0 kg⋅m/14 lb⋅ft)
M10: 29.4 N⋅m(3.0 kg⋅m/22 lb⋅ft)
1. Fuel Feed Hose
2. Fuel Return Hose
• Plug the hose to prevent fuel from getting spilt, and
tie it to the frame with the plugged end up.
3. Fuel Gauge Unit Connector
• Remove the connector of the fuel gauge.
4. Band
• Remove the nut of the fuel tank fixing band, and
then remove the band end on the frame side.
5. Fuel Tank
• Pull out the fuel tank to the outside.
Note:
When it is not possible to pull out the fuel tank, remove
the bracket and then draw out the fuel tank downward.
Installation
1. Fuel Tank
Note:
When the bracket was removed to take off the fuel tank,
install the bracket to the frame and tighten it to the spec-
ified torque.
Tighten:
54 N⋅m(5.5 kg⋅m/40 lb⋅ft)
When mounting the fuel tank on the bracket, be sure to
place the packing section pasted on the fuel tank se-
curely on the bracket.
2. Band
• Tighten the band to the specified torque.
Tighten:
13 N⋅m(1.3 kg⋅m/113 lb⋅in)
• Connect the fuel gauge unit connector.
4. Fuel Return Hose
5. Fuel Feed Hose
• Set the hose to the pipe more than 25 mm (0.98 in)
deep.

LNW81DMF001001
(a) M8: 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

M10: 29.4 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
(b) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
Fuel Gauge Unit

Component
LNW81DMF000701
Legend
1. Fuel gauge unit 3. Fuel gauge unit harness
2. Fuel gauge unit gasket 4. Fuel tank
Removal • Connect the wiring connector to the fuel gauge

Preparation: unit.

• Disconnect fuel gauge unit connector from fuel
gauge unit.
2. Fuel Gauge Unit
• Remove fuel gauge unit fixing screw and fuel
gauge unit.
Note:
• After removing fuel gauge unit, cover fuel tank with
waste to prevent any dust entering.
3. Fuel Gauge Unit Gasket
Installation
1. Fuel Gauge Unit Gasket
2. Fuel Gauge Unit
Engine Electrical (4JB1) 1E-1
ENGINE
Engine Electrical
(4JB1)
TABLE OF CONTENTS
Battery................................................................... 1E-2
General Description........................................... 1E-2
Diagnosis........................................................... 1E-2
Battery Charging................................................ 1E-3
Jump Starting .................................................... 1E-4
Removal and Installation of the Battery............. 1E-5
Starting System..................................................... 1E-6
General Description........................................... 1E-6
Starter Motor ......................................................... 1E-8
Component ........................................................ 1E-8
Removal (On-Vehicle) ..................................... 1E-10
Disassembly .................................................... 1E-10
Inspection and Repair...................................... 1E-12
Reassembly..................................................... 1E-15
Installation (On-Vehicle) .................................. 1E-16
List of Tightening Torques ............................... 1E-17
Charging System................................................. 1E-18
General Description......................................... 1E-18
Generator ............................................................ 1E-20
Component ...................................................... 1E-20
Removal (On-Vehicle) ..................................... 1E-22
Disassembly .................................................... 1E-22
Inspection and Repair...................................... 1E-24
Reassembly..................................................... 1E-29
Installation (On-Vehicle) .................................. 1E-30
List of Tightening Torques ............................... 1E-32
1E-2 Engine Electrical (4JB1)
Battery
General Description
Legend
There are six battery fluid caps at the top of the battery. 1. Cherge test indicator
These are covered by a paper label. 2. Upper level
The battery is completely sealed except for the six small
3. Lower level
vent holes at the side. these vent holes permit the es-
cape of small amounts of gas generated by the battery. 3. Voltage Check
This type of battery has the following advantages over
1) Put voltmeter test leads to battery terminals.
conventional batteries.
1. There is no need to add water during the entire ser- a. Voltage is 12.4V or Above - Battery condi-
vice life of the battery. tion OK.
b. Voltage is Under 12.4V - Go to procedure 2)
2. The battery protects itself against overcharging.
below.
The battery will refuse to accept an excessive
charge. 2) Determine fast charge amperage from specifi-
cation (See Main Data and Specifications in
(A conventional battery will accept an excessive
this section).
charge, resulting in gassing and loss of battery flu-
Fast charge battery for 30 minutes at amper-
id.)
age rate no higher than specified value.
3. The battery is much less vulnerable to self dis-
charge than a conventional type battery. Take voltage and amperage readings after
charge.
Diagnosis a. Voltage is Above 16V at Below 1/3 of Am-
1. Visual Inspection perage Rate — Replace battery.
Inspect the battery for obvious physical damage, b. Voltmeter is Above 16V at Above 1/3 of Am-
such as a cracked or broken case, which would perage Rate — Drop charging voltage to
permit electrolyte loss. 15V and charge for 10 — 15 hours.
Replace the battery if obvious physical damage is c. Voltage is Between 12V and 16V - Continue
discovered during inspection. charging at the same rate for an additional 3
Check for any other physical damage and correct it — 3.5 hours.
as necessary. If not, proceed to Step 2. d. Voltage is Below 12V — Replace battery.
2. Fluid Level Check 4. Load Test
The fluid level should be between the upper level 1) Connect a voltmeter and a battery load tester
line and lower level line on side of the battery. across the battery terminals.
a. Correct Fluid Level - Charge the battery. 2) Apply 300 ampere load for 15 seconds to re-
b. Below Lower Level - Replace battery. move surface charge from the battery.
Remove load.
3) Wait 15 seconds to let battery recover. Then
apply specified load from specifications (See
Main Data and Specifications in this section).
Read voltage after 15 seconds, then remove
load.
a. Voltage does not Drop Below the Minimum
Listed in Following Table - The battery is
good and should be returned to service.
b. Voltage is Less Than Minimum Listed - Re-
place battery.
LNW81ESH005901

Battery Charging
Estimated Temperature Minimum Voltage
Observe the following safety precautions when
°F °C Limit charging the battery:
70 21 9.6 1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
60 16 9.5
battery. In this case, the battery must be replaced.
50 10 9.4 2. Pay close attention to the battery during the charg-
40 4 9.3 ing procedure.
Battery charging should be discontinued or the rate
30 -1 9.1
of charge reduced if the battery feels hot to the
20 -7 8.9 touch.
10 -12 8.7 Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
0 -18 8.5 spew electrolyte from the vent holes.
The battery temperature must be estimated by atmo- 3. In order to more easily view the hydrometer blue
sphere temperature and outside temperature (the dot or ring, it may be necessary to jiggle or tilt the
battery has been exposed to for the preceding few battery.
hours). 4. Battery temperature can have a great effect on bat-
tery charging capacity.
5. The sealed battery used on this vehicle may be ei-
ther quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.

Jump Starting Jump Starting Procedure
1. Set the vehicle parking brake.
Jump Starting With an Auxiliary (Booster) Bat- If the vehicle is equipped with an automatic trans-
tery mission, place the selector lever in the “PARK” po-
sition.
Caution:
Never push or tow the vehicle in an attempt to start it. If the vehicle is equipped with a manual transmis-
sion place the shift lever in the “NEUTRAL” posi-
Serious damage to the emission system as well as other
tion.
vehicle parts will result.
Turn “OFF” the ignition.
Treat both the discharged battery and the booster bat-
tery with great care when using jumper cables. Turn “OFF” all lights and any other accessory re-
quiring electrical power.
Carefully follow the jump starting procedure, being care-
ful at all times to avoid sparking. 2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
WARNING:
Warning: completely clear, do not try to jump start.
FAILURE TO CAREFULLY FOLLOW THE JUMP 3. Attach the other end of the same cable to the pos-
STARTING PROCEDURE COULD RESULT IN THE itive terminal of the discharged battery.
FOLLOWING: Attach the end of one jumper cable to the positive
1. SERIOUS PERSONAL INJURY, PARTICULAR- terminal of the booster battery.
LY TO YOUR EYES. Do not allow the vehicles to touch each other.
2. PROPERTY DAMAGE FROM A BATTERY EX- This will cause a ground connection, effectively
PLOSION, BATTERY ACID, OR AN ELECTRI- neutralizing the charging procedure.
CAL FIRE. Be sure that the booster battery has a 12 volt rat-
3. DAMAGE TO THE ELECTRONIC COMPO- ing.
NENTS OF ONE OR BOTH VEHICLES PARTIC- 4. Attach one end of the remaining cable to the nega-
ULARLY. tive terminal of the booster battery.
NEVER EXPOSE THE BATTERY TO AN OPEN Attach the other end of the same cable to a solid
FLAME OR ELECTRICAL SPARK. GAS GENERAT- engine ground (such as the A/C compressor brack-
ED BY THE BATTERY MAY CATCH FIRE OR EX- et or the generator mounting bracket) of the vehicle
PLODE. with the discharged battery.
REMOVE ANY RINGS, WATCHES, OR OTHER JEW- This ground connection must be at least 450 mm
ELRY BEFORE WORKING AROUND THE BATTERY. (18 in) from the battery of the vehicle whose battery
PROTECT YOUR EYES BY WEARING AN AP- is being charged.
PROVED SET OF GOGGLES.
NEVER ALLOW BATTERY FLUID TO COME IN CON- WARNING:
Warning:
TACT WITH YOUR EYES OR SKIN. NEVER ATTACH THE END OF THE JUMPER CABLE
DIRECTLY TO THE NEGATIVE TERMINAL OF THE
NEVER ALLOW BATTERY FLUID TO COME IN CON-
DEAD BATTERY.
TACT WITH FABRICS OR PAINTED SURFACES.
5. Start the engine of the vehicle with the good bat-
BATTERY FLUID IS A HIGHLY CORROSIVE ACID.
tery.
SHOULD BATTERY FLUID COME IN CONTACT Make sure that all unnecessary electrical accesso-
WITH YOUR EYES, SKIN, FABRIC, OR A PAINTED ries have been turned “OFF”.
SURFACE, IMMEDIATELY AND THOROUGHLY
6. Start the engine of the vehicle with the dead bat-
RINSE THE AFFECTED AREA WITH CLEAN TAP
tery.
WATER.
7. To remove the jumper cables, follow the above di-
NEVER ALLOW METAL TOOLS OR JUMPER CA-
rections in the reverse order.
BLES TO COME IN CONTACT WITH THE POSITIVE
Be sure to first disconnect the negative cable from
BATTERY TERMINAL, OR ANY OTHER METAL SUR-
the vehicle with the discharged battery.
FACE OF THE VEHICLE. THIS WILL PROTECT
AGAINST A SHORT CIRCUIT.
ALWAYS KEEP BATTERIES OUT OF THE REACH
OF YOUNG CHILDREN.

Removal and Installation of the Battery
Removal
1. All switches should be in the “OFF” position.
2. Disconnect the battery ground cable. (2)
3. Disconnect the battery positive cable. (1)
4. Disconnect the battery cable.
LNW81ESH006001
Caution:
It is important that the battery ground cable be discon-
nected first.
Disconnecting the battery positive cable first can result
in a short circuit.
Installation
To install the battery, follow the removal procedure in
the reverse order, noting the following points:
1. Make sure that the rod is hooked on the body side.
Starting System
General Description
Starting Circuit
The cranking system consists of a battery, starter, starter switch, starter relay, etc. and these main components are
connected as shown in Figure. For details of the starting circuit.
LNW81EMF000601
Legend
1. Starter motor 7. Mognetic switch
2. Relay; starter 8. Pull in coil
3. Starter switch 9. Pinion clutch
4. Battery 10. Hold coil
5. “50” terminal 11. Contacts
6. “30” terminal
Starter
The starting system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft.
When the starter switch is turned on, the contacts of magnetic switch are closed, and the armature rotates.
At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with ring gear.
Then, the ring gear runs to start the engine. When the engine starts and the starter switch is turned off, the plunger
returns, the pinion is disengaged from ring gear, and the armature stops rotation. When the engine speed is higher
than the pinion, the pinion idles, so that the armature is not driven.

Starting Circuit
LNW81EXF000101
Starter Motor
Component
LNW21ESF000401
Legend
1. S terminal 3. B terminal
2. Earth cable terminal 4. Starter assembly
LNW81EMF000101
Legend
1. Yoke assembly 8. Return spring
2. Brush and brush holder 9. Steel ball
3. Cover yoke 10. Overrunning clutch
4. Through bolt 11. Drive side housing
5. Lead wire 12. Retainer
6. Magnetic switch 13. Roller
7. Idle pinion 14. Armature

Removal (On-Vehicle)
Preparation
• Disconnect Battery Ground Cable.
1. B Terminal
2. S Terminal
3. Earth Cable Terminal
4. Starter Assembly
LNW81ESH000401
3. Yoke Assembly
Separate the yoke from the solenoid switch.
4. Yoke Cover
LNW21ESH002501
Disassembly
1. Lead Wire
Disconnect the lead wire from the magnetic switch.
LNW81ESH000501
5. Brush and Brush Holder

Remove (pull out) the brushes and the brush hold-
er from the armature with a pair of long-nose pliers.
LNW81ESH000301
2. Through Bolt
Remove the through bolts from the yoke.
LNW81ESH000601 LNW81ESH000801
10. Steel Ball

Legend Remove the steel ball from the overrunning clutch.
1. Bush
2. Spring
6. Armature
7. Drive Side Housing
8. Overrunning Clutch
Remove the overrunning clutch from the housing.
LNW81ESH000901
11. Idle Pinion

Remove the idle pinion from housing.
LNW81ESH000701
9. Return Spring
Remove the return spring from magnetic switch.
12. Retainer Check the mica segment for wear.

Remove the retainer from housing.
Depth of mica segment mm (in)
Standard Limit
0.7 — 0.9 (0.028 — 0.035) 0.20 (0.008)
LNW81ESH001101
13. Roller
14. Magnetic Switch
Inspection and Repair LNW81ESH001301
Make necessary correction or parts replacement if wear,

damage or any other abnormal condition are found Legend
through inspection. 1. Insulator
Armature 2. Commutator segments
Check the commutator for run-out and replace if the
Check the commutator outer diameter.
amount of run-out exceeds the limit.
Commutator outer diameter mm (in)
Run-out test mm (in)
Standard Limit
Standard Limit
0.02 (0.0008) 0.05 (0.0020) 35.00 (1.378) 34.00 (1.339)
Armature Short Circuit Test Armature Continuity Test

Check the armature for short circuit by placing it on a Connect the probes of a circuit tester across the 2 seg-
growler tester. Hold a piece of hacksaw blade against ments. There should be continuity at any test points.
the armature core while slowly rotating the armature. A Replace if it is open-circuited.
short-circuited armature will cause the blade to vibrate
and to be attracted by the core. If the hacksaw blade is
attracted or vibrates, the armature, is short circuited,
and must be replaced.
LNW81ESH001701
Yoke
Field Winding Ground Test
LNW81ESH001501 Using circuit tester, touch one probe to the field winding
end or brush and the other to the bare surface of yoke
Armature Ground Test body.
Touch one probe of a circuit tester to the commutator There should be no continuity. If the tester indicates a
segment and the other to the armature core. There continuity, the field coil is grounded and yoke assembly
should be no continuity. If there is a continuity, the arma- should be replaced.
ture is grounded. Replace the armature if it is grounded.
Field Winding Continuity Test Brush Holder Insulation Test

Using a circuit tester, touch one probe to the “C” terminal Using a circuit tester, check the brush holder insulation.
lead wire and the other to the brush. There should be Touch one probe to the holder plate and the other to the
continuity. Replace the yoke if it is open. positive brush holder. There should be no continuity.
Brush and Brush Holder Overrunning Clutch

Measure the brush length and replace if it is worn be- Inspect the teeth of pinion for wear and damage.
yond the service limit. Replace if it damaged.
Rotate the pinion in direction of rotation (clockwise).
Brush length mm (in) It should rotate smoothly. But in opposite direction, it
Standard Limit should be locked.
16 (0.63) 10 (0.39)
Bearing
Check the bearings for wear and damage. If the bear- Legend
ings are noisy during operation, they should be re- 1. Steel ball
placed. 2. Idle gear
3. Roller
Magnetic Switch
Temporarily connect the solenoid switch between the
clutch and the housing and run the following tests.
Complete each test within three to five seconds.
1. Pull-in test
Connect the battery negative terminal with the so-
lenoid switch body and the M terminal. When cur-
rent is applied to the S terminal from the battery
positive terminal, the pinion should flutter.
LNW81ESH002301
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
• Magnetic Switch
• Idle Gear
• Clutch assembly
• Housing
1. Install the clutch asm to the magnetic switch.
LNW81ESH002501
2. Install the idle gear and housing.
Note: Legend
Do not fail to assemble the steel ball and the spring be- 1. M terminal
tween the clutch and magnetic switch. 2. S terminal
Assemble the roller to the idle gear in advance.
2. Hold-in test

Disconnect the lead at the M terminal. The pinion For lead wires, use thick ones since a large amount of
should continue to flutter. current flows through them.
Legend Legend
1. Disconnect 1. S terminal
3. Return test
Connect the battery negative terminal to the 50 ter- Installation (On-Vehicle)
minal and the body. Connect the battery positive 1. Starter Assembly
terminal to the M terminal. The pinion will flutter. • Tighten the fixing bolt and nut to the specified
When the lead to the 50 terminal is disconnected, torque
the pinion should immediately return to its station-
ary positions. Tighten:
Starter Bolts and Nuts to 81 N⋅m (8.3 Kg⋅m/60 lb⋅ft)
2. Earth Cable Terminal
• Connect the earth cable terminal.
3. “B” Terminal
• Connect the harness connector.
4. “S” Terminal
• Connect the battery cable terminal with starter
switch harness terminal, then tighten nut to the
specified torque.
Tighten:
Fixing Nut to 9 N⋅m (0.9 Kg⋅m/78 lb⋅in)
• Connect the battery cable.
LNW81ESH002701
4. Current value
• Make connections as shown in the illustration,
and measure the current value.
Standard = 120 A or less
Note:
For a battery, be sure to use one fully charged.

LNW81ESF000701
(a) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)

(b) 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
Charging System
General Description
The charging system is the IC integral regulator charging system and its main components are connected as shown
in Figure.
The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator in-
stalled on the rear end cover.
The generator does not require particular maintenance such as voltage adjustment. The rectifier connected to the
stators coil has nine diodes to transform A.C. voltage into D.C. voltage. This D.C. voltage is connected to the output
terminal of generator.
Generator (12V-50A)
LNW81EMF000201
Legend
1. Fan 8. Vacuum pump
2. Stator 9. Rear cover
3. Rotor 10. Slip ring
4. Brush 11. Through bolt
5. IC regulator 12. Front cover
6. Ball bearing 13. Pulley
7. Oil seal 14. Ball bearing

Diagnosis
General On-Vehicle Inspection
The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on
when the starter switch is turned on “ON” position. The charging system operates normally if the lamp goes off when
the engine starts. If the warning lamp shows abnormality or if undercharged or overcharged battery condition is sus-
pected, perform diagnosis by checking the charging system as follows:
LNW81ELF000501
1. Check visually the belt and wiring connector.

2. With the engine in stop status, turn the starter
switch to “ON” position and observe the warning
lamp.
• If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L” on connector side.
• If lamp comes on:
Repair or replace the generator.
Generator
Component
Generator
LNW81EMF000701
Legend
1. Bracket 7. AC generator drive belt
2. Power steering oil pipe bracket 8. AC generator assembly
3. Clip 9. Oil hose
4. Clip 10. Vacuum hose
5. Lock bolt 11. Harness connector
6. AC generator fixing bolt

12V-50A
LNW81ELF000201
Legend
1. Rotor and front cover assembly 8. Rear cover
2. Rotor 9. Diode
3. Rear bearing 10. Stator
4. Through bolts 11. Brush holder
5. Lead wire 12. IC regulator assembly
6. Vacuum pump 13. Stator and rear cover assembly
7. Terminal nut and bolt

Removal (On-Vehicle) 5. AC Generator Fixing Bolts
Preparation 6. AC Generator Assembly
• Disconnect battery ground cable. Disassembly
1. Vacuum Hose (Exhaust Brake Model) 1. Vacuum Pump
• Remove the vacuum hose to vacuum tank and • Drain fluid from discharged port.
exhaust actuator.
• Remove the vacuum pump fixing bolts. Hold
2. Oil Hose
the center plate and remove the vacuum pump
• Remove the oil hose from oil pan. horizontally in direction in line with the rotor
• Remove the oil hose of vacuum pump side. shaft.
2. Lead Wire
3. Through Bolts
LNW81ESH002901

LNW81ESH003201
• Loosen the adjust plate fixing bolt.
• Remove the adjust bolt.
Legend
• Loosen the AC Generator fixing bolt then re- 1. Seal protector
move the fan belt.
4. Power Steering Oil Pipe Bracket (P/S Model) 4. Rotor and Front Cover Assembly
• Remove the oil pressure pipe bracket fixing bolt 5. Stator and Rear Cover Assembly
and pipe clip bolt. • Insert a screwdriver into the clearance between
• Remove the oil suction pipe clip bolt. the front cover and the stator core, and remove
the assembly.
LNW81ESH003001
LNW81ESH003301

• Separate the diodes from the stator by melting
Note:
away solder on stator coil and diode.
Take care not to damage the stator coil with the screw-
When melting solder, hold the lead wire with
driver. When the assembly will not come off, hold down
long nose pliers to prevent heat from being
the rear cover and hit the end face of the shaft gently
transferred to the diodes.
with a plastic hammer to detach it.
12. IC Regulator Assembly
6. Rotor
• Separate the IC regulator from the diode by
• With the rotor gripped with a vise, remove the melting away solder on IC regulator holder
pulley nut (5), and then take off the pulley (4), plate and removing the nut.
fan (3), front cover (1) and the rotor (2).
LNW81ESH003601
LNW81ESH003401
7. Rear Bearing Legend

8. Terminal Bolt and Nut 1. Terminal bolt
9. Rear Cover 2. Terminal plate
3. Rivet
• Remove the nuts fixing the B terminal and di-
ode holder. 4. Diode
Separate the stator and rear cover.
13. Brush Holder
Note the position of insulation washers to en-
sure reassembly into original position. • Remove the serrated bolts and melt away sol-
der on IC regulator.
• Do not remove the serrated bolts unless the re-
placement of brush or condenser.
To install, follow the removal steps in the re-
verse order.
LNW81ESH003501
10. Stator
11. Diode
Legend Legend
1. Wear limit 1. Slip ring
2. Tester
Inspection and Repair 4. Check for continuity between slip ring and rotor
Repair or replace necessary parts if extreme wear or core or slip ring and rotor shaft.
damage is found during inspection. In case of continuity, replace the rotor assembly.
Rotor
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500 — 600
sandpaper.
2. Measure the slip ring diameter, and replace if it ex-
ceeds the limit.
mm (in)
Standard Limit
34.6 (1.36) 33.6 (1.32)
LNW81ESH003901
Legend
1. Slip ring
2. Tester
Rear Ball Bearing

Check to see if the ball bearing rotates smoothly with no
noises.
When it does not rotate smoothly or any noises are
heard, replace it with a new one.
LNW81ESH003801 When installing the bearing, press it in with the stopper
ring turned to the spline side, while pushing the bearing
3. Check for continuity between slip rings, and re- inner ring.
place if there is no continuity.
Bearing press-in measurement: a

mm (in)
Standard 41.8 — 42.0 (1.64 — 1.65)
LNW81ESH004101
Legend
1. Tester
2. Lead wire
LNW81ESH004001
Diode
Legend 1. Check for continuity across the terminal (example:
1. Stopper ring across BAT and U). If a continuity exists, the diode
is in satisfactory condition. If no continuity exists
2. Ball bearing
the diode is defective.
3. Spline
2. Make a test with the polarities reversed. If no con-
Stator Coil tinuity exists, the diode is in satisfactory condition.
1. Check for continuity between respective phases. If a continuity exists at any point, the diode is de-
In case of no continuity, replace the stator. fective and should be replaced.
Auxiliary diodes are not provided with the terminal
and continuity test should be made across the ter-
minals of the conventional diodes.
LNW81ESH004101
Legend
LNW81ESH004201
1. Tester
2. Lead wire
Legend
2. Check for continuity across one of the stator coils 1. Tester
and stator core. If a continuity exists, replace the
coil.
- side diode check

Across terminals BAT (Positive side (+) diodes)
Tester
Positive side Negative side
pin
Positive
No continuity
side
U.V.W
Negative
Continuity
side
+ side diode check

Across terminals E (Negative side (−) diodes)
Tester
Positive side Negative side
pin
Positive LNW81ESH003701
Continuity
side
U.V.W
Negative Legend
No continuity
side 1. Wear limit
IC Regulator
Measuring instruments is necessary.
Take the following measurements with the instruments
connected as shown in the illustration.
V1 Voltage at Battery1 V
Standard 10 — 13
V2 Voltage across F — E V
Standard Limit
2 or less 2 or more
Take measurement with ‘S’ terminal disconnected.
V3 Measure the voltage at Battery1 — Battery2.

V
LNW81ESH004301
Standard 20 — 26
Brush
Measure length of brushes.
Brush length (L)
mm (in)
Standard Limit
20 (0.79) 6 (0.24)
Brushes are provided with a line which indicates the limit

of usage.

Check to see if voltage increases from lower than 2V to
range from 10 to 13 volts.
If the voltage does not vary, the regulator is defective
and should be replaced.
Check the voltage across the intermediate tap of the
variable resistor and terminal E without actuating the
variable resistor.
V
Standard voltage at 20°C (68°F) 14.5 — 16.9
If measured voltage deviates from the standard value,

replace the regulator.
Vacuum Pump
Visual Check
• Inspect the following parts for wear, damage or
other abnormal conditions.
LNW81ESH004401 Disassembly of Vacuum Pump
• For the center plate, rotor and vane in the men-
• Measurement the voltage across the E — F while
tioned.
varying resistance gradually from zero using vari-
able resistor.
Then check that voltage increases from 2V to 10 —
13.
If increase in voltage is interrupted at any point, re-
place the regulator.
• V4 Measure the voltage across the intermediate
tap on variable resistor and ‘E’ terminal without ac-
tuating the variable resistor.
V
Standard voltage at 20°C (68°F) 14.0 — 14.9
If measured value deviates from the standard, re-

place the regulator.
LNW81ESH004601
Legend
1. Center plate
2. Vane
3. Rotor
4. Housing
Housing
• Measure the inside diameter of housing and place
if it exceed the standard.
mm (in)
Standard 57.0 — 57.1 (2.244 — 2.248)
LNW81ESH004501
Check the following with the instrument connected as il-

lustrated.
Measure the voltage across the terminals B and E by
gradually increasing voltage with variable resistor RV.
LNW81ESH004701
Vane
Measure the length of vanes
mm (in)
Standard 12.5 — 13.5 (0.492 — 0.531)
Check Valve
1. Apply a light pressure onto the “2” side of valve
with a screwdriver and check that valve operates
smoothly.
2. Apply compressed air 100 — 500 kPa (1 — 5 kg/
cm2/14.5 — 72.5 psi) onto “1” side of valve and
check if there is air leak.
LNW81ESH004801
Legend
1. “1” side
2. “2” side
3. Push
4. Compressed air

Reassembly of Vacuum Pump • Put the IC regulator on the brush holder and
1. Position the rotor, with the serrated boss turned up, press the bolt.
on the center plate and housing. Bushing and connecting plate (1) must be in-
Align the holes in center plate and rotor. stalled when pressing the bolt.
2. Install vanes into slits in rotor.
The vanes should be installed with chamfered side
turned outward.
3. Install the O-ring and center plate
LNW81ESH005101
3. Diode
• Connect the terminals by fixing the rivet at (1)
and soldering the terminal at (2).
LNW81ESH004901
Legend
1. Chamfered side
Reassembly
1. Brush Holder
2. IC Regulator Assembly
• Hold the brush in the holder as shown in the il-
lustration and solder the lead wire.
LNW81ESH005201
4. Stator
• When connecting stator coil leads and diode
leads using solder, use long-nose pliers and
finish the work as quickly as possible to prevent
the heat from being transferred to the diodes.
LNW81ESH005001
5. Rear Cover 12. Lead wire

6. Terminal Bolt and Nut 13. Vacuum Pump
7. Rear Bearing • Install and mount the housing to the generator
8. Rotor using 3 bolts.
• Cover vice with copper plates, clamp the rotor • Pour engine oil (5 cc or so) in through the filler
with the vice, and tighten nut to the specified port, then check that generator pulley can be
torque. turned smoothly with hand.
Tighten: • Tighten the pump fixing bolts (1) to the speci-
Pulley Nut to 90 N⋅m (9.2 kg⋅m/67 lb⋅ft) fied torque.
Tighten:
Through Bolts to 3.5 N⋅m (0.36 kg⋅m/31 lb⋅in)
LNW81ESH005401
9. Stator and Rear Cover Assembly LNW81ESH005601

10. Rotor and Front Cover Assembly
11. Through Bolts • Pour engine oil (5 cc or so) through the filler
port, and then check the pulley for smooth rota-
• Place guide bar through the holes in front cover
tion.
and rear cover flange for alignment, then install
the through bolts. Installation (On-Vehicle)
• Tighten the through bolts to the specified
1. AC Generator Assembly
torque
• Set the AC generator.
Tighten:
Through Bolts to 3.5 N⋅m (0.36 kg⋅m/31 lb⋅in)

2. AC Generator Fixing Bolts
• Temporary install the AC generator fixing bolt.
3. Power Steering Oil Pipe Bracket (P/S Model)
• Install the oil pipe bracket and tighten bolts to
Tighten:
Pipe Bracket Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
LNW81ESH014801
Legend
• Install the fixing bolt and tighten bolt to the

specified torque.
LNW81ESH003001
Tighten:
• Install the suction pipe clip bolt and tighten bolt • Generator Fixing Bolt to 40 N⋅m (4.1/ kg⋅m/30 lb⋅ft)
to the specified torque. • Adjust Plate Fixing Bolt to 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
5. Oil Hose
Tighten:
Pipe Clip Bolt to 10 N⋅m (1.0 kg⋅m/87 lb⋅in) • Install the oil hose (1) to vacuum pump.
• Install the pressure pipe and suction pipe clip • Install the oil hose (2) to oil pan.
bolt, then tighten bolt to the specified torque.
Tighten:
Pipe Clip Bolt to 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
• Install the AC Generator drive belt and adjust
belt tension.
• Depress the drive belt mid-portion with a 98 N
(10 kg/22 lb) force.
Amount of Frequency
mm (in) Hz
For a new 7-9
133 - 157
drive belt 9-11
(0.35-0.43)
For a new 8 - 11 LNW81ESH003101
135 - 165
drive belt 11 - 12 6. Vacuum Hose (Exhaust Brake Model)
(0.43-0.47) • Install the vacuum hose to vacuum tank and ex-
haust actuator.

LNW81ELF000601
(a) 90 N⋅m (9.2 kg⋅m / 67 lb⋅ft)

(b) 3.5 N⋅m (0.36 kg⋅m / 31 lb⋅in)
(c) 3.5 N⋅m (0.36 kg⋅m / 31 lb⋅in)
Engine Exhaust (4JB1) 1G-1
ENGINE
Engine Exhaust
(4JB1)
TABLE OF CONTENTS
General Description ..............................................1G-2
Catalytic Converter (4JB1-TC ONLY) ...................1G-4
On-Vehicle Service............................................1G-4
Front Exhaust Pipe (4JB1-TC) ..............................1G-5
Component ........................................................1G-5
Removal ............................................................1G-5
Installation .........................................................1G-6
List of Tightening Torques .................................1G-7
Front Exhaust Pipe (4JB1NA) ...............................1G-8
Component ........................................................1G-8
Removal ............................................................1G-8
Installation .........................................................1G-8
List of Tightening Torques ...............................1G-10
Exhaust Brake Unit (4JB1-TC) ............................1G-11
Inspection ........................................................1G-11
Exhaust Brake Unit (4JB1NA) .............................1G-12
Inspection ........................................................1G-12
1G-2 Engine Exhaust (4JB1)
General Description
Without exhaust brake
4JB1-TC
LNW81GSF000201
4JB1NA
LNWB1GSF000101

With exhaust brake
4JB1-TC
4JB1NA
LNWB1GSF000201
When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on
the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation
and trim materials.
Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes
to seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may be an in-
dication of a problem in one of these areas. Any faulty areas should be corrected immediately.
Catalytic Converter (4JB1-TC ONLY)

The catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from
the exhaust gas stream.
LNW81GSH000401
Caution:
The catalytic converter requires the use of designated
fuel only.
Periodic maintenance of the exhaust system is not re-
quired. If the vehicle is raised for other service, it is ad-
visable to check the condition of the complete exhaust
system.
The structure of this catalytic converter consists of a
built-in catalyst, which is located throughout the broad
section at the center of the device.
The arrow (in the center of the diagram above), which is
press-processed on the case, indicates the flow direc-
tion of exhaust gas.
Install the device in the correct direction when installing
to the vehicle.
On-Vehicle Service
Rattles and noise vibrations in the exhaust system are
usually caused by misalignment of parts. When aligning
the system, leave all bolts or nuts loose until all parts are
properly aligned; then tighten, working from front to rear.
1. Check connections for looseness or damage, es-
pecially for exhaust gas leakage.
2. Check clamps and rubbers for weakness, cracks or
damage.
3. If any part of the converter is damaged or dented to
the extent that it contacts the catalyst, repair or re-
place.
4. Check for dents or damage and for any holes or
cracks caused by corrosion.
Front Exhaust Pipe (4JB1-TC)

Component
LNW81GMF000701
Legend
1. Exhaust manifold fixing nut. 4. Without exhaust brake
2. Front exhaust pipe. 5. With exhaust brake
3. Front exhaust pipe fixing nut. 6. Front exhaust pipe mounting clamp fixing nut and
bolt .
Removal
Preparation
• Remove two fixing nuts from exhaust manifold and
front pipe.
bolt.
LNW81BSH015201

• Remove two bolts fixed from front pipe and center
pipe.
• Take out the exhaust pipe to another side.
Installation
Note:
• Vibrations and looseness of the exhaust system
can be caused by mis-positioning when assem-
bling. Temporarily install the bolts while all the
components are positioned. After positioning is
completed, tighten them from the engine side to
the tail pipe side.
• Do not reuse the removed gasket or nut.
2. Exhaust manifold fixing nuts
(Engine side)
Tighten:
• 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
bolt.
Tighten:
• 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(With exhaust brake, without exhaust brake).
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
LNW81GSH002101


LNW81GMF000901
(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
Front Exhaust Pipe (4JB1NA)

Component
LNWB1GLF000301
Legend
1. Exhaust manifold fixing nut. 4. Without exhaust brake
2. Front exhaust pipe. 5. With exhaust brake
3. Front exhaust pipe fixing nut. 6. Front exhaust pipe mounting clamp fixing nut and
bolt .
Removal • Remove two bolts fixed from front pipe and silenc-
er.
Preparation
• Take out the exhaust pipe to another side.
• Remove two fixing nuts from exhaust manifold and Installation
front pipe.
2. Front exhaust pipe mounting clamp fixing nut and Note:
bolt. • Vibrations and looseness of the exhaust system
3. Front exhaust pipe fixing nuts and bolts. can be caused by mis-positioning when assem-

bling. Temporarily install the bolts while all the
components are positioned.
Tighten them after positioning is completed.
• Do not reuse the removed gasket or nut.
2. Front exhaust pipe fixing nuts and torque.
(with exhaust brake, without exhaust brake).
Tighten:
• 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
bolt.
• Tighten the fixing bolt to the specified torque.
Tighten:
• 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(Engine side).
Tighten:
• 37.2 N⋅m (3.8 kg⋅m / 27 lb⋅ft)

LNWB1GLF000401
(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 37.2 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
Exhaust Brake Unit (4JB1-TC)

Inspection
Operational Inspection
• With the engine idling, operate the exhaust brake
to check for the sound of the valve hitting against
the stopper.
Unit Inspection
• Check to see if the exhaust valve opens and closes
smoothly when the power chamber is applied with
a negative pressure 66.7 kPa — 93.3 kPa (0.68 kg/
cm2 — 0.95 kg/cm2/ 9.7 psi — 13.5 psi) by the vac-
uum pump.
LNW81GSH002301
LNW81GSH002201
• Check to see if the clearance between the valve

and the body is in the range of 0.15 mm — 0.35
mm (0.0059 in — 0.0138 in) (the minimum of 0.15
mm (0.0059 in)) on an average of the points “a”
and “b” when the power chamber is applied with a
negative pressure 86.7 kPa — 93.3 kPa (0.88 kg/
cm2 — 0.95 kg/cm2/ 12.5 psi — 13.5 psi) by the
vacuum pump.
When the clearance is outside this range, adjust
the clearance with the adjust bolt.
Exhaust Brake Unit (4JB1NA)

Inspection
Operational Inspection
• With the engine idling, operate the exhaust brake
to check for the sound of the valve hitting against
the stopper.
Unit Inspection
• Check to see if the exhaust valve opens and closes
smoothly when the power chamber is applied with
a negative pressure 53.3 kPa — 93.3 kPa (0.54 kg/
cm2 — 0.95 kg/cm2/ 7.7 psi — 13.5 psi) by the vac-
uum pump.
LNWB1GSH000901
LNWB1GSH00101
• Check to see if the clearance between the valve

and the body is in the range of 0.1 mm — 0.2 mm
(0.0040 in — 0.0080 in) (the minimum of 0.1 mm
(0.0040 in)) on an average of the points “a” and “b”
when the power chamber is applied with a negative
pressure 86.7 kPa — 93.3 kPa (0.88 kg/cm2 —
0.95 kg/cm2/ 12.5 psi — 13.5 psi) by the vacuum
pump.
When the clearance is outside this range, adjust
the clearance with the adjust bolt.
Engine Lubrication (4JB1) 1H-1
ENGINE
Engine Lubrication
(4JB1)
TABLE OF CONTENTS
Lubrication System................................................1H-2
Maintenance Precautions ..................................1H-2
Functional and Operational Description ............1H-2
Oil Filter Cartridge .................................................1H-3
Component ........................................................1H-3
Removal ............................................................1H-3
Installation .........................................................1H-3
Oil Cooler (Oil Cooler Model) ................................1H-4
Component ........................................................1H-4
Removal ............................................................1H-4
Inspection ..........................................................1H-4
Installation .........................................................1H-5
List of Tightening Torques .................................1H-6
Oil Pan ..................................................................1H-7
Component ........................................................1H-7
Removal ............................................................1H-7
Installation .........................................................1H-8
List of Tightening Torques ...............................1H-10
Oil Pump Assembly.............................................1H-11
Component ......................................................1H-11
Removal ..........................................................1H-11
Installation .......................................................1H-12
List of Tightening Torques ...............................1H-13
1H-2 Engine Lubrication (4JB1)
Lubrication System
Maintenance Precautions zures. If an insufficient amount is applied, it causes the
oil and water leaks.
Use a scraper to completely scrape off old liquid gasket
Overlap the beginning and ending of the application.
from the locations where liquid gasket is used. After
cleaning using a rag, etc., to completely remove any oil, Functional and Operational Description
moisture and filth, apply the specified liquid gasket.
Apply the proper amount to avoid an excess or lack in Ecological full-flow element, water cooling oil cooler,
application. If an excessive amount is applied, the oil and piston coolant oil jet are adopted for the lubrication
gallery and oil jet head can clog, which leads to sei- system.
LNW81HLF000501
Operating Pressure
Oil filter relief valve (1): 559 — 618 kPa (5.7 — 6.3 kg/cm2/81 — 90 psi)
Oil cooler safety valve (2): 314 — 373 kPa (3.2 — 3.8 kg/cm2/46 — 54 psi)
Oil filter safety valve (3): 78 — 118 kPa (0.8 — 1.2 kg/cm2/11 — 19 psi)
Oil pressure switch (4): 29.4 — 49.0 kPa (0.3 — 0.5 kg/cm2/4.3 — 7.1 psi)
The 4J Series engine lubricating system is a full flow type.
Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter (re-
placeable type oil filters have on oil cooler). It is then delivered to the vital parts of the engine from the cylinder body
oil gallery.
Oil Filter Cartridge

Component
LNW81HSF000601
Removal
• Place a receptacle beneath the oil filter to contain
the drained oil.
• Remove the oil filter cartridge using filter wrench.
Filter wrench: 5-8840-0200-0
LNW21HSH003501
Installation
• Lightly oil the O-ring of oil filter cartridge.
• Turn in the new oil filter cartridge by hand until the
sealing face is fitted against the O-ring.
• Use the filter wrench to turn in the oil filter and ad-
ditional one and 1.1/8 turns or specified torque.
Tighten:
Oil filter cartridge to 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
• Start the engine and check for oil leakage from oil
filter.
Oil Cooler (Oil Cooler Model)

Component
LNW81HSF000501
Legend
1. Oil cooler fixing bolt 3. Oil cooler
2. Water hose
Removal
Preparation
• Disconnect battery ground cable
• Drain coolant
• Put rag to beneath side of oil cooler to prevent oil
leaking.
1. Water Hose
• Disconnect water inlet and outlet hose.
2. Oil Cooler Fixing Bolt
3. Oil Cooler
Inspection
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 LNW81BSH010401
pressure.
Oil Cooler
Relief Valve Opening kPa (kg/cm2/psi) Check for water leakage at the water passage.
Pressure 1. Plug one side of the oil cooler water passage.
559 — 618 2. Submerge the oil cooler in water.
Type1
(5.7 — 6.3/81.0 — 89.6) 3. Apply compressed air (196 kPa (2 kg/cm2 / 28.5
422 — 461 psi)) to the other side of the oil cooler water pas-
Type2 sage.
(4.3 — 4.7/61.1 — 66.8)
If air bubbles rise to the surface, there is water
leakage.
LNW21HSH003701
Installation
1. Oil Cooler
• Install the O-ring to oil filter body and set the oil
cooler.
2. Oil Cooler Fixing Bolt
Tighten:
• Oil cooler bolt to 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
LNW21HSH003801
3. Water Hose
• Connect water hose.

LNW81HSF000301
(a) 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
LNW81HSF000701
(a) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)

Oil Pan
Component
LNW81BLF002601
Legend
1. Stiffener and space rubber 4. Vacuum pump oil hose
2. Rigid suspension (4 × 2) 5. Oil pan assembly
3. Engine mount bolts
Removal 1. Vacuum Pump Oil Hose

Preparation • Remove oil hose (1) from oil pan.
• Lift up car.
Note:
Install drain plug with new gasket.
Tighten:
• 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
2. Engine Mount Bolts • Fit the gasket rear lipped portion into the No.5
• Remove the engine mount bolts right & left side. groove.
3. Stiffener & Space Rubber
• Remove the exhaust pipe bracket.
• Remove the stiffener from of the oil pan left & right
side.
• Take out space rubber.
LNW81BSH010001
• Be absolutely sure that the lipped portion in fitted

snugly in to the groove.
• Install the oil pan to the cylinder body.
• Tighten the oil pan bolts to the specified torque.
LNW21HSH004701
Tighten:
4. Oil Pan Assembly • Oil pan bolt to 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Raising the engine about 50mm. 2. Stiffener and Space Rubber
• Remove the oil pan from cylinder block. • Install the space rubber.
• Install the stiffener left side and right side tighten
Installation bolt to the specified torque.
1. Oil Pan Assembly
Tighten:
• Apply the recommended liquid gasket or its equiv- • Engine body side to 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
alent to the No.5 bearing cap arches, the grooves,
• Clutch housing side to 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
and the timing gearcase arches at the positions
shown in the illustration. • Install exhaust pipe bracket.

3. Engine Mount Bolts
• Install the mount bolts and tighten to the specified
torque.
Tighten:
• Mount bolt to 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
• Install the oil hose to oil pan.
4. Vacuum Pump Oil Hose
• Pour engine oil

LNW81HMF000301
(a) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)

(b) 19 N⋅m (1.9 kg⋅m /14 lb⋅ft)
Oil Pump Assembly

Component
LNW81BLF002701
Legend
1. Vacuum pump oil hose 4. Oil pan assembly
2. Stiffener and space rubber 5. Engine mount nuts and bolts
3. Oil pump assembly 6. Rigid suspension (4 × 2)
Removal 1. Vacuum Pump Oil Hose

Preparation • Remove the oil hose (1) from oil pan and cylinder
block.
• Lift up car.
Note:
Tighten:
• 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)

• Apply engine oil to oil pipe O-ring and insert the O-
ring in O-ring hold on cylinder block.
• Install oil pump asm with oil pipe in cylinder block
and tighten fixing bolts to the specified torque.
Tighten:
• 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Tighten sleeve nut to the specified torque.
Tighten:
• 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
LNW21BSH039201

• Remove the engine mount bolts right & left side.
• Remove the exhaust pipe bracket.
• Remove the stiffener from of the oil pan left & right
side.
• Take out space rubber.
LNW21HSH004601
2. Oil Pan Assembly

5. Vacuum Pump Oil Hose
manual.
LNW21HSH004701
4. Oil Pan Assembly

• Raise the engine about 50mm (1.97 in).
• Remove the oil pan from cylinder block.
• Remove the oil pump from cylinder block.
Installation
• Prepare a solution of 80% engine oil and 20% mo-
lybdenum disulfide.
• Apply and ample coat of the solution to the teeth of
the oil pump pinion.

LNW81HMF000401
(a) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
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Engine Speed Control System (4JB1) 1I-1
ENGINE
Engine Speed Control System
(4JB1)
TABLE OF CONTENTS
Accelerator Control Cable ...................................... 1I-2
Component ......................................................... 1I-2
Removal ............................................................. 1I-2
Inspection ........................................................... 1I-2
Installation .......................................................... 1I-2
Accelerator Pedal................................................... 1I-4
Component ......................................................... 1I-4
Removal ............................................................. 1I-4
Installation .......................................................... 1I-4
Idling Control Cable................................................ 1I-6
Component ......................................................... 1I-6
Removal ............................................................. 1I-6
Installation .......................................................... 1I-6
Inspection ........................................................... 1I-7
1I-2 Engine Speed Control System (4JB1)
Accelerator Control Cable

Component
LNW81IMF000201
Legend
1. Adjust unit 3. Accelerator control wire
2. Accelerator control wire 4. Accelerator control cable
Removal • The control cable should move smoothly.

1. Adjust Nut • The control cable should not be bent or kinked.
• Loosen the adjust nut on the cable bracket mount- • The control cable should be free of damage and
ed on the inlet manifold. corrosion.
2. Accelerator Control Wire (Injection Pump Side)
Installation
• Remove the control wire from injection pump con-
1. Accelerator Control Cable
trol lever.
• Take care that the core wire of the cable does not
3. Accelerator Control Wire (Accelerator Pedal Side)
get damaged or kinked.
• Remove the accelerator control wire from acceler-
• Pull the cable through the grommet hole from un-
ator pedal.
der the floor.
• Set the groove of the grommet securely into the
• Remove the cable clip from intake manifold duct.
floor panel.
• Remove the cable clip from chassis frame.
• Lower the cab.
• Pull out the wire to the chassis side through the 2. Accelerator Control Wire (Accelerator pedal side)
grommet hole of the floor board, and remove the
control cable. • Connect the accelerator control wire to the acceler-
ator pedal.
Inspection • Tilt up the cab.
Check the following items, and replace the control cable 3. Accelerator Control Wire (Injection pump side)
if any abnormality is found.

• Install the tip end of the wire to the engine control
lever.
LNW81BSH013401
4. Lock Bolt
• With the accelerator control lever attached to the
stopper bolt, pull the cable lightly toward the front
of the axis and fasten the cable bracket with the
lock bolt.
• Check to see if the injection pump lever is at the
idle position (with the lever in touch with the stop-
per bolt).
• Connect the battery ground cable.
• Lower the cab.
• Check to see if the accelerator pedal play is in the
range of 5 — 10 mm (0.2 — 0.4 in) above the pedal
pad.
• Press down on the accelerator pedal fully, and
check to see if the engine rotates at the maximum
speed with the linkage in the smooth operation.
• In the operating range of the accelerator pedal,
check to see if the accelerator pedal and the injec-
tion pump lever return without fail to their original
positions respectively.
Accelerator Pedal
Component
LNW81IMF000101
Legend
1. RHD Model 4. Accelerator control cable
2. LHD Model 5. Accelerator pedal assembly
3. Accelerator pedal assembly 6. Accelerator control cable
Removal • After installing each cable, give a full stroke to the

accelerator pedal while pushing the accelerator
pedal pad by hand.
• Remove control cable from accelerator pedal
• Adjust the stopper bolt so that the clearance be-
bracket.
tween the pedal pad stopper bolt and the back of
2. Accelerator Pedal Assembly
the pad becomes 0 — 2 mm (0 — 0.079 in), and
• Remove accelerator pedal assembly from brake tighten the lock nut to the specified torque.
pedal bracket.
Tighten:
Installation 7.4 N⋅m (0.75 kg⋅m/65 lb⋅ft)
1. Accelerator Pedal Assembly • Check to see if the accelerator pedal play is in the
• Apply the sliding section with grease, and install it range of 5 — 10 mm (0.2 — 0.4 in) above the pedal
to the brake pedal bracket. pad.
2. Accelerator Control Cable • Press down on the accelerator pedal fully, and
• After confirming that the idling control knob is fully check to see if the engine rotates at the maximum
turned to the left, install the accelerator control ca- speed with the linkage in the smooth operation.
ble. • In the operating range of the accelerator pedal,
Adjustment of the Press-Down Amount of the Accel- check to see if the accelerator pedal and the injec-
erator Pedal tion pump lever return without fail to their original
positions respectively.

RHD Model
LNW81ISH000201
Legend
(a) Full stroke 0 — 2 mm (0 — 0.079 in)
LHD Model
LNW81ISH000301
Legend
(a) 23 ± 5 mm (0.91 ± 0.2 in)
Idling Control Cable

Component
LNWB1ILF000101
Legend
1. Idling control cable assembly 6. Instrument panel driver bracket
2. Instrument reinforcement 7. Instrument reinforcement
3. Stud bolt 8. Engine control link assembly
4. Engine control link assembly 9. RHD Model
5. Idling control cable assembly 10. LHD Model
Removal Installation
1. Idling Control Cable 1. Idling Control Cable Bolt (RHD Model)
• Remove the idling control cable from the engine • Install the idling control cable assembly to the in-
control link assembly. strument reinforcement together with the instru-
• Remove the idling control cable assembly with the ment panel driver bracket.
bracket from the instrument reinforcement. Tighten:
Idling control cable bolt to 9 N⋅m (0.9 kg⋅m/78 lb⋅in)

• Install the idling control cable to the engine control
link assembly.
2. Idling Control Cable Nut (LHD Model)
• Install the idling control cable assembly to the stud
bolt of the instrument reinforcement.
Tighten:
Idling control cable nut to 9 N⋅m (0.9 kg⋅m/78 lb⋅in)
• Install the idling control cable to the engine control
link assembly.
Inspection
• With the idling control knob not in use, check to see
if the injection pump lever is at the idle position
(with the lever in contact with the stopper bolt).
• With the idling control knob turned fully to the right,
check to see if the number of the engine idling ro-
tations gets to 1,500 r/min or more.
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Induction (4JB1) 1J-1
ENGINE
Induction
(4JB1)
TABEL OF CONTENTS
Air Cleaner Element ...............................................1J-2
Component .........................................................1J-2
Removal .............................................................1J-2
Inspection ...........................................................1J-2
Installation ..........................................................1J-3
Turbocharger..........................................................1J-4
Main Data and Specifications .............................1J-4
General Description............................................1J-5
Component .........................................................1J-7
Removal .............................................................1J-7
Inspection And Repair ........................................1J-8
Installation ........................................................1J-10
List of Tightening Torques ................................1J-12
Intercooler ............................................................1J-13
Components .....................................................1J-13
Removal ...........................................................1J-13
Inspection .........................................................1J-13
Installation ........................................................1J-14
Trouble Shooting..................................................1J-15
Engine Has Less Than Normal Power .............1J-15
Blue or Black Smoke ........................................1J-17
Excessive Oil Consumption..............................1J-18
Excessive Turbocharger Noise.........................1J-19
Excessive Rotating Part Wear..........................1J-21
1J-2 Induction (4JB1)
Air Cleaner Element

Component
LNW81JSF000201
Legend
1. Body assembly 3. Gasket
2. Air cleaner element 4. Cover assembly
Removal 2. Remove the air cleaner element from the body.

1. Remove the 3 clips to remove the air cleaner cov- Inspection
er.
• Inspect the element for damage and for clogging
caused by filth.
When the element is dirty or when the dust clog in-
dicator light is lit, clean the element. Replace it if it
is damaged.
Cleaning period Every 6 months

Replacement period Every 40,000 km
(24,856 mile) or every
24 months
LNW71JSH001901

Cleaning
(When dry dust from dust sand is adhering)
Blow air at pressures of 690 kPa(7 kg/cm2 /100 psi) or
below from the inside to remove the dust, while turning
the element.
LNW71JSH001901
LNW21JSH000201
(When blackened by oil burnt smoke such as soot)

• Dissolve a mild detergent in water and soak for ap-
proximately 30 minutes. Thoroughly rinse with wa-
ter and allow to dry naturally (for 2 to 3 days). Do
not use compressed air or fire to dry.
Note:
There is no problem in dissolving mild detergent in water
for cleaning, but if the part is excessively dirty, replace it.
HCW31BSH057501
Installation
1. Install the air cleaner element.
2. Carefully align the air cleaner cover claw and notch
on the body, and securely fasten the clips at 3 plac-
es.
Turbocharger
Main Data and Specifications
Model IHI RHF 4H

Turbine type Mixed-flow
Compressor type Centrifugal
Maximum permissible speed r/min 180,000
Wastegate opening pressure kPa (mmHg) 82 ± 3.3 (615 ± 25)
Weight N (kg/lb) 41 (4.2/9.3)

General Description
LNW81JMF000101
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings.
These parts are supported by the bearing housing.
The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing air
exhaust port.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger is indicated.

Identification of Unit Turbocharger Servicing
The turbocharger nameplate gives the date of manufac- 1. Refer to TROUBLESHOOTING in this Manual to
ture and other important information required to identify determine whether or not turbocharger repair or
the unit when service inquiries are made. overhaul is required.
2. The following procedures should also be per-
formed (either with the turbocharger on the vehicle
or removed from the vehicle but not disassembled)
to determine whether or not turbocharger repair or
overhaul is required.
• Visual checks
• Clearance measurements
• End play measurements
Refer to INSPECTION AND REPAIR
3. The turbocharger compressor and turbine housing
may be removed from the center housing and ro-
tating assembly (CHRA) for further visual inspec-
tion.
Refer to DISASSEMBLY and REASSEMBLY.
Precautions
Turbocharger servicing requires great care and exper-
LNW81JSH000701
tise.
Faulty turbocharger servicing procedures can result in
The turbocharger nameplate has the following informa-
serious damage to pistons, valves, cylinder liners, and
tion stamped on it.
other important engine parts.
1. Turbocharger Specification Number, Production ISUZU does not recommended the performance of any
Year and Month servicing procedure not specified described in this Man-
2. Production Date, Serial Number ual.
3. ISUZU Parts Number
LNW81JSH000601
Legend
1. Date
2. Year
3. Month
4. Line name
5. Sequence No. pre DAY
6. ISUZU parts number

Component
LNW81GLF000701
Legend
1. Exhaust manifold 4. Water pipe assembly
2. Oil feed pipe 5. Turbocharger assembly
3. Adaptor 6. Oil return pipe
Removal
1. Drain the coolant.
2. Remove the front exhaust pipe.
3. Remove the air cleaner charge hose.
4. Remove the exhaust adaptor from the turbocharg-
er.
• Remove the exhaust adaptor.
• Remove the gasket from the turbocharger.
LNW81GSH002701 LNW81GSH002801
5. Remove the oil pipe and water pipe from the turbo- Inspection And Repair
charger assembly.
a. Oil feed pipe (1) placements if excessive wear or damage is discovered
b. Water pipe (2) during inspection.
c. Oil return pipe (3) Turbocharger Pressure Check
1. Remove the waste gate control chamber connect-
ing hose.
2. Connect the pressure gauge.
3. Start the engine and gradually increase the engine
speed (the vehicle must be stationary with no load
applied to the engine).
4. Check to see that turbocharger pressure rises to
approximately 500 mmHg (66.7 kPa).
Pressure Gauge: 5-8840-0075-0
LNW81GSH002601
6. Remove the turbocharger assembly from the ex-

haust manifold.
LNW81GSH000601

Waste Gate Operation Check
1. Remove the hose between the waste gate control
chamber and the intake pipe.
2. Connect the pressure gauge.
3. Check to see that the rod begins to move when a
pressure of approximately 615 mmHg (82 kPa) is
applied to the waste gate, control chamber.
Note:
Do not apply a pressure greater than 1467 mmHg (196
kPa) to the waste gate during this check.
LNW81GSH000801
Important wheel shaft end play and bearing clearance

standards and limits are included below for your refer-
ence.
Wheel Shaft End Play
Use a dial indicator to measure the wheel shaft end play.
Apply a force of 1.2 kg (2.6 lb / 11.8 N) alternately to the
compressor wheel end and the turbine wheel end.
Wheel Shaft End Play mm (in)

Standard Limit
LNW81GSH000701
0.02 — 0.08 0.09 (0.0035)
(0.0008 — 0.0031)
Legend
1. Rod
2. Pressure
4. Check to see the pressure required to move the

control rod 2 mm (0.079 in) is within the limits
shown below.
Control Rod Operating kPa (mmHg)

Pressure
4JB1-TC (IHI RHF4) 98 ± 3.8 (734 ± 29)
LNW81GSH000901
LNW81GSH002401 LNW81GSH002501
Wheel Shaft and Bearing Clearance Installation

Use a dial indicator to measure the wheel shaft and
1. Installation the turbocharger assembly
bearing clearance.
• Installation the gasket and turbocharger assembly
Wheel Shaft and Bearing mm (in) and tighten them at the specified torque.
Clearance
Tightening torque:
Standard Limit
Nuts 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
0.07 — 0.12 0.16 (0.0063)
(0.0028 — 0.0047)
LNW81GSH002801
LNW81GSH001001 2. Install the oil return pipe.

• Insert the gasket to both ends of the oil return pipe
Legend and tighten the bolts at the specified torque.
1. Oil return port
Turbo side
2. Oil feed port
Tightening torque: 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)

3. Install the water pipe.
• Tighten the water return pipe eyebolt at its speci-
fied torque.
Tightening torque: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
Note:
Carefully install the clip so that it doesn't interfere with
the heat protector.
4. Install the oil feed pipe.
• Install the eyebolt to the oil feed pipe on the top
surface of the turbo and tighten it at the specified
torque.
Turbo side
Tightening torque: 22 N⋅m (2.3 kg⋅m / 16 lb⋅ft)
LNW81GSH002701
Crankcase side
LNW81GSH002601
5. Exhaust adaptor.
• Install the gasket and exhaust adaptor and tighten
them at the specified torque.


LNW81LF000801
(a) 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)

(b) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(c) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(d) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(e) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
Intercooler
Components
LNWB1JLF000101
Legend
1. Intercooler 3. Radiator assembly
2. Air duct 4. Air duct
Removal Washing the intercooler core

1. Disconnect the air duct from the intercooler.
Caution:
2. Remove the intercooler from the radiator assem- Do not perform high-pressure washing onto the radiator,
bly. intercooler and surrounding parts when they are still in-
stalled on the vehicle.
Inspection
1. If the intercooler fins are deformed, this can lead to 1. Seal the hose connecting section with a cap or fab-
a drop in heat dissipation and reduce engine per- ric tape.
formance. Repair the fins. When repairing, be 2. Sufficiently wet the front and back surfaces of the
careful not to damage the base of the fins. intercooler.
2. Inspect the inside of the intercooler for filth. If it is
significantly dirty, clean it.

• Adhering matter which easily comes off with a
splash of tap water should be washed off sufficient-
ly in advance.
Note:
Do not use a high-pressure washer or brush.
3. Prepare a mild detergent.
• Use a type which contains approx. 8% of surface
acting agent.
Note:
Do not use anything other than a mild detergent. Use of
any product other than a mild detergent may cause cor-
rosion.
4. Spray the mild detergent onto both sides of the
fins, and leave them as is for 10 minutes.
5. Rinse off the mild detergent using a high-pressure
washer.
• Start washing from the engine side of the intercool-
er.
Note:
• Apply the high-pressure water in a direction per-
pendicular to the fins.
• Do not bring the high-pressure water too close to
the fins.
• Be careful not to deform the fins.
6. After washing is finished, inspect the fins to confirm
that the dirt is removed sufficiently.
• If washing is not sufficient, wash them again.
Note:
If some dirt is still left, fine black particles attached on
the fins can be seen.
7. Rinse off the detergent constituents on the fins and
resin parts using the tap water.
8. Remove the seal on the hose connecting section.
9. Clean and dry the hose connecting section suffi-
ciently.
Installation
1. Install the intercooler to the radiator.
2. Install the air duct to the intercooler.
Trouble Shooting
Engine Has Less Than Normal Power
N6A3633E
N6A3634E

Blue or Black Smoke
N6A3635E

Excessive Oil Consumption
N6A3636E

Excessive Turbocharger Noise
N6A3637E
N6A3638E

Excessive Rotating Part Wear
N6A3639E
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Pre-Heating System (4JB1) 1K-1
ENGINE
Pre-Heating System
(4JB1)
TABLE OF CONTENTS
QOSII Preheating System..................................... 1K-2
General Description........................................... 1K-2
QOS II Timing Chart .......................................... 1K-2
Inspection on QOSII System Operation ............ 1K-3
QOSII System Troubleshooting......................... 1K-4
1K-2 Pre-Heating System (4JB1)
QOSII Preheating System

General Description
QOS II preheating system features a quick-on glow plug with thermometer control of the glowing time and the after-
glow time function.
The system consists of a controller, indicator lamp, thermoswitch, relay, and glow plug (4 pcs).
With the employment of the thermoswitch, the glow time changes according to the engine coolant temperature, thus
allowing optimum starting conditions to be obtained.
System Diagram
LNW81ESF000501
QOS II Timing Chart
LNW81ESF000601

Inspection on QOSII System Operation
Thermo Switch
The thermo switch is located on the water outlet pipe.
LNW81ESH005801
LNW81CSH001901
Use a circuit tester to check the thermo switch for conti-

nuity.
OFF → ON : 7 — 13°C (44.6 — 55.4°F)

ON → OFF : Below 3°C (37.4°F)
LNW81ESH005701
Glow Plug
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference)

Ohms
Conventional model Approximately 1.5
Quick on start model Approximately 0.9
1K-4 Pre-Heating System (4JB1)

QOSII System Troubleshooting
LNW81EMF000501
1. Problems when the water temperature of the engine is 0°C (32°F) below.
Condition Cause Circuit

Glow plug relay will Bad connection of Fusible link wire between battery and starter. 3
not be lit. Bad connection or disconnection of starter SW circuit
Bad connection or disconnection of Fuse No. SBF3
2
Malfunction of other circuits occurred simultaneously.
Bad starter switch.
Bad connection of glow plug relay terminal. 1
Disconnection of glow plug relay excitation coil.
Disconnection of circuit between glow plug relay and timer. 6
Bad glow relay. (The main contact does not pass electricity.)
Bad connection of timer.
Bad timer.
Bad earth circuit of timer. 7
Bad thermoswitch. (It remains ON even in water temperature below 0°C
(32°F).)
Earth short-circuiting of thermo switch. 7
Through glow plug Bad connection of Fusible link wire between battery and glow relay. 1
relay turns ON, pre-
Bad connection or disconnection in preheating circuit of glow relay main
heating is not done.
contact terminal connector.
Bad connection between plug connector and preheating circuit. 9

Glow plug relay Bad timer.
turns ON, but does Bad timer. Short circuiting in circuit or earth between 5 terminal and glow
not go OFF. 6
relay.
Bad glow relay.
Indication lamp is Bad timer.
not lit. Burning-out of light bulb. 8 8
Note:
Circuit number is shown in the previous pre-heating chart.
2. Problems when the time water temperature of the engine is 0°C or above.

Indicator lamp is not Bad timer
lit Burning-out of bulb. 8 8
Turn glow relay ON. Bad thermoswitch or disconnection of thermo SW circuit.
4
(Indicator will light up for 3.5 seconds.)
Bad timer.
Bad timer. Short-circuiting in circuit or earth between terminals 5 and glow
relay.
Note:
Circuit number is shown in the previous pre-heating chart.
3. Burning-out of glow plug
When only one line is burned out, it has no effect on the start up of the engine. Even if one line is burned out,
judging from the characteristics of the glow plug, the impressed voltage will change only slightly.
Therefore, no judgment can be made by normal testing while the glow plug is installed. In order to check for
disconnections and burn-outs, the glow plugs will have to be removed from the connectors and checked one by
one for continuity.
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LG4JB-WE-0871_4305340_奥付 2012.10.24 3:22 PM ページ 1
Published: Oct., 2012 All rights reserved.

Fourth Edition
WORKSHOP MANUAL
ENGINE
(4JB1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LG4JB-WE-0871_4305340_奥付 2012.10.24 3:22 PM ページ 2
2008-2012MY
2008-2012MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4JB1 model)

ENGINE
(4JB1 model)
No.LG4JB-WE-0871

Workshop Manual: Engine

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2008-2012MY

WORKSHOP MANUAL ENGINE (4JB1 model)

Engine Mechanical (4JB1) 1B-1

1B-2 Engine Mechanical (4JB1)

Engine Mechanical (4JB1) 1B-3

1B-4 Engine Mechanical (4JB1)

Engine Mechanical (4JB1) 1B-5

1B-6 Engine Mechanical (4JB1)

Connecting rod cap bolt

Fuel filter with sedimenter

Engine Mechanical (4JB1) 1B-7

Adjust the No. 1 or the No. 4 cylinder valve clear-

1B-8 Engine Mechanical (4JB1)

4. Turn the engine over with the starter motor and

Compression Pressure at 200 rpm kPa (kg/cm2/psi)

Compression Pressure Measure-ment

Engine Mechanical (4JB1) 1B-9

2. Bring the piston in the No. (2) cylinder to TDC 1 on

7. Rotate the crankshaft to bring the piston in the No.

1B-10 Engine Mechanical (4JB1)

Standard Reading mm (in) Glow Plug Terminal Voltage V

If the injection timing is outside the specified range,

2. Turn the starter switch to the “ON” position.

Engine Mechanical (4JB1) 1B-11

1B-12 Engine Mechanical (4JB1)

Checkpoint Possible cause Correction

2. Starter Motor Operates But Engine Does Not Turn Over

Checkpoint Possible cause Correction

Engine Mechanical (4JB1) 1B-13

Checkpoint Possible cause Correction

4. Quick-On Start System

1B-14 Engine Mechanical (4JB1)

Checkpoint Possible cause Correction

Engine Mechanical (4JB1) 1B-15

Checkpoint Possible cause Correction

1B-16 Engine Mechanical (4JB1)

Checkpoint Possible cause Correction

Engine Mechanical (4JB1) 1B-17

Checkpoint Possible cause Correction

Excessive Oil Consumption

Checkpoint Possible cause Correction

Checkpoint Possible cause Correction

1B-18 Engine Mechanical (4JB1)

Checkpoint Possible cause Correction

Dark Exhaust Smoke

Checkpoint Possible cause Correction

Oil Pressure Does Not Rise

Checkpoint Possible cause Correction

Engine Mechanical (4JB1) 1B-19

Checkpoint Possible cause Correction

2. Gas Leakage Noise

Checkpoint Possible cause Correction

Checkpoint Possible cause Correction

Checkpoint Possible cause Correction

1B-20 Engine Mechanical (4JB1)

Checkpoint Possible cause Correction

Engine Mechanical (4JB1) 1B-21

Item Engine type 4JB1-TC Engine type 4JB1NA

1B-22 Engine Mechanical (4JB1)

Item Engine type 4JB1-TC 4JB1NA

Engine Mechanical (4JB1) 1B-23

Tool Number / Tool Number /

9-8523-1423-0 (J-29760) 5-8840-0145-0 / Measur-