LG4JB-WE-0871 1st WSMW 080 N G.Exp VN53 PDF

WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE (4JB1 model)

ENGINE
(4JB1 model)
No.LG4JB-WE-0871
55897_Maegaki 08.5.27 11:13 AM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
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
LG4JB-WE-0871.book 1 ページ２００８年８月２７日　水曜日　午前９時２８分
Engine Mechanical (4JB1) 1B-1
ENGINE
Engine Mechanical
(4JB1)
TABLE OF CONTENTS
4JB1 ENGINE ....................................................... 1B-3 TIMING GEAR.....................................................1B-45
MAINTENANCE PRECAUTIONS ..................... 1B-3 Component ......................................................1B-45
READING THE MODEL .................................... 1B-4 Removal...........................................................1B-45
DESCRIPTION OF FUNCTION AND IInstallation.......................................................1B-48
OPERATION .................................................... 1B-5 List of Tightening Torques ...............................1B-52
FUNCTIONAL AND OPERATIONAL VALVE SPRING, VALVE GUIDE OIL SEAL,
DESCRIPTION ................................................. 1B-6 VALVE GUIDE, PUSH ROD...............................1B-53
FUNCTIONAL INSPECTION:............................ 1B-7 Component ......................................................1B-53
FAILURE PHENOMENON LIST...................... 1B-11 Removal...........................................................1B-53
Hard Starting ................................................... 1B-12 Disassembly.....................................................1B-54
Unstable Idling................................................. 1B-15 Inspection and Repair ......................................1B-54
Insufficient Power ............................................ 1B-16 Reassembly .....................................................1B-59
Excessive Fuel Consumption .......................... 1B-17 Installation........................................................1B-60
Excessive Oil Consumption............................. 1B-17 ROCKER ARM ASSEMBLY................................1B-62
Overheating ..................................................... 1B-17 Component ......................................................1B-62
White Exhaust Smoke ..................................... 1B-18 Disassembly.....................................................1B-63
Dark Exhaust Smoke....................................... 1B-18 Inspection and Repair ......................................1B-63
Oil Pressure Does Not Rise............................. 1B-18 Reassembly .....................................................1B-64
Abnormal Engine Noise................................... 1B-19 Installation........................................................1B-64
Engine Cooling Trouble ................................... 1B-20 CAMSHAFT AND TAPPET .................................1B-67
PRIMARY SPECIFICATIONS ......................... 1B-21 Component ......................................................1B-67
SPECIAL TOOLS ............................................ 1B-23 Removal...........................................................1B-67
ENGINE ASSEMBLY .......................................... 1B-25 Disassembly.....................................................1B-69
Component ...................................................... 1B-25 Inspection and Repair ......................................1B-70
Removal .......................................................... 1B-25 Reassembly .....................................................1B-73
Installation ....................................................... 1B-29 Installation........................................................1B-75
ENGINE MOUNT (RH)........................................ 1B-34 List of Tightening Torques ...............................1B-76
Component ...................................................... 1B-34 CYLINDER HEAD ASSEMBLY ...........................1B-77
Removal .......................................................... 1B-34 Component ......................................................1B-77
Installation ....................................................... 1B-35 Removal...........................................................1B-77
ENGINE MOUNT (LH) ........................................ 1B-36 Disassembly.....................................................1B-79
Component ...................................................... 1B-36 Clean................................................................1B-80
Removal .......................................................... 1B-36 Inspection and Repair ......................................1B-80
Installation ....................................................... 1B-36 Reassembly .....................................................1B-82
List of Tightening Torques ............................... 1B-37 Installation........................................................1B-84
CYLINDER HEAD COVER ................................. 1B-38 List of Tightening Torques ...............................1B-89
Component ...................................................... 1B-38 PISTON AND CONNECTING ROD ....................1B-90
Removal .......................................................... 1B-38 Component ......................................................1B-90
Installation ....................................................... 1B-38 Removal...........................................................1B-90
List of Tightening Torques ............................... 1B-39 Disassembly.....................................................1B-92
INLET MANIFOLD .............................................. 1B-40 Inspection and Repair ......................................1B-93
Component ...................................................... 1B-40 Reassembly .....................................................1B-97
Removal .......................................................... 1B-40 Installation........................................................1B-99
Installation ....................................................... 1B-41 List of Tightening Torques .............................1B-105
List of Tightening Torques ............................... 1B-42 FLYWHEEL AND PILOT BEARING ..................1B-106
EXHAUST MANIFOLD........................................ 1B-43 Component ....................................................1B-106
Component ...................................................... 1B-43 Removal.........................................................1B-106
Removal .......................................................... 1B-43 Installation......................................................1B-107
Inspection ........................................................ 1B-44 List of Tightening Torques .............................1B-108
Installation ....................................................... 1B-44 CRANKSHAFT FRONT OIL SEAL....................1B-109
1B-2 Engine Mechanical (4JB1)

Component .................................................... 1B-109
Removal ........................................................ 1B-109
Installation ..................................................... 1B-110
List of Tightening Torques ............................. 1B-111
CRANKSHAFT REAR OIL SEAL ...................... 1B-112
Component .................................................... 1B-112
Removal ........................................................ 1B-112
Installation ..................................................... 1B-114
CRANKSHAFT.................................................. 1B-118
Component .................................................... 1B-118
Removal ........................................................ 1B-118
Disassembly .................................................. 1B-121
Inspection and Repair.................................... 1B-121
Reassembly................................................... 1B-125
Installation ..................................................... 1B-131
List of Tightening Torques ............................. 1B-135
CYLINDER BLOCK........................................... 1B-136
Component .................................................... 1B-136
Disassembly .................................................. 1B-136
Inspection and Repair.................................... 1B-136
Reassembly................................................... 1B-140
List of tightening Torque ................................ 1B-146
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
shown in the illustration.
• 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)
LNW81BSH015601
2. Bring the piston in the No. (2) cylinder to TDC 1 on

the compression stroke by turning the crankshaft LNW81BSH015801
until the crankshaft pulley TDC line is aligned with
the timing mark (1). 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. LNW81BSH015901
If the No. 1 cylinder intake and exhaust valve push rods 10. Turn the crankshaft clockwise and read the gauge
have play, the No. 1 piston is at TDC on the compres- indication when the crankshaft pulley timing mark
sion stroke. is aligned with the pointer.
3. Disconnect the injection pipe from the injection
pump. 4JB1-TC BTDC 4°
4. Remove one bolt from the distributor head.
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 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 3
(in ) 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
2,511 (256/564)
Fuel injection order 1—3—4—2
Fuel injection timing deg BTDC 4
Specified fuel type SAE No. 2 diesel fuel
Idling speed rpm 750 — 790
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) deg 24.5
Close at (BTDC) deg 55.5
Exhaust valves Open at (BTDC) deg 54
Close at (BTDC) deg 26
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/UK gal) 6.6 — 7.1 (1.74 — 1.87/2.62 — 2.82)
(For EC 6.2 — 8.2 (2.17 — 1.64/1.36 — 1.80))
Oil cooler type Water cooled
Item Engine type 4JB1-TC

Fuel system
Injection pump type Bosch distributor
Governor type Mechanical (Partially variable speed)
(For EC Variable speed)
Injection nozzle type Hole
Injection nozzle opening pressure kPa (kg/cm2/psi) 1st: 19,500 (199/2,830)
2nd: 26,500 (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) (For EC 5.8 (5.1))
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) (For EC 7.3 (6.42))
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
5-8840-0266-0 / Angle
5-8840-2033-0 / Oil Seal
Gauge
Installer
5884002660
5884020330
5-8840-9016-0 / Injec-
5-8840-9018-0 / Piston
tion Nozzle Tester
Ring Compressor
5884090160
5884090180
5-8840-2034-0 / Nozzle
9-8523-1212-0 / Valve Holder Remover (4JB1
Guide Replacer only)
5884020340
9852312120
5-8840-2038-0 / Cam-
5-8840-2675-0 / Com-
shaft Bearing Replacer
pression gauge
5884020380
5884026750
Tool Number / Tool Number /

Illustration Illustration
Description / Remarks Description / Remarks
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
9-8522-0020-0 / Crank-
5-8840-2000-0 / Pilot
shaft Timing Gear
Bearing Remover
Installer
5884020000 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)
3. Front Exhaust Pipe
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 10 kg 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
• Support the transmission with mission jack.
Caution:
To prevent the falling of the transmission, tie it securely
to the jack with a chain or belt.
LNW81BSH011801
2) Pressure Plate Assembly

• 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
• Tighten the fixing nuts to the specified
torque
(Engine side)
ENGINE MOUNT (RH)

Component
LNW81BMF003001
Legend
1. Fan shroud 4. Fan 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
2. Fan Belt
• 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)
2. Fan Belt
• Install the fan 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)
LNW81BSH014801
Legend
1. Fan belt
2. P/S oil pump drive belt
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 / 9 lb⋅ft)
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 / 9 lb⋅ft)

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)
Inspection
Installation
1. Front exhaust pipe.
2. Front exhaust pipe fixing bolts and nuts.
• Tighten the fixing nuts to the specified torque
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 LNW81GSH002101
• Tighten the fixing nuts to the specified torque • Connect battery ground cable.
(Engine side)
• After assembling each part, start the engine to
check for any leakage of gas at each connection.
LNW81GMF000801
(a) 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft) (c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(b) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
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
IInstallation
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
the specified torque.
Tighten:
• Oil pipe eye bolt to 13 N⋅m (1.3 kg⋅m / 9 lb⋅ft)
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
3) Tighten the idle gear bolt to the specified

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)
12. AC Generator Drive Belt
• 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.
8. Noise Cover Spacer
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 / 9 lb⋅ft) (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
Valve spring compressor: 9-8523-1423-0 (J-
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
the valve guide must be replaced as a set.
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.

• Apply engine oil to the rocker arms and the valve
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
as shown in the illustration.
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
5. Oil Pump Assembly
6. Camshaft Timing Gear
• 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
Inspection and Repair

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

LG4JB-WE-0871 1st WSMW 080 N G.Exp VN53 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

LG4JB-WE-0871 1st WSMW 080 N G.Exp VN53 PDF

Uploaded by

Copyright:

Available Formats

WORKSHOP MANUAL

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

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

1B-22 Engine Mechanical (4JB1)

Item Engine type 4JB1-TC

Engine Mechanical (4JB1) 1B-23

Tool Number / Tool Number /

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

1B-24 Engine Mechanical (4JB1)