Professional Documents
Culture Documents
ISUZU
Engine Manual
4HK1
6HK1
ENGINE DISASSEMBLY AND ASSEMBLY
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In tro d u c tio n
This M anual describes the stru ctu re and the tro u b le sh o o tin g of e le ctron ic
control fuel injection system (common rail type) in 4HK1 and 6HK1 industrial
engines.
Use this manual sufficiently to perform service work properly and quickly.
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General Contents
Disassemble and Assemble Engine
General Information
Engine Mechanical (4HK1, 6HK1)
Cooling System
Fuel System
Engine Electrical
Exhaust System and Turbocharger
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General Information
GENERAL INFORMATION
General Information
Contents
General Information . 0A-2
Service Precautions 0A-2
Reading the model. 0A-6
General information 0A-7
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General Information
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General Information 0A-1
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0A-2 General Information
General Information
Service Precautions
In order to carry out work safely
1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical
system, always remove the minus side cable from
the battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.
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General Information 0A-3
WSHK0191 WSHK0192
Liquid gasket
1. Each time you disassemble parts that use liquid
gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to
completely remove oil, water, and dirt etc. from the
various surfaces. Using the specified type of liquid
gasket, apply new liquid gasket to each of the
surfaces before reassembling the parts.
HCW30ZSH001601
2. In order to make it easier to clean liquid gasket
9. Pay close attention to the risk of ignition if you are surfaces, apply gasket remover liquid (Pando-
handling parts that carry a high voltage. 391D made by Three Bond Co., Ltd.) and leave
Furthermore, any oil or grease spilt onto rubber the part to stand for approximately 10 minutes,
parts must be wiped off immediately, as it will after which the old liquid gasket residue will be
cause deterioration of the rubber. easier to remove.
However, this should not be used on resin
components or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when re
installing the liquid gasket parts to each other. If
there are gaps between the two parts, re-apply the
liquid gasket. Some parts, especially the oil pan,
use the same size studs as a guide to eliminate the
need for knock pin positioning etc.
5. Re-install these parts within 7 minutes of applying
the liquid gasket.
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0A-4 General Information
If more than 7 minutes passes, remove the
previous liquid gasket and re-apply it.
6. Please wait for at least 30 minutes since the last
part is installed before starting the engine.
Liquid gasket
Application procedure
1. Wipe the contact surfaces clean of all water,
grease or oil. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.
Notes:
If there are special regulations concerning the
application procedure in the repair document, please
follow those regulations.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
Important:
screw thread section clean of water, grease, and
After tightening the bolt, do not apply excessive torque
oil. The contact surfaces should be dry.
or try to rotate the bolt until at least one hour has
2. Apply Loctite to the top 1/3 of the screw. passed, and the Loctite has hardened.
3. Tighten the bolt to the correct tightening torque.
Procedure for using the Plastigauge
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General Information 0A-5
• Line up the marks on the connecting rod and cap • Cut the plastigauge to the same size as the journal
and install the crank pin, apply molybdenum width, and while avoiding the oil pore of the journal
disulfide to the thread section and bearing surface lay the gauge parallel to the journal.
of the fastening bolt, and rotate both cap and bolt • Gently rest the crank case on the cylinder block,
to the correct torque. apply molybdenum disulfide to the thread section
and bearing surface of the fastening bolt, and
Important:
tighten in sequence to the correct torque.
Do not move the connecting rod while using the
plastigauge. Important:
• Gently remove the cap and connecting rod, and Do not rotate the crankshaft while using the
measure the crushed width of the plastigauge plastigauge.
(clearance between rod and pin) using the scale • Gently remove the crankcase, and measure the
printed on the bag. crushed width of the plastigauge (clearance
between bearing and journal) using the scale
printed on the bag.
HCW30ASH002101
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0A-6 General Information
Reading the model
Engine number stamping position
4HK1
©
WSHK0185
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General Information 0A-7
6HK1
WSHK0186
General information
Terminology, description of abbreviations
Terminology definitions
Term Explanation
Maintenance standard The generic name for reference values required for maintenance, such as nominal
dimension, selection of a reference point, and limit.
Nominal dimension Shows the standard value at the point of manufacture that does not include the
common difference.
Selection of a reference point Shows the standard value after assembling, repairing, or adjusting.
Limit When this value (dimensions) is reached, it shows that the part has reached its full
limit and must be replaced or repaired.
Front • rear, left • right, upper • These show each orientations of parts installed to the vehicle when looking from
lower the vehicle's forward direction.
Unit Units written to SI conventions (mainly torque, pressure, force)
[Example] Length: mm, Torque: N m {kgfm }
Warning Items that carry the warning mark pose a danger to life or threat of serious injury if
not strictly observed.
Caution Items that carry the caution mark may cause injury or lead to accidents if not strictly
observed.
Important Items that carry the important mark may cause the vehicle to break down, or may
prevent the guaranteed normal operation of the system or related parts if not strictly
observed.
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0A-8 General Information
Term Explanation
Notes Items that should receive special mention within a work procedure.
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General Information 0A-9
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0A-10 General Information
Table of tightening torque
The tightening torque values in the table below apply to
all situations unless a special tightening torque is
specified.
bolts, nuts
N -m {kgf -m}
Strength 4.8
7T
classification 4T
Bolt head
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
section shape
* M10 x 1.5 19.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1}
68.1 ~ 102.1 {6.9 ~
M12 x 1.25 49.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}
10.4}
* M12 x 1.75 45.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6}
76.5 ~ 114.7 {7.8 ~ 83.0 ~ 124.5 {8.5 ~ 93.2 ~ 139.3 {9.5 ~ 100.8 ~ 151.1 {10.3 ~
M14 x 1.5
11.7} 12.7} 14.2} 15.4}
71.6 ~ 106.9 {7.3 ~ 77.2 ~ 115.8 {7.9 ~ 88.3 ~ 131.4 {9.0 ~ 94.9 ~ 142.3 {9.7 ~
* M 14x 2
10.9} 11.8} 13.4} 14.5}
104.0 ~ 157.0 {10.6 ~ 115.6 ~ 173.3 {11.8 ~ 135.3 ~ 204.0 {13.8 ~ 150.1 ~ 225.2 {15.3 ~
M16 x 1.5
16.0} 17.7} 20.8} 23.0}
100.0 ~ 149.1 {10.2 ~ 109.4 ~ 164.2 {11.2 ~ 129.4 ~ 194.2 {13.2 ~ 142.5 ~ 213.8 {14.5 ~
* M 16x 2
15.2} 16.7} 19.8} 21.8}
151.0 ~ 225.6 {15.4 ~ 195.2 ~ 293.2 {19.9 ~
M18 x 1.5 — —
23.0} 29.9}
151.0 ~ 225.6 {15.4 ~ 196.1 ~ 294.2 {20.0 ~
* M18 x 2.5 — —
23.0} 30.0}
206.0 - 310.0 {21.0 ~ 269.7 ~ 405.0 {27.5 ~
M20 x 1.5 — —
31.6} 41.3}
190.2 ~ 286.4 {19.4 - 249.1 ~ 374.6 {25.4 ~
* M20 x 2.5 — —
29.2} 38.2}
251.1 - 413.8 {25.6 ~ 362.8 ~ 544.3 {37.0 ~
M22 x 1.5 — —
42.2} 55.5}
217.7 ~ 327.5 {22.2 ~ 338.3 ~ 507.0 {34.5 ~
* M22 x 2.5 — —
33.4} 51.7}
358.9 ~ 539.4 {36.6 ~ 430.5 ~ 711.0 {43.9 ~
M24 x 2 — —
55.0} 72.5}
338.3 ~ 507.0 {34.5 ~ 406.0 ~ 608.0 {41.4 ~
* M24 x 3 — —
51.7} 62.0}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
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General Information 0A-11
N -m {kgf-m}
9.8
Strength classification 8.8
9T
Bolt head section
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
shape
5.6 ~ 11.2 {0.6 ~ 6.6 ~ 12.2 {0.6 ~
M6 x 1 — —
1.1} 1.2}
13.4 ~ 25.7 {1.4 ~ 15.3 ~ 28.4 {1.6 ~ 16.7 ~ 30.4 {1.7 ~ 18.1 ~ 33.6 {1.9 ~
M8 x 1.25
2.6} 2.9} 3.1} 3.4}
31.3 ~ 52.5 {3.2 ~ 35.4 ~ 58.9 {3.6 ~ 37.3 ~ 62.8 {3.8 ~ 42.3 ~ 70.5 {4.3 ~
M10 x 1.25
5.4} 6.1} 6.4} 7.2}
31.3 ~ 51.4 {3.2 ~ 34.5 ~ 57.5 {3.5 ~ 36.3 ~ 59.8 {3.7 ~ 40.1 ~ 66.9 {4.1 ~
* M10 x 1.5
5.2} 5.8} 6.1} 6.8}
69.3 ~ 104.0 {7.1 ~ 77.7 ~ 116.5 {7.9 ~ 75.5 ~ 113.8 {7.7 ~ 85.0 ~ 127.5 {8.7 ~
M12 x 1.25
10.6} 11.9} 11.6} 13.0}
64.8 ~ 96.1 {6.6 ~ 71.4 ~ 107.2 {7.3 ~ 71.6 ~ 106.9 {7.3 ~ 79.5 ~ 119.2 {8.1 ~
* M12 x 1.75
9.8} 10.9} 10.9} 12.2}
106.2 ~ 158.8 {10.8 114.9 ~ 172.3 {11.7 113.8 ~ 170.6 {11.6 123.4 ~ 185.1 {12.6
M14 x 1.5
~ 16.2} ~ 17.6} ~ 17.4} ~ 18.9}
100.6 ~ 149.8 {10.3 108.2 ~ 162.2 {11.1 106.9 ~ 160.0 {10.9 115.5 ~ 173.3 {11.8
* M 14x 2
~ 15.3} ~ 16.6} ~ 16.3} ~ 17.7}
154.3 ~ 232.5 {15.7 171.1 ~ 256.7 {17.4 160.0 ~ 240.3 {16.3 176.9 ~ 265.3 {18.0
M16 x 1.5
~ 23.7} ~ 26.2} ~ 24.5} ~ 27.1}
147.6 ~ 221.4 {15.0 162.5 ~ 243.8 {16.6 153.0 ~ 229.5 {15.6 168.5 ~ 252.7 {17.2
* M 16x 2
~ 22.6} ~ 24.9} ~ 23.4} ~ 25.8}
222.5 ~ 334.3 {22.7 229.5 ~ 345.2 {23.4
M18 x 1.5 — —
~ 34.1} ~ 35.2}
223.6 ~ 335.4 {22.8 230.5 ~ 346.2 {23.6
* M18 x 2.5 — —
~ 34.2} ~ 35.3}
307.4 ~ 461.7 {31.4 316.8 ~ 475.6 {32.3
M20 x 1.5 — —
~ 47.1} ~ 48.5}
284.0 ~ 472.1 {29.0 293.2 ~ 440.3 {29.2
* M20 x 2.5 — —
~ 43.5} ~ 44.9}
413.6 ~ 620.5 {42.2 424.6 ~ 636.5 {43.3
M22 x 1.5 — —
~ 63.3} ~ 64.9}
385.7 ~ 578.0 {39.3 394.2 ~ 592.3 {40.0
* M22 x 2.5 — —
~ 58.9} ~ 60.4}
490.8 ~ 810.5 {50.0 554.1 ~ 830.6 {56.5
M24 x 2 — —
~ 82.7} ~ 84.7}
462.8 ~ 693.1 {47.2 520.7 ~ 781.6 {53.1
* M24 x 3 — —
~ 70.7} ~ 79.7}
The * mark indicates where soft materials have been used for internal thread sections, such as castings.
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0A-12 General Information
Designations for bolt heads
Legend
1. Hexagon head bolt(4.8, 4T) 9. Hexagon head bolt(Un-refined 8.8)
2. Hexagon head bolt(4.8, 4T) 10. Hexagon head bolt(Un-refined 8.8)
3. Flange bolt(4.8, 4T) 11. Flange bolt(8.8)
4. Flange bolt(4.8, 4T) 12. Flange bolt(8.8)
5. Hexagon head bolt(7T) 13. Hexagon head bolt(9.8, 9T)
6. Flange bolt(7T) 14. Hexagon head bolt(9.8, 9T)
7. Hexagon head bolt (refined 8.8) 15. Flange bolt(9.8, 9T)
8. Hexagon head bolt (refined 8.8) 16. Flange bolt(9.8, 9T)
Flare nut
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General Information 0A-13
Taper screw from connectors (brass)
N-m {kgf-m}
Screw size PT(R) 1/8 PT(R) 1/4 PT(R) 3/8 PT(R) 1/12
— 2.0 ~ 14.7 4.9 ~ 15.7 9.8 ~ 16.7 9.8 ~ 17.7
(0.2 ~ 1.5) (0.5 ~ 1.6) (1.0 ~ 1.7) (1.0 ~ 1.8)
A; Essential tool
Servicing operation cannot be done with any other tools than the essential tool.
B; Recommended tool
Servicing work can be done with a general-purpose tool commercially available.
However, it is advisable to use the recommended tool as much as possible for a reduced work time and an improved
safety in work operations.
C; Available tool
Although it takes a more working time, servicing operations can be made with a tool commercially available as
substitute for the available tool.
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0A-14 General Information
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ENGINE MECHANICAL (4HK1, 6HK1)
ENGINE
ENGINE MECHANICAL (4HK1, 6HK1)
TABLE OF CONTENTS
DIESEL ENGINE (4HK1, 6 H K 1).............................1A-3 Inspection.............................................................1A-81
Precautions on Service W ork............................... 1A-3 Reassembly.........................................................1A-87
Main Data and Specifications............................. 1A-11 Installation...........................................................1A-94
Cylinder Head Cover.............................................. 1A-14 Torque Specifications........................................1A-101
Components.........................................................1A-14 Special T o o l.......................................................1A-101
Removal............................................................... 1A-15 Piston, Connecting Rod ..................................... 1A-103
Installation...........................................................1A-16 Components.......................................................1A-103
Torque Specifications..........................................1A-18 Removal.............................................................1A-103
Inlet Cover............................................................... 1A-20 Disassembly...................................................... 1A-104
Components.........................................................1A-20 Reassembly.......................................................1A-110
Removal............................................................... 1A-21 Installation.........................................................1A-112
Installation...........................................................1A-22 Torque Specifications........................................1A-114
Torque Specifications..........................................1A-24 Special T o o l.......................................................1A-114
Turbocharger and Exhaust Manifold.................... 1A-25 F lyw heel............................................................... 1A-115
Components.........................................................1A-25 Components.......................................................1A-115
Removal............................................................... 1A-26 Removal............................................................. 1A-115
Inspection.............................................................1A-27 Inspection........................................................... 1A-117
Installation...........................................................1A-28 Installation.........................................................1A-117
Torque Specifications..........................................1A-31 Torque Specifications........................................1A-119
Timing Gear T ra in .................................................. 1A-34 Special T o o l.......................................................1A-119
Components.........................................................1A-34 Front C over...........................................................1A-120
Removal............................................................... 1A-35 Components.......................................................1A-120
Inspection.............................................................1A-37 Removal.............................................................1A-121
Installation...........................................................1A-39 Installation.........................................................1A-122
Torque Specifications..........................................1A-50 Torque Specifications........................................1A-124
Special Tool ........................................................ 1A-51 Crankshaft Front Oil S e a l................................... 1A-126
Rocker Arm Shaft A S M ..........................................1A-52 Components.......................................................1A-126
Components.........................................................1A-52 Removal.............................................................1A-126
Removal............................................................... 1A-52 Installation ........................................................ 1A-128
Disassembly.........................................................1A-53 Torque Specifications........................................1A-133
Reassembly.........................................................1A-55 Special T o o l.......................................................1A-133
Installation...........................................................1A-56 Crankshaft Rear Oil Seal..................................... 1A-134
Torque Specifications..........................................1A-58 Components.......................................................1A-134
Camshaft A S M .......................................................1A-59 Removal.............................................................1A-134
Components.........................................................1A-59 Installation.........................................................1A-135
Removal............................................................... 1A-60 Special T o o l.......................................................1A-138
Disassembly.........................................................1A-61 Crankshaft.............................................................1A-139
Reassembly.........................................................1A-63 Components.......................................................1A-139
Fixing to rq u e .......................................................1A-65 Removal.............................................................1A-139
Special T o o l.........................................................1A-65 Disassembly...................................................... 1A-141
Installation...........................................................1A-66 Reassembly...................................................... 1A-141
Torque Specifications..........................................1A-68 Inspection...........................................................1A-141
Valve Stem Seal, Valve S p rin g .............................1A-69 Installation.........................................................1A-146
Components.........................................................1A-69 Torque Specifications........................................1A-150
Removal............................................................... 1A-69 Special T o o l.......................................................1A-150
Inspection.............................................................1A-70 Cylinder B lock.......................................................1A-152
Installation .......................................................... 1A-71 Components.......................................................1A-152
Special T o o l.........................................................1A-73 Removal.............................................................1A-152
Cylinder H ead.........................................................1A-74 Inspection...........................................................1A-153
Components.........................................................1A-74 Installation.........................................................1A-154
Removal............................................................... 1A-74 Lubrication S ystem .............................................. 1A-157
Disassembly.........................................................1A-78 Precautions on Service W ork...........................1A-157
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ENGINE MECHANICAL (4HK1, 6HK1)
Function C h e c k ................................................ 1A-158
Special T o o l.......................................................1A-159
Oil Port Cover ASM .............................................. 1A-160
Components...................................................... 1A-160
Removal............................................................. 1A-160
Installation ........................................................ 1A-160
Oil Cooler ............................................................ 1A-162
Components...................................................... 1A-162
Removal............................................................. 1A-163
Disassembly..................................................... 1A-164
Reassembly ..................................................... 1A-164
Installation.........................................................1A-165
Oil P a n ................................................................. 1A-168
Components.......................................................1A-168
Removal............................................................. 1A-168
Installation.........................................................1A-169
Oil Pump .............................................................. 1A-171
Components.......................................................1A-171
Removal............................................................. 1A-171
Disassembly..................................................... 1A-172
Reassembly ..................................................... 1A-172
Inspection...........................................................1A-173
Installation ........................................................ 1A-174
Oil Pressure Switch.............................................. 1A-178
Inspection...........................................................1A-178
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-3
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1A-4 ENGINE MECHANICAL (4HK1, 6HK1)
How to read the model
4HK1
PNW56ALF001001
Name
1. Cast The Engine Model 2. Stamp An Engine Number
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-5
6HK1
Name
1. Stamp An Engine Number
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1A-6 ENGINE MECHANICAL (4HK1, 6HK1)
Crankshaft • Rotate the crankshaft to make the No.1 cylinder
Tuftriding is given, while on the No. 1 balance weight meet the compression top dead center (TDC).
imprinted is the grade of each journal diameter. 4HK1
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Common rail-type electronic control injection
system
The common rail-type electronic control injection
system is composed of a fuel supply pump that sets the
target pressure of high-pressure fuel and supply it, a
common rail that measures such high-pressure fuel
and a fuel injector that turns it into a fine spray and
injects it. Each is controlled via ECM based upon
various signals, while injection timing or fuel injection
quantity is controlled under every possible driving
condition.
Fuel injector
The fuel injector is a 7-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the
fuel injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injectors according to ID code data in
memory. At the replacement of fuel injectors, ID code
data should be stored in ECM.
Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system WSHK0049
The preheating system consists the ECM, the glow • Insert a 0.4 mm (0.016 in) thickness gauge into a
relay, glow plugs and the glow indicator lamp. The clearance between the rocker arm and the bridge
preheating system is operated when the engine coolant to check it and adjust it if needed.
temperature is low, and make the engine easy to start.
Valve clearance mm (in)
Lubrication system
It is an oil filter with full-flow bypass, which uses a Intake valve 0.4 (0.016)
water-cool oil cooler and oil jet to cool the piston. Exhaust valve 0.4 (0.016)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-7
a. Completely loosen all of the bridge and rocker • With a thickness gauge kept inserted, tighten
arm adjusting nuts and adjusting screws an adjusting screw of the bridge lightly and
(4HK1: 8 nuts and 8 screws, 6HK1: 12 nuts and make sure that the tip of the adjusting screw
12 screws). touches the end of valve axis and the
b. Place a 0.4 mm (0.016 in) thickness gauge movement of the thickness gauge has become
between the No. 1 cylinder rocker arm end and tight.
the bridge cap. • Then, check if the end of the valve axis on the
c. Tighten the rocker arm adjusting screw until the opposite side is unstable or hits diagonally. If
thickness gauge is snug (not tight) between the so, loosen the bridge adjusting screw a little so
rocker arm end and the bridge cap. that the end of the valves on both sides may
touch properly.
d. Tighten the rocker arm lock nut.
Valve bridge clearance: ± 0.1 mm (0.0039 in) or
e. Tighten the bridge adjusting screw until the less
bridge contacts the valve head.
• After making an adjustment so that the end of
f. Tighten the bridge lock nut. the valves on both sides may touch properly,
g. Check that the thickness gauge is still held tighten up an adjusting screw nut of the bridge
snugly between the rocker arm end and the with a flathead screwdriver so that the bridge
bridge cap. If it is too tight, slightly loosen the adjusting screw may not rotate.
bridge adjusting screw and lock nut to restore Tightening torque: 22 N-m (2.2 kg-m/16 lb ft)
snugness.
h. Remove the thickness gauge. Caution:
i. Repeat the above procedure for the remaining If the adjusting screw of the bridge is poorly adjusted,
cylinders. the bridge would tilt and be pushed down and seized,
which may damage the bridge guide, for example.
Tightening torque: 22 N-m (2.2 kg-m/16 lb ft)
Thus, adjust it accurately.
3 2
LNW46ASH005101 LNW21BSH029801
Tightening torque:
Name
1. Rocker Arm Rocker arm adjustment 22 N-m (2.2 kg-m/16 lb ft)
2. Bridge Cap screw nut
3. Bridge Bridge adjustment screw 22 N-m (2.2 kg-m/16 lb ft)
nut
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1A-8 ENGINE MECHANICAL (4HK1, 6HK1)
Adjustment table (4HK1)
Cylinder No. 1 2 3 4
Valve arrangement IN EX IN EX IN EX IN EX
No. 1 cylinder
O O O O
Compression top dead center position
No. 4 cylinder
x x x x
Compression top dead center position
6HK1
LNW21BSH029901
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-9
4HK1
WSHK0003
Note:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
• Install the cylinder head cover.
Refer to the “Cylinder Head Cover”.
Compression pressure inspection
• Warm-up the engine.
• Remove a negative terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
built on the lower head cover (no fuel will be
injected). Name
1. Fuel Injection Harness Connector
Caution:
When the harness connector is removed, ECM judges
• Install the negative terminal of the battery.
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory • Turn on the starter to emit foreign matter within the
of ECM. cylinders.
(For how to clear memory of ECM, refer to the Engine • Install an adapter and a gauge of a compression
Control System Section) gauge of the special tool.
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1A-10 ENGINE MECHANICAL (4HK1, 6HK1)
PNW56ASH001901
6HK1
Compression pressure MPa (psi) / 200 rpm
Standard 3.24 (469)
Limit 2.26 (327)
Differences among
294 kPa (43)
the cylinders
Caution:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.
• Remove a negative terminal of the batteries.
• Install a harness connector for the fuel injector built
on the lower head cover.
• Install all the glow plugs.
Tightening torque: 20 N-m (2.0 kg-m/15 lb ft)
• Install the negative terminal of the battery.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-11
Main Data and Specifications
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1A-12 ENGINE MECHANICAL (4HK1, 6HK1)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-13
Special tool
tJ 5-8840-26750-0
J-26999-12
Compression gauge
EN-46722
Compression gauge
adapter
(4HK1)
5-8840-2622-0
Compression gauge
adapter
(6HK1)
'acaa= ^
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1A-14 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-15
6HK1
WSHK0005
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
Removal
1. Remove the head cover.
2. Remove the gasket.
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1A-16 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1 4HK1
PNW56ASH000101 PNW56ASH002401
Name Name
1. Head Cover 1. Head Cover Case
2. Fuel Injector Harness Connector
6HK1
6HK1
WSHK0007
Name
1. Head Cover Name
1. Head Cover Case
3. Remove the fuel injector harness connector. 2. Fuel Injector Harness Connector
4. Remove the head cover case.
5. Remove the gasket.
Installation
1. Install the gasket on the lower cover.
2. Install the head cover case.
Tightening torque: 4HK1: 18 N m (1.8 kg m/13 lb ft),
6HK1: 13 N m (1.3 kg m/9.6 lb ft)
3. Install the fuel injector harness connector.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-17
Caution: 4HK1
Push it in thoroughly until the claws of the lock raise.
4HK1
6HK1
PNW56ASH002401
Name
1. Head Cover Case
2. Fuel Injector Harness Connector
6HK1
WSHK0007
Name
1. Head Cover Case
2. Fuel Injector Harness Connector
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1A-18 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
4HK1
PNW56ALF000301
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-19
6HK1
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1A-20 ENGINE MECHANICAL (4HK1, 6HK1)
Inlet Cover
Components
4HK1
Name
1. Case ASM 4. Inlet Pipe
2. Inlet Cover 5. Reed Valve
3. Inlet Pipe Gasket
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-21
6HK1
WSHK0177
Name
1. Case ASM 4. Inlet Pipe
2. Inlet Cover 5. Reed Valve
3. Inlet Pipe Gasket 4. Bolt
Removal 4HK1
1. Remove the common rail.
Refer to the “Common Rail” in the fuel system
section.
2. Remove the inlet pipe.
3. Remove the case ASM.
• Remove the reed valve from the case ASM.
• Inspect the valve whether the carbon has not come
in contact around the valve.
PNW56ASH000201
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1A-22 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
Installation
1
1. Install the inlet cover.
• Apply the liquid gasket (ThreeBond 1207C or
equivalent) by using a bead diameter of 2.5 - 5.5
mm (0.1 - 0.2 in) along a groove of the inlet cover.
Caution:
• Be careful not to forget to fasten the bolt indicated
with an arrow.
• Tighten up the stud part together with the common
rail.
WSHK0236
Name
1. Boost Pressure Sensor
2. Bracket
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-23
2. Install the boost pressure sensor and bracket. Name
Apply Loctite to the bolt shown on the illustration 1. Case ASM
and install it. 2. Reed Valve
Tightening torque: 21.6 N-m (2.2 kg-m/16 lb ft) 3. Bolt
6HK1
i
WSHK0236
WSHK0179
Name
1. Boost Pressure Sensor Name
2. Bracket 1. Case ASM
2. Reed Valve
3. Install the reed valve to the case ASM 3. Bolt
• Apply the liquid gasket (Loctite 262) on the
5. Install the gasket on the inlet pipe and tighten up
mounting bolt and tighten it to the specified torque.
with the specified torque.
Tightening torque: 9.8 N-m (1.0 kg-m/7.2 lb ft) Tightening torque: 24 N-m (2.4 kg-m/18 lb ft)
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1A-24 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
4HK1
6HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-25
Name
1. Oil Feed Pipe 5. Turbo Charger ASM
2. Water Return Pipe 6. Exhaust Adapter
3. Exhaust Manifold 7. Oil Return Pipe
4. Water Feed Pipe
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1A-26 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
Name
1. Oil Feed Pipe 4. Exhaust Adapter
2. Exhaust Manifold 5. Oil Return Pipe
3. Turbo Charger ASM
Removal
1. Loosen the radiator drain cock to drain coolant.
(4HK1 only)
2. Remove the air intake duct from the turbocharger
and the air cleaner.
3. Remove the charge air pipe from the turbocharger
and the charge air cooler.
4. Disconnect the exhaust pipe.
5. Remove the EGR pipe.
6. Remove the oil feed pipe.
7. Remove the oil return pipe.
8. Remove the water feed pipe. (4HK1 only)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-27
• Remove the water return pipe. (4HK1 only) 6HK1
Name Name
1. Water Return Pipe 1. Exhaust Manifold
2. Turbocharger
9. Remove the heat protector on the turbocharger. 3. Exhaust Adapter
10. Remove the exhaust adapter bolts.
11. Remove the four turbocharger clamping nuts.
12. Remove the turbocharger from the exhaust Inspection
manifold. • Inspection of exhaust manifold
13. Remove the exhaust manifold. Inspect the plane surface of the plane on which the
4HK1 manifold and the cylinder head are to be installed.
Caution:
If the plane surface exceeds the limit, replace it.
PNW56ASH000501
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
PNW56ASH000601
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1A-28 ENGINE MECHANICAL (4HK1, 6HK1)
• Check a crack in the exhaust manifold visually. 6HK1
Carefully inspect the turbocharger for abrasion and/or
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.
Inspecting the turbocharger is refered to the “Turbo
chager” in the exhaust system section.
Installation
1. Put the gasket in to install the exhaust manifold.
• 4HK1: Tighten up with the 2 nuts and 6 bolts
according to the order given on the figure.
PNW56ASH000701
i 1
3 2 PNW56ASH000501
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-29
6HK1 Tightening torque: 41 N-m (4.2 kg-m/30 lb ft)
6. Install the water return pipe bracket. Tighten the
bolts to the specified torque. (4HK1 only)
4HK1
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
PNW56ASH000801
Name
1. Water Feed Pipe
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1A-30 ENGINE MECHANICAL (4HK1, 6HK1)
1
PNW56ASH000901
Name
1. Oil Return Pipe
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-31
Torque Specifications
4HK1
PNW56ALF000501
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1A-32 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
N- m(kg-m/lb -ft)
WSHK0015
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-33
WSHK0232
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1A-34 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Crankshaft Position Sensor
5. PTO Idle Gear Cover 11. Oil Pan
6. Flywheel 12. Fuel Supply Pump
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-35
6HK1
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Idle Gear A Shaft
5. PTO Idle Gear Cover 11. PTO Idle Gear Shaft
6. Flywheel 12. Oil Pump
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
3. Remove the camshaft ASM.
Refer to “Camshaft ASM”.
4. Remove the cylinder head ASM.
Refer to the “Cylinder Head”.
5. Remove the fuel supply pump ASM.
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1A-36 ENGINE MECHANICAL (4HK1, 6HK1)
Refer to “Fuel Supply Pump” in the fuel system
section.
V
LNW46CSH002301
7. Remove the flywheel.
* 4HK1 is shown for illustration. • Install the crankshaft stopper on the starter part of
6. Remove the crankshaft position sensor. the flywheel housing to stop the crankshaft from
• Remove the crankshaft position sensor before rotating.
remove flywheel.
Caution:
4HK1 Check if the stopper meshes with the ring gear without
fail and is installed properly.
Special tool
Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx)
LNW21BSH007701
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-37
Caution: • Never fail to remove the bolt(s) given on the figure.
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
x-xxxx-xxxx-x (For 4HK1)
8-9439-6858-0 (For 6HK1)
LNW21BSH053601
HCW31BSH019401
18. Remove the idle gear B shaft.
LNW21BSH003201
LNW21BSH003001 Inspection
* 4HK1 is shown for illustration. 1. Measurement of idle gear backlash
13. Remove the flywheel housing. • Apply a dial gauge on the teeth of the idle gear to
be measured and move the gear to right and left
lightly to read how much the dial gauge shook
(never fail to fix the gear).
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1A-38 ENGINE MECHANICAL (4HK1, 6HK1)
LNW21BSH003401
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-39
6HK1 6HK1
Outside diameter of idle gear shaft mm (in) Clearance between the idle gear and the mm (in)
shaft
Standard 29.959 - 29.980 (1.179 - 1.180)
Standard 0.020 - 0.062 (0.0007 - 0.0024)
Limit 29.9 (1.177)
Limit 0.200 (0.0079)
External diameter of the idle gear A shaft mm (in)
Clearance between the idle gear A and the mm (in)
Standard 49.950 - 49.975 (1.967 - 1.968)
shaft
Limit 49.9 (1.965)
Standard 0.025 - 0.075 (0.0010 - 0.0030)
Limit 0.200 (0.0079)
4HK1
Tightening torque: 31 N-m (3.2 kg-m/23 lb ft)
Clearance between the idle gear and the mm (in) • After installation, apply engine oil to the shaft.
shaft
Standard 0.020 - 0.062 (0.0007 - 0.0024)
Limit 0.200 (0.0079)
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1A-40 ENGINE MECHANICAL (4HK1, 6HK1)
LNW21BSH003801
Name
1. Idle Gear
2. Thrust Collar
3. Bolt
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-41
Name
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. PTO Gear 9. Idle Gear A
5. PTO Idle Gear
LNW21BSH033201
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1A-42 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1 • Align with the knock pin of the cylinder block and
install the flywheel housing.
4HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-43
WSHK0044
• Put the idle gear and the shaft together and install
it on the location given on the figure and tighten up
with the specified torque.
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1A-44 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
LNW21BSH004301
• Install the O-ring on the cover and install it on the 9. Install the oil pan.
flywheel housing and tighten up the tightening • Apply the liquid gasket (ThreeBond 1207B or
bolts with the specified torque. equivalent) on a joint between the cylinder block,
the front cover and the flywheel housing with a
Tightening torque: 19 N-m (1.9 kg-m/14 lb ft) beat diameter of 3 mm (0.12 in).
LNW21BSH004401
LNW21BSH004601
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-45
1 2
PNW56ASH001101
3
LNW21BSH013801
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1A-46 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
• Fastening the oil pan from the part of A or B in
clock wise order.
• It tightens again by specified torque.
WSHK0197
Special tool
4HK1
Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx)
6HK1
Oil seal setting tool: 8-94396-856-0
• Install the slinger (1) to the end of adapter (2).
Install the adapter to the crankshaft (3).
• Install the slinger sleeve (4) to the adapter. Tighten
the center bolt (5) until the sleeve comes in contact
with the adapter stopper.
4
Distance (B): 10.8±0.1 mm (0.4±0.004 in)
LNW21BSH073201
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-47
6HK1
WSHK0199
Distance (A): 17±0.3 mm (0.7±0.01 in) distance between crankshaft end surface and the
oil seal as specified.
Caution: 4HK1
Be sure to replace the slinger and oil seal as a set.
11. Install the rear oil seal using installer, setting tool.
4HK1
Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx)
6HK1
Oil seal setting tool: 8-94396-856-0
• Apply engine oil to the oil seal lip.
Caution:
Do not allow engine oil to come in contact with the
outside oil seal and felt ring.
• Insert the oil seal (1) into the adapter (2).
• Insert the oil seal sleeve (3) to the adapter.
• Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
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1A-48 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1 13. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
14. Remove the oil drain adapter.
15. Install the O-ring on the fuel supply pump and
make the slits with an arrow meet and with the stud
bolt as a guide, install the fuel supply pump
tentatively.
Caution:
• When removing the fuel supply pump, if the stud
bolt on the cylinder block side loosens, or the stud
bolt is replaced, apply the Loctite No. 262 on the
side where the stud bolt is to be buried before
assembly.
WSHK0203
Tightening torque:
1st step = 78 N-m (8.0 kg-m/58 lb ft)
2nd step = 60°
3rd step = 60°
LNW46CSH002001
LNW21BSH072801
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-49
17. Install the cylinder head ASM.
Refer to the “Cylinder Head”.
18. Install the camshaft ASM.
Refer to “Camshaft ASM”.
19. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
20. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
Name
1. Plug Hole
2. Alignment Mark
16. Install the oil drain adapter ASM on the plug hole
and tighten with the specified torque.
Tightening torque: 6 N-m (0.6 kg-m/53 lb in)
• Apply engine oil over the O-ring nice and thin and
install it.
Name
1. Adapter
2. O-Ring
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1A-50 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
N-m{kg-m/lb-ft}
31 {3.2 / 23}
19 {1.9 / 14}
78 {8 / 58} -» 6 0 ° >60
30 {3.1 / 22}
W S H K 0 06 5
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-51
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
x-xxxx-xxxx-x
xx-xxxxx
Crankshaft stopper
Rank B
Al 1-8521-0027-0
Slinger remover
ITS
Rank B
x-xxxx-xxxx-x
x-xxxxx
Oil seal installer kit
ef®
(4HK1)
Rank A
8-9439-6856-0
Oil seal setting tool
(6HK1)
Rank A
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1A-52 ENGINE MECHANICAL (4HK1, 6HK1)
LNW21BLF003701
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
• Along with the camshaft bracket, remove the
rocker arm shaft ASM.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-53
• Because the bolt(s) shown on the figure is are 6. Remove the camshaft bracket to take the shaft out.
designed to fix the rocker arm shaft, do not remove
it for now.
Name
Caution: 1. Camshaft Bracket
Pay full attention so as not to drop the bridge cap in the 2. Rocker Arm
gear case of the rear part of the cylinder head or the 3. Wave Washer
hole into which oil pours back in the front. 4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
Disassembly 7. Rocker Arm Shaft
1. Remove the camshaft bracket.
2. Remove the rocker arm. 7. Check if the oil hole is clogged of the camshaft
bracket (on the rear side).
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
• Disassemble according to the order (2) - (4)
thereafter.
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1A-54 ENGINE MECHANICAL (4HK1, 6HK1)
• If the bend of the shaft exceeds the limit, replace 10. Inspect a clearance between the rocker arm and
the shaft. the rocker arm shaft.
• Use a cylinder gauge to measure an inside
diameter of the bushing of the rocker arm to
Bend of the rocker arm shaft mm (in)
measure a clearance between the external
Limit 0.3 (0.012) diameter of the shaft.
Standard 22.0 (0.866) 11. Inspect a clearance between the roller of the
Limit 21.85 (0.860) rocker arm and the rocker arm pin.
a. Pass a string, for instance, through an opening
between the rocker arm and the roller, pull it in
the direction indicated with an arrow strongly
and measure the gap between the rocker arm
and the roller with the roller stuck out. Figure 1
b. After marking the measuring point, pull the
string out and measure the gap of the marked
place with the roller pushed deep into the end.
Figure 2
c. The gap between the measurement taken
under a. and that under b. will be a clearance
between the roller and the rocker arm pin. If it
exceeds the limit, replace the rocker arm.
LNW21BSH019101
Limit 0.2 (0.0079)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-55
LNW21BSH033101
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1A-56 ENGINE MECHANICAL (4HK1, 6HK1)
Installation
1. Install the rocker arm shaft ASM.
• If the bridge cap comes off, apply engine oil over
the inside of the bridge cap and put it together with
the bridge.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
Tightening torque:
4HK1
Bolt (3) = 56 N-m (5.7 kg-m/41 lb ft)
Nut (1), Bolt (2), (4) = 27 N-m (2.8 kg-m/20 lb ft)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-57
Name
1. Camshaft Bracket Fixing Nut
2. Camshaft Bracket Fixing Bolt
3. Rocker Arm Bracket Fixing Bolt
4. Rocker Arm Shaft Set Bolt
6HK1
Nut (1) - (4) and Bolt (10) - (13) =
27 N-m (2.8 kg-m/20 lb ft)
Bolt (5) - (9) = 56 N-m (5.7 kg-m/41 lb ft)
4 6 8 9 7 5 3
11 12 13 10
WSHK0204
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1A-58 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
27 { 2.8 / 20}
LNW46AMF000901
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-59
Camshaft ASM
Components
4HK1
Name
1. Bearing Cap 3. Knock Pin
2. Bearing 4. Camshaft Gear
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1A-60 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
Name
1. Bolt 7. Sub Gear
2. Washer 8. Dish Spring
3. Gear 9. Snap Ring
4. Pin 10. Pin
5. Spring 11. Camshaft
6. Pin
Removal Caution:
Put the removed bearings in order with a tag, for
1. Remove the cylinder head cover.
Refer to ‘ Cylinder Head Cover". example' by cylinder
2. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
5. Remove the camshaft ASM.
6. Remove the bearing lower.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-61
1 2 3 4 5
WSHK0057
Name
Disassembly 1. Snap Ring
1. Remove the scissors gear ASM. (6HK1) 2. Dish Spring
3. Sub Gear
• Fix the hexagon portion of the camshaft in a vise
4. Spring
using a mouth ring. Use snap ring pliers to remove
5. Camshaft Gear
the sub gear.
2. Remove the camshaft gear.
Caution:
Take care not to damage to the cam portion and the • Remove the fastening bolts of the camshaft gear
journal portion of the camshaft. and put the block of wood in a puller to remove the
camshaft gear.
WSHK0056
LNW21BSH056201
Name
1. Wood
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1A-62 ENGINE MECHANICAL (4HK1, 6HK1)
• If the height of the cam lobe is the limit or less,
replace the camshaft.
LNW21BSH020201
Standard 0.085 - 0.205 (0.033 - 0.008) 7. Check if the camshaft journal is worn.
Limit 0.25 (0.009) • Use a micrometer to measure wear which is not
even with a diameter of the camshaft journal.
Caution:
• If the measured uneven wear exceeds the limit,
Measure an end clearance of the camshaft before
replace the camshaft.
disassembling.
LNW21BSH020301
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-63
LNW21BSH020501
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
LNW21BSH020601
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1A-64 ENGINE MECHANICAL (4HK1, 6HK1)
• Fix the hexagon portion of the camshaft in a vise • Before installing the camshaft to the cylinder head,
using a mouth ring. Assemble the spring with its rotate the sub gear using the special tool to
left end contacting the pin of camshaft main gear to prevent the spring force which acts on the sub
make a gap on the right. gear from affecting. Align the hole of the sub gear
• Assemble the sub gear so that its pin is inserted with the camshaft main gear and install the phase
into the gap between the right side of pin of the alignment pin from the sub gear side to match the
camshaft main gear and the right end of the spring. teeth.
Special tool
Scissors gear spring wrench: 5-8840-2674-1
1 2 3 4 5
WSHK0057
Name WSHK0244
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-65
Fixing torque
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
5-8840-2674-1
Scissors gear spring
wrench
Rank A
WSHK0245
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1A-66 ENGINE MECHANICAL (4HK1, 6HK1)
Installation 4HK1
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
4HK1
LNW46AS H001301
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-67
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1A-68 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-69
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1A-70 ENGINE MECHANICAL (4HK1, 6HK1)
8. Remove the valve spring.
Put the removed valve springs in order by cylinder
number.
9. Remove the valve stem oil seal.
• Use pliers to remove the oil seal.
LNW21BSH031301
Name
1. Bridge Cap
2. Bridge
Caution:
LNW218SH056801
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front. Caution:
Do not reuse the removed oil seal.
6. Remove the split collar.
• Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home Inspection
position.
Check the valve spring.
• Use a replacer to compress the valve spring to Caution:
remove the split collar. Check the valve spring visually and if there is clear
damage or wear-out, replace it.
Special tool 1. Free length
Valve spring replacer: 5-8840-2621-0 (J-43263)
• Measure free length of the spring and if it is shorter
Pivot: 8-9439-6862-0 (EN-46721)
than the specified limit, replace the spring.
4HK1
6HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-71
4HK1
6HK1
6HK1
LNW21BSH056701
Installation
1. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a valve
stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
LNW21BSH017101
3. Tension
• Use a spring tester to compress the spring to the
installation height. Measure tension of the
compressed spring. If the measurement is lower
than the limit, replace the spring.
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1A-72 ENGINE MECHANICAL (4HK1, 6HK1)
Special tool 3. Install the spring upper seat.
4HK1 4. Install the split collar.
Valve stem seal installer: 8-9439-6815-0 (EN-47685) • Apply compressed air over the cylinder from the
6HK1 glow plug holes to keep the valve at the home
Valve guide oil seal installer: 5-8840-2625-0 (J- position.
43267)
• Use a replacer to compress the valve spring and
install the split collar.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 8-9439-6862-0 (EN-46721)
LNW21BSH031901
Paint mark 5. Apply engine oil over the bridge and install it.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
PNW56ASH001201
Name
1. Spring Pitch
2. Paint Mark
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-73
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
5-8840-2621-0
J-43263
Valve spring remover
Rank B
Name
1. Bridge Cap
2. Bridge
\_ 8-9439-6862-0
EN-46721
Pivot ASM
Rank B
8-9439-6815-0
Refer to “Camshaft ASM”.
EN-47685
8. Install the rocker arm shaft ASM. Valve stem seal installer
Refer to “Rocker Arm Shaft ASM”. (4HK1)
9. Install the cylinder head cover. / / Rank B
Refer to “Cylinder Head Cover”.
0_
5-8840-2625-0
J-43267
Valve guide oil seal
installer
(6HK1)
Rank B
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1A-74 ENGINE MECHANICAL (4HK1, 6HK1)
Cylinder Head
Components
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the ‘OFF’ position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Disconnect the exhaust pipe.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-75
4. Remove the turbocharger.
Refer to the “Turbocharger and Exhaust Manifold”.
5. Remove the left-hand EGR adapter and right-hand
EGR pipe.
6. Remove the EGR water feed pipe.
7. Remove the EGR water return pipe.
8. Remove the EGR cooler.
9. Remove the water feed pipe for coolant water for
the EGR cooler and the water return pipe.
2 4
PNW56ASH002501
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal Nut
4. Nozzle Leak-Off Pipe
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
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1A-76 ENGINE MECHANICAL (4HK1, 6HK1)
Name Name
1. High Pressure Pipe 1. Water Bypass
2. Leak-Off Pipe
20. Remove the EGR valve and EGR valve connector.
19. Remove the water bypass hose from the cylinder 21. Remove the cam angle sensor connector.
head side.
22. Remove the rocker arm shaft ASM.
• Remove the engine coolant temperature sensor Refer to “Rocker Arm Shaft ASM”.
connector.
23. Remove the camshaft ASM.
4HK1 Refer to “Camshaft ASM”.
24. Remove the bridge cap carefully so that it does not
fall into inside the engine.
25. Remove the bridge.
Caution:
Store the removed bridge and bridge cap so that they
can be placed in their original locations.
26. Remove the glow plug connector.
27. Remove the glow plug.
PNW56ASH001701
Name
1. Water Bypass
LNW21BSH055301
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-77
28. Remove the injection pipe clip, and remove the 31. If you have difficulty in removing the fuel injector,
injection pipe. set the fuel injector remover in the fuel injector,
tighten the attachment part on the joint of the leak-
Important: off pipe and pull out the fuel injector upward.
Do not reuse the high-pressure pipe in fuel system if it
has been removed. Special tool
4HK1 Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)
Caution:
When pulling out the fuel injector using a special tool,
check that the fuel injector sleeve does not come off.
PNW56ASH001801
Name
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
6HK1
Name
1. Sliding Hammer
2. Fuel Injector Remover
3. Fuel Injector ASM
Caution:
Attach a cylinder number to the removed fuel injector
when storing it.
Be sure not to make the nozzle touch something.
Name
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
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1A-78 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
WSHK0236
Name
1. Boost Pressure Sensor
2. Bracket
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-79
LNW21BSH054701
LNW21BSH055601
Name
1. Idle Gear C
2. Shaft
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1A-80 ENGINE MECHANICAL (4HK1, 6HK1)
14. Remove the intake and exhaust valves. 16. Remove the valve guide.
• Sort the removed valves according to cylinders by • Use the valve guide replacer to press out the
using tags and others. valve guides from the bottom side of the cylinder
head.
Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272)
LNW21BSH016801
Special tool
Nozzle sleeve remover: 5-8840-2623-0 (J-43265)
Caution:
• Be sure not to scratch the bottom side of the
cylinder head.
• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-81
Name
1. Nozzle Sleeve Inspection
1. Check the cylinder head ASM.
18. Remove the bridge guide.
• Remove varnish, soot and others adhered on the
• Electrically weld the nut on the head of the bridge
metal surface completely. Use metal brush and
guide, attach the sliding hammer and pull it out.
others so that the seal surface of the surface
where the gasket is installed is not hurt.
- Improper installation
- Defective tightening of the cylinder head.
- Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening torque
Caution:
Replace suspicious bolt.
b. Inside the combustion chamber, glow plug hole.
LNW21BSH058201
Name
1. Nut
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1A-82 ENGINE MECHANICAL (4HK1, 6HK1)
• Check whether there is a crack between the • Use a straight edge ruler and thickness gauge
valve seats and in the cylinder head of the to measure the four sides and diagonal lines as
exhaust port part, and replace the cylinder head shown in the drawing, and replace if they
if there is serious damage or crack. Check the exceed the limit.
collar if necessary.
Distortion of the surface where the mm (in)
manifold and cover are installed
Standard 0.05 (0.002) or less
Limit 0.2 (0.0079)
LNW21BSH032401
LNW21BSH032501
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-83
Gap mm (in)
Assembly standard 0.020 (0.00079) -
0.057 (0.00224)
Usage limit 0.1 (0.0039)
PNW56ASH000601
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1A-84 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1
LNW21BSH017401
6HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-85
4HK1
6HK1
Valve seat
• Remove carbon, water stain and others on the
under surface of the cylinder head.
Install the valve in the cylinder head.
Measure the depth of the valve from the under
surface of the cylinder head, using a depth
gauge or straight edge ruler.
If the value exceeds the limit, replace the valve
insert or the cylinder head ASM.
4HK1
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1A-86 ENGINE MECHANICAL (4HK1, 6HK1)
Repair of the seat surface • Attach compound in the valve insert seat.
• Remove carbon from the surface of the valve • Insert the valve into the valve guide.
seat. • Attach compound on the valve seat surface,
• Use a seat cutter to minimize the scratch and rotate the valve and hit it lightly to grind them,
other roughness (15/45/75°-blade), thereby and confirm that it has even contact all round.
returning the contact width to the standard
value. Caution:
Remove compound completely after grinding.
LNW21BSH018201
LNW21BSH031801
Caution:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Do not let the valve cutter pilot waver inside the valve
guide.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-87
Replace the valve seat insert
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve
seat insert.
• Cool the valve seat insert for two to three
minutes. Contraction fur to cooling makes it
easier to remove the valve seat insert.
• Remove the valve seat insert, using a screw
driver. Be sure not to hurt the cylinder head.
Name
1. Washer
2. Valve Seat
3. Press
Reassembly
LNW21BSH056001 1. Install the oil seal.
• Install on the surface of injection pipe insert.
Name
1. Arc-Weld • Hammer it in so that the seal does not incline.
2. Valve Seat Insert
3. Screw Driver Caution:
Be sure not to hurt the rip.
Install the valve seat insert Special tool
• Carefully place a washer (the outer diameter is Oil seal installer: 5-8840-2627-0 (J-43269)
smaller than the valve seat insert) on the valve
seat insert.
• Use the press to apply pressure gradually on
the washer, thereby pushing the valve seat
insert.
• After replacement of the valve seat, Attach
compound on the valve seat surface, rotate the
valve and hit it lightly to grind them, and confirm
that it has even contact all round.
Caution:
Do not apply too much pressure with the press.
Remove compound completely after grinding.
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1A-88 ENGINE MECHANICAL (4HK1, 6HK1)
LNW21BSH058301
Name
1. Cylinder Head
2. Oil Seal Installer
• Insert the sleeve and fix it with the tighten and bolt.
Caution:
• Leave the cylinder head floating so that the ball
comes off from the under surface.
LNW21BSH058401
3. Nozzle sleeve
• Install the O-ring on the nozzle sleeve, apply
engine oil.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-89
Special tool Special tool
Nozzle sleeve installer: 5-8840-2624-0 (J-43266) Valve guide replacer: 5-8840-2628-0 (J-43272)
LNW21BSH031601
Caution:
When replacing the valve guide, it must be replaced
together with the valve.
LNW21BMH001001
Name
1. Punch Bar
2. Ball
3. Guide Sleeve
4. Nozzle Sleeve
5. Bracket
6. Bolt
LNW21BSH017701
Caution:
After installation of the valve stem seal, confirm that the
oil seal is not inclining and the garter spring is in place.
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1A-90 ENGINE MECHANICAL (4HK1, 6HK1)
Special tool
4HK1
Valve stem seal installer: 8-9439-6815-0 (EN-47685)
6HK1
Valve guide oil seal installer: 5-8840-2625-0 (J-
43267)
PNW56ASH001201
Name
1. Spring Pitch
2. Paint Mark
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 8-9439-6862-0 (EN-46721)
LNW21BSH018801
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-91
Name
Name 1. Thermostat
1. Idle Gear C
2. Shaft 6HK1
Special tool
Sealing cup installer: 5-8840-2222-0 (EN-47690)
WSHK0024
Name
1. Thermostat
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1A-92 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
CZZZZD LNW21BSH001701
PNW56ASH001301
Name
6HK1
1. Distance Tube
2. Conical Spring
3. Nut
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
4HK1
WSHK0025
PNW56ASH000701
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-93
6HK1 4HK1
6 9
WSHK0014 LNW46ASH002701
• Tighten the stud bolts (6) and (9) jointly with the
common rail.
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1A-94 ENGINE MECHANICAL (4HK1, 6HK1)
LNW21BSH068001
WSHK0236
PNW56ASH000301
Installation
1. Install the cylinder head gasket.
• Select the cylinder head gasket. (4HK1 only)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-95
LNW21BSH015501
LNW46ASH001601
Name
1. Grade Recognition Hole
Caution:
Be sure not to hurt the head gasket when installing it.
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1A-96 ENGINE MECHANICAL (4HK1, 6HK1)
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
4HK1
13 5 4 12
LNW21BSH007901
Tightening torque:
M14 bolt (4HK1: 1 - 1 8 , 6HK1: 1 - 2 6 )
1st step = 98 N m (10.0 kg m/72 lb ft)
2nd step = 147 N m (15.0 kgm/108 lb ft)
3rd step = 30° - 60°
M10 bolt (4HK1: 19, 20; 6HK1: 27, 28)
4th step = 38 N m (3.9 kg m/28 lb ft)
Use a stud bolt for (4HK1: 16).
WSHK0027
Important:
Reinstall each fuel injector to the original cylinder from
which it was removed during the disassembly
procedure.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-97
LNW46ASH004301
Name
1. Fuel Injector ASM
2. Fuel Injector Tighten Bolt
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1A-98 ENGINE MECHANICAL (4HK1, 6HK1)
PNW56ASH002701 LNW21BSH031301
Caution:
Move it up and down to check if it moves smoothly.
12. Apply a thin coat of engine oil inside the bridge
cap, install it.
LNW46ASH001501
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-99
• Install the fuel leak-off hose on the fuel leak-off 4HK1
pipe and fix it with a clip.
6HK1
LNW21DSH003401
Caution:
MFW41BSH026201 • Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
20. Install the fuel injector harness connector from
unified.
inside, tighten the harness bracket with the
designated torque. • Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
Tightening torque: 48 N-m (4.9 kg-m/35 lb ft)
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1A-100 ENGINE MECHANICAL (4HK1, 6HK1)
26. Connect the exhaust pipe.
27. Install the engine harness.
28. Replenish the coolant.
Name
1. Fuel Injector
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-101
Torque Specifications
Special Tool
Tool Number/Description/ Tool Number/Description/
Illustration Illustration
Special Tool Rank Special Tool Rank
8-9439-6815-0
5-8840-0019-0
EN-47685
J-23907
Valve stem seal installer
Sliding hammer
(4HK1)
Rank B
- Rank B
0
5-8840-2625-0
5-8840-2628-0 J-43267
J-43272 Valve guide oil seal
Valve guide remover installer
Rank B ^
(6HK1)
Rank B
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1A-102 ENGINE MECHANICAL (4HK1, 6HK1)
5-8840-0266-0
5-8840-2621-0
J-45059
J-43263
KM470-B
Valve spring remover
Angle gauge
Rank B
Rank B
V
5-8840-2624-0 8-9439-6862-0
J-43266 EN-46721
Nozzle sleeve installer Pivot ASM
Rank A Rank B
^L
5-8840-2626-0 5-8840-2222-0
J-43268 EN-47690
Bridge guide installer Seal ring installer
Rank A Rank A
5-8840-2627-0
J-43269
Oil seal installer
Rank A
5-8840-2623-0
J-43265
Nozzle sleeve remover
Rank A
5-8840-2826-0
EN-46720
Injector remover
Rank A
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-103
Name
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
1. Remove the oil pan.
Refer to “Oil Pan”.
2. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
3. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
4. Remove the camshaft ASM.
Refer to “Camshaft ASM”.
5. Remove the cylinder head.
Refer to the “Cylinder Head”.
6. Remove the connecting rod cap.
Caution:
Sort the removed bearings according to cylinders by
using tags.
LNW21BSH004901
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1A-104 ENGINE MECHANICAL (4HK1, 6HK1)
• Remove carbon on the upper side of the cylinder
liner with a scraper.
Caution:
Be sure not to damage the oil jet and cylinder liner
when pushing out the connecting rod.
LNW21BSH005101
Caution:
Sort the disassembled piston pins, pistons and
connecting rods together in the order of cylinders.
LNW21BSH005001
Caution:
Sort the bearings in the order of cylinders when reusing
them so that they will not be confused with the bearing
of other cylinders.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Caution:
Sort the piston rings in the order of cylinders when
reusing them so that they will not be confused with the
pistons and piston rings of other cylinders. LNW21BSH005201
Caution:
Do not use wire brush to clean the piston because it
scratches the piston.
Inspect the piston with eyes for cracks, burns and other
excessive wear, and replace it if there is any
abnormality.
6. Measure the gap between the piston and the inner
diameter of the cylinder liner.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-105
Cylinder liner inner diameter Gap between the piston and the inner mm (in)
• Use a cylinder bore dial indicator to measure the diameter of the cylinder liner
liner inner diameter both in the thrust and radial
Standard 0 .0 8 2-0.1 3 0
directions in the designated position.
(0.0032-0.0051)
• Measurement position (from the upper surface of
the cylinder block) 6HK1
1. 20 mm (0.79 in) 2. 110 mm (4.33 in)
3. 190 mm (7.48 in) Piston diameter mm (in)
• Measure the liner inner diameter based on the Standard 114.974 - 114.989
average value of the actual measurement values (4.52652 -4.52711)
on 6 positions.
Gap between the piston and the inner mm (in)
Cylinder liner inner diameter mm (in) diameter of the cylinder liner
Caution:
If it is found that the gap between the cylinder liner
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder liner.
LNW21BSH009001
Name
1. 20 mm (0.79 in)
2. 110 mm (4.33 in)
3. 190 mm (7.48 in) LNW21BSH009101
7. Piston replacement
Piston outside diameter
• You do not need to select grades because there is
• Use a micrometer tomeasure the outsidediameter
only one grade for each of the piston and the
of the piston in the right angle to thepiston pin in
cylinder liner inner diameter.
the designated position.
If you replace the cylinder liner, you must select
• Measurement position (from the upper surface of the cylinder block (1, 2, 3) because there are two
the piston) 82 mm (3.2 in). types of the liner outer diameter.
• Refer to “Cylinder Block” if you replace the cylinder
4HK1 liner.
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1A-106 ENGINE MECHANICAL (4HK1, 6HK1)
• Insert the piston ring into the cylinder liner. Top ring 0.18 - 0.28 1.2
(0.0071 - 0.0110) (0.047)
• Use the piston to push the ring to reach the under
Second ring 0.35 - 0.50 1.2
edge of the cylinder liner.
Third ring (0.0138 - 0.0197) (0.047)
Oil ring 0.15 - 0.35 1.2
(0.0059 - 0.0138) (0.047)
LNW21BSH009301
Piston ring and piston ring groove mm (in)
• Use a thickness gauge to measure the gap of the clearance
ring joint.
Piston ring Standard Limit
Top ring 0.057 - 0.097 0.20
(0.0022 - 0.0038) (0.0079)
Second ring 0.085 - 0.120 0.20
Third ring (0.0033 - 0.0047) (0.0079)
Oil ring 0.020 - 0.060 0.20
(0.0008 - 0.0024) (0.0079)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-107
LNW21BSH009601
LNW21BSH009501
4HK1 LNW21BSH009701
6HK1
Piston pin and connecting rod small end mm (in)
Piston pin outer diameter mm (in) bushing clearance
Standard 40.0 (1.5748) Standard 0.012 - 0.027
(0.0005 - 0.0011)
Limit 39.95 (1.5728)
Limit 0.05(0.0020)
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1A-108 ENGINE MECHANICAL (4HK1, 6HK1)
Standard 0.004 - 0.017 (0.00016 - 0.00067) • Use the bench press to replace the bush.
Limit 0.04 (0.0016)
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
11. Remove the bushing. (EN-47682)
• Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
LNW21BSH010001
Name
1. Bolt
2. Connecting Rod Bushing Replacer
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-109
Use a connecting rod aligner to measure the
torsion and parallel level of the big end hole and
the small end hole. If the measured value exceeds
the limit, replace it.
LNW21BSH010501
Install the bearing cap and tighten the bolt with the
designated torque.
Apply molybdenum disulfide on the screw part and
the bearing surface. LNW21BSH010601
Connecting rod bearing cap bolt torque: N-m 14. Select the connecting rod bearing.
(kg-m/lb ft) • Refer to the bearing selection table when installing
1st step 39 (4.0/29) a new connecting rod or replacing bearings in use.
CD
O
2nd step
O
3rd step
o
Caution:
Do not rotate the crankshaft.
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1A-110 ENGINE MECHANICAL (4HK1, 6HK1)
Reassembly
1. Install the bush
• Place the connecting rod bushing replacer base on
the bench press, set the connecting rod and
tighten the fixation bolt.
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
(EN-47682)
LNW21BSH028401
Name
1. Recognition Boss: When putting, 4HK1:Front,
6HK1:Back
2. Big End Diameter Grade Mark
3. Cylinder Number
• Adjust the oil hole of the connecting rod and the oil
hole of the bush, and use the bench press to install
the bush.
LNW21BSH010801
Name
1. Grade Identification Color
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-111
• 6HK1: Install it so that the front mark of the head of
the piston and the connecting rod forging mark
(projecting) on the connecting rod face the
opposite direction.
Name
1. Setting Bar
2. Connecting Rod
3. Nut
4. Collar
5. Bushing LNW46ASH004601
6. Collar
Name
After installing the new bush, use a grinder to 1. Snap Ring
machine the pin hole so that the pin clearance 2. Front Mark
equals the standard value. 3. Forging Mark (Projecting): 4HK1: Front, 6HK1:
Back
Caution:
Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.
LNW21BSH011001
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1A-112 ENGINE MECHANICAL (4HK1, 6HK1)
• Install the oil ring so that the joint angle of the ring Installation
and coil expander is in the opposite 180° direction.
1. Install the connecting rod bearing.
• Install the piston ring so that the marks “N” face • Install the bearing on the connecting rod, apply
upward. engine oil on the bearing.
Special tool
Piston ring setting tool: 1-8522-1029-0 2. Install pistons and connecting rod ASM.
• Apply enough engine oil on the piston ring, ring
groove and piston side surface.
Caution:
• Be sure not to make the connecting rod touch the
oil jet when pushing in the piston.
• Be sure not to hurt the inside of the liner when
pushing in the piston.
Special tool
WSHK0183
Piston ring compressor: 5-8840-9018-0 (J-8037)
Name
1. Top Ring
2. Second Ring
3. Third Ring
4. Oil ring
Caution:
Note that the shapes are different for each piston ring.
Make sure that there is not gap in the position indicated
in the drawing when the oil ring coil expander was
installed.
W SHK0187
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-113
5. Install the camshaft ASM.
Refer to “Camshaft ASM”.
6. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”
7. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
8. Install the oil pan.
Refer to “Oil Pan”.
Name
1. Recognition Boss: When putting, 4HK1:Front,
6HK1:Back
2. Big End Diameter Grade Mark
3. Cylinder Number
Tightening torque:
1st step = 39 N-m (4.0 kg-m/29 lb ft)
2nd step = 60°
3rd step = 30°
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Make sure that the crankshaft rotates smoothly.
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1A-114 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
WSHK0182
Special Tool
Tool Number/Description/ Tool Number/Description/
Illustration Illustration
Special Tool Rank Special Tool Rank
5-8840-2340-0
EN-47682 x-xxxx-xxxx-x
Connecting rod bushing Piston ring setting tool
remover Rank B
Rank B
<e_ x-xxxx-xxxx-x
x-xxxx
Piston ring compressor
Rank B
C?
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Rank B
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-115
Flywheel
Components
Name
1. Flywheel Housing 3. Washer
2. Flywheel ASM 4. Crankshaft Position Sensor
Removal 4HK1
1. Remove the starter motor.
• Remove the ground cable of the starter motor.
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1A-116 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1 Special tool
Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx)
LNW21BSH007701
• Remove to prevent contact damage when the • Gradually loosen the flywheel installation bolts in
flywheel is removed. the order shown in the drawing so that the flywheel
does not rotate.
• Do not throw or drop because it is vulnerable to
shock. • After loosening all the bolts, remove the stopper to
* 4HK1 is shown for illustration. remove the flywheel.
LNW21BSH072801
3. Remove the washer and flywheel. 4. Take out the ring gear.
• Install the crankshaft stopper to the starter • Put a bar on the ring gear and hit it with a hammer
installing portion of the flywheel housing. to remove it.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-117
PNW56ASH002001
Inspection Installation
1. Visual check 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks and • After heating the ring gear with a gas burner
damages, and replace it if it has abnormality. equally, install it in the flywheel.
• Inspect the tooth part of the ring gear, replace the • In the case of shrinkage cooling of the ring gear,
ring gear if it has damage or serious wear. maintain the flatness by applying weight of 68.6 kN
(15,400 lbf).
2. Measurement of the friction surface
• Measure the depth of the flywheel friction surface. Caution:
• Install the ring gear so that the side with a pattern
• Adjust it if the measured value is within the faces forward.
standard value and the limit.
• Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
• If the measured value exceeds the limit, replace
complete.
the flywheel.
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1A-118 ENGINE MECHANICAL (4HK1, 6HK1)
• Apply molybdenum disulfide on the screw part and 4HK1
setting face of the bolt.
Tightening torque:
1st step = 78 N-m (8.0 kg-m/58 lb ft)
2nd step = 120° - 150°
Special tool
Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx)
Angle gauge: 5-8840-0266-0 (J-45059)
6HK1
LNW21BSH007701
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-119
Torque Specifications
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
x-xxxx-xxxx-x
xx-xxxxx
Crankshaft stopper
Rank B
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Rank B
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1A-120 ENGINE MECHANICAL (4HK1, 6HK1)
Front Cover
Components
4HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-121
6HK1
Name
1. Front Cover 7. Fan Belt
2. Oil Pan Gasket 8. Water Pump Pulley
3. Oil Pan 9. Spacer
4. Front Oil Seal 10. Fan ASM
5. Crankshaft Pulley 11. Adjusting Plate
6. Water Pump ASM 12. Generator
Removal • Remove the oil relief valve (arrow), loosen the front
cover installation bolts and remove the front cover.
1. Remove the front oil seal.
Refer to “Crankshaft Front Oil Seal”.
2. Remove the oil pan.
Refer to “Oil Pan”.
3. Remove the water pump.
Refer to the “Water Pump” in the cooling system
section.
4. Remove the front cover.
• Remove the generator adjust plate. (6HK1 only)
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1A-122 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
Installation Name
1. O-Ring
1. Install the front cover.
• Clean the cylinder block front surface. In particular, 6HK1
remove liquid gasket leaked during installation of
the crankcase.
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
Name
1. O-Ring
Caution:
Along with the front cover, install the water pump ASM
(before liquid gasket hardens).
4HK1
Tightening torque
Front cover bolt (1): 23.5 N-m (2.4 kg-m/17 lb ft)
Front cover bolt (2): 52 N-m (5.3 kg-m/38 lb ft)
Front cover bolt (3): 23.5 N-m (2.4 kg-m/17 lb ft)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-123
• Tighten the oil relief valve (4) to the specified
torque.
Tightening torque
Oil relief valve: 39 N-m (4.0 kg-m/29 lb ft)
WSHK0032
6HK1
Tightening torque
Front cover bolts (13 bolts): 18 N-m (1.8 kg-m/13
lb ft)
• Tighten bolt with (*) mark together with the adjust
plate of the generator.
Tightening torque
Stud bolt for water pump: 12.7 N-m (1.3 kg-m/9.4
lb ft)
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1A-124 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
4HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-125
6HK1
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1A-126 ENGINE MECHANICAL (4HK1, 6HK1)
Removal 4HK1
1. Drain coolant.
2. Remove the starter.
• Disconnect the starter ground cable.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-127
6HK1 Special tool
Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx)
LNW21BSH007701
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
PNW56ASH003201
Name
1. Felt
2. Slinger
3. Oil Seal
Caution:
Be sure to replace the slinger and oil seal as a set.
11. Remove the front slinger.
• Use the slinger remover to remove the front
slinger.
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1A-128 ENGINE MECHANICAL (4HK1, 6HK1)
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
x-xxxx-xxxx-x (For 4HK1)
8-9439-6858-0 (For 6HK1)
Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx)
6HK1
Oil seal setting tool: 8-94396-856-0
• Install the slinger (1) to the end of adapter (2).
Install the adapter to the crankshaft (3).
• Install the slinger sleeve (4) to the adapter. Tighten
the center bolt (5) until the sleeve comes in contact
with the adapter stopper.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-129
6HK1 Special tool
4HK1
Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx)
6HK1
Oil seal setting tool: 8-94396-856-0
(Use the parts listed below for the front oil seal.)
Caution:
Be sure to replace the slinger and oil seal as a set.
2. Install the crankshaft front oil seal.
• Press fit the oil seal using an oil seal installer,
setting tool.
PNW56ASH003501
Name
1. Adapter
• Apply engine oil to the lip of the oil seal and place it
on the front side adapter.
LNW21BSH073301
• Put the front side adapter ring in the sleeve and fix
the sleeve on the adapter with the center bolt and
Name a washer.
1. Oil Seal
2. Adapter (Front) • Tighten the bolt until the sleeve touches the
3. Adapter Ring (Front) adapter to press fit the front oil seal.
4. Fixing Bolt
5. Sleeve (Front)
6. Washer (Front)
7. Center Bolt
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1A-130 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
LNW21BSH013201
LNW21BSH013401
Name
1. Oil Seal Name
2. Adapter Ring 1. Adapter Ring
3. Sleeve 2. Sleeve
4. Bolt and Washer 3. Adapter
4. Oil Seal
6HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-131
LNW21BSH000601
WSHK0033
PNW56ASH003701
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1A-132 ENGINE MECHANICAL (4HK1, 6HK1)
8. Connect the lower radiator hose.
9. Connect the coolant reserve tank hose.
10. Connect the upper radiator hose.
11. Install the starter in the flywheel housing with nuts
and tighten to the specified tightening torque.
Tightening torque: 76 N-m (7.7 kg-m/56 lb ft)
• Connect the starter ground cable.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-133
Torque Specifications
Special Tool
Tool Number/Description/ Tool Number/Description/
Illustration Illustration
Special Tool Rank Special Tool Rank
x-xxxx-xxxx-x
x-xxxx-xxxx-x
x-xxxxx
xx-xxxxx
Oil seal installer kit
Crankshaft stopper
(4HK1)
Rank B
Rank A
St
8-94396-856-0
1-8521-0027-0
Oil seal setting tool
Slinger remover
(6HK1)
Rank B
Rank A
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1A-134 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Flywheel 2. Crankshaft Rear Oil Seal
Removal
1. Remove the flywheel.
Refer to the “Flywheel”.
2. Remove the crankshaft rear oil seal.
• Remove the oil seal off with a screwdriver or the
like avoiding damage to the oil seal contact surface
on the flywheel housing and the shaft.
Name
1. Felt
2. Slinger
3. Oil Seal
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-135
3. Use the slinger remover to remove the slinger.
Caution:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
x-xxxx-xxxx-x (For 4HK1)
8-9439-6858-0 (For 6HK1)
HCW31BSH019401
Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx)
6HK1 After pressing in the slinger, make sure that the
Oil seal setting tool: 8-94396-856-0 distance between crankshaft end surface and the
• Install the slinger (1) to the end of adapter (2). slinger is A as specified.
Install the adapter to the crankshaft (3).
• Install the slinger sleeve (4) to the adapter. Tighten
the center bolt (5) until the sleeve comes in contact
with the adapter stopper.
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1A-136 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
Name
Distance (A): 17.3±0.3 mm (0.7±0.01 in) 1. Adapter (Rear)
Distance (B): 10.8±0.1 mm (0.4±0.004 in) 2. Fixing Bolt
6HK1 3. Center Bolt
4. Sleeve (Rear)
5. Collar (Rear)
6. Adapter Ring (Rear)
7. Oil Seal
Special tool
4HK1
Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx)
6HK1
Oil seal setting tool: 8-94396-856-0
Caution:
Put a collar on the fixing bolt and mount the
Be sure to replace the slinger and oil seal as a set.
adaptor onto the crankshaft.
2. Install the crankshaft rear oil seal.
• Press-fit the rear oil seal using an oil seal installer,
setting tool.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-137
• Apply engine oil to the lip of the oil seal and place it
in the rear side adapter.
1
• Put the rear side adapter ring in the sleeve and put
the sleeve on the adapter and fix with the center
bolt.
LNW21BSH014801
Name
1. Rear Part of The Crankshaft
2. Oil Seal
3. 4HK1: 7.8 ± 0.3 mm (0.31 ± 0.012 in),
6HK1: 7.5 ± 0.15 mm (0.3 ± 0.006 in)
4. Collar
LNW21BSH014601
5. Adapter Ring
6. Sleeve
* 4HK1 is shown for illustration. 7. Adapter
Name
3. Install the flywheel.
1. Sleeve
Refer to the “Flywheel”.
2. Adapter Ring
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1A-138 ENGINE MECHANICAL (4HK1, 6HK1)
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
&L
1-8521-0027-0
Slinger remover
Rank B
ITS x-xxxx-xxxx-x
x-xxxxx
Oil seal installer kit
(4HK1)
Rank A
8-94396-856-0
Oil seal setting tool
(6HK1)
Rank A
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-139
Crankshaft
Components
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1A-140 ENGINE MECHANICAL (4HK1, 6HK1)
7. Remove the crankshaft rear oil seal.
Refer to the “Crankshaft Rear Oil Seal”.
8. Remove the oil pan.
Refer to “Oil Pan”.
9. Remove the water pump.
Refer to the “Water Pump” in the Cooling System
Section.
10. Remove the front cover.
Refer to the “Front Cover”.
11. Remove the timing gear train.
Refer to the “Timing Gear Train”.
12. Remove the oil pump.
Refer to the “Oil Pump”.
13. Remove the piston and connecting rod.
Refer to the “Pistons and Connecting Rod”.
14. Remove the crankcase.
• Gradually loosen crankcase mounting bolts in the
sequence shown and remove the crankcase using
the replacer holes (arrowed holes in the figure).
4HK1 16. Remove the lower crankshaft bearings.
14 17 13 9 5
LNW21BSH023601
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-141
Special tool
Crankshaft gear puller: 8-9439-6819-0 (EN-41222)
1 LNW21BSH023801
Disassembly
Name
1. Remove the gear.
1. Alignment Mark
• Remove the gear using a gear puller.
Special tool
Crankshaft gear puller: 8-9439-6818-0 (EN-47684) Inspection
1. Thrust clearance
• Set a dial gauge as shown and measure the
crankshaft thrust clearance.
Caution:
Measure the thrust clearance before dismounting.
LNW21BSH023901
Reassembly
1. Install the gear.
• Heat the gear to 1 7 0 -2 5 0 °C (3 3 8-48 2 °F ) and
install it aligning the groove on the gear with the
pin on the crankshaft.
• Insert the gear at one push into the flange with its
end side with the alignment mark “S” facing
outward. If you are fitting the gear while it is cold,
beat the gear in until it impinges on the end using
the installer.
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1A-142 ENGINE MECHANICAL (4HK1, 6HK1)
Caution:
Turn the crankshaft about 30° to allow the bearings to
settle in.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-143
Tightening torque:
M14 bolt 4HK1: (1 - 10), 6HK1: (1 - 14)
1st step = 98 N m (10.0 kg m/72 lb ft)
2nd step = 1 32 N m (13.5 kg m/97 lb ft)
3rd step = 30° - 60°
M10 bolt 4HK1: (11 -2 7 ), 6HK1: 1 5 -3 9 )
4th step = 37 N m (3.8 kg m/27 lb ft)
• Tighten bolts from 1 to 10 (M14) and confirm that
they are tightened to a torque of 142 N m (14.5
kg m/105 lb ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Do not rotate the crankshaft after tightening the
crankcase.
• Loosen the bolts and gently remove the
* 4HK1 is shown for illustration.
crankcase.
4HK1
• Measure the widest part of the Plastigauge
flattened by tightening the crankcase to determine
the clearance.
4HK1
6HK1
37 33 29 25 21 17 16 20 24 28 32 3639
WSHK0035
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1A-144 ENGINE MECHANICAL (4HK1, 6HK1)
• If the journal oil clearance exceeds the limit, 4. Measure the journal and the crank pin diameters
replace the main bearings altogether or the and uneven wear.
crankshaft. • Measure outer diameters of the journal and the pin
and calculate differences between the maximum
• Remove the plastigauge from the bearing and
and the minimum values. Take measurements at
crank pin.
four positions for both the journal and the pin.
Inspection of crankshaft
• Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil seal
contact surface for excessive wear and damage.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowly
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
4HK1
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-145
6HK1
Caution:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
shall not polish the surface of the crankshaft.
Name
1. Upper Bearing
2. Oil Gallery
3. Grade Identification Color
4. Oil Groove
LNW21BSH024701
5. Lower Bearing
6. Grade Identification Color
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1A-146 ENGINE MECHANICAL (4HK1, 6HK1)
Bearing selection table
4HK1
6HK1
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing in the cylinder block and
apply oil.
Caution:
When replacing the crankshaft bearings, select grades
referring to the Crankshaft Bearing Grade Selection.
Do not apply oil to the bearing installation surface on
the cylinder block and external surface of the bearing.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-147
• Install the upper thrust bearing in the front side of 5. Install the lower thrust bearing.
the cylinder block journal No.5 (4HK1) or No.7 • Install the lower thrust bearing in the rear side of
(6HK1). In doing this, you may attach the upper the crankcase journal No.5 (4HK1) or No.7
thrust bearing to the cylinder block with grease. (6HK1).
Then, be sure to wipe up excess grease.
• Install the thrust bearing so that the oil groove
Caution: contacts the crankshaft.
Install the thrust bearing so that the oil groove contacts
the crankshaft.
LNW21BSH025501
LNW21BSH025401
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1A-148 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
6HK1
mm(in)
WSHK0036
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-149
• Apply Molybdenum Disulfide to M14 bolts' threads 6HK1
and setting faces and tighten them to the specified
tightening torque in the sequence shown.
37 33 29 25 21 17 16 20 24 28 32 3639
Tightening torque:
M14 bolt 4HK1: (1 - 10), 6HK1: (1 - 14)
1st step = 98 N m (10.0 kg m/72 lb ft)
2nd step = 1 32 N m (13.5 kg m/97 lb ft)
3rd step = 30° - 60°
M10 bolt 4HK1: (1 1 -2 7 ), 6HK1: (1 5 -3 9 )
4th step = 37 N m (3.8 kg m/27 lb ft)
• Tighten the bolts (M14) from 1 to 10 (4HK1) or 1 to
14 (6HK1) and confirm that they are tightened to a
torque of 142 N m (14.5 kg m/105 lb ft) or more.
Special tool
WSHK0035
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
7. Install pistons and connecting rods.
Caution: Refer to the “Pistons and Connecting Rod”.
Confirm that the crankshaft turns smoothly. 8. Install the oil pump.
4HK1 Refer to the “Oil Pump”.
9. Install the timing gear train.
Refer to the “Timing Gear Train”.
10. Install the front cover.
Refer to the “Front Cover”.
11. Install the water pump.
Refer to the “Water Pump” in the Cooling System
Section.
12. Install the oil pan.
Refer to “Oil Pan”.
13. Install the crankshaft rear oil seal.
Refer to the “Crankshaft Rear Oil Seal”.
14. Install the crankshaft front oil seal.
Refer to “Crankshaft Front Oil Seal”.
14 11 15 19 23 15. Install the fuel supply pump.
Refer to the “Fuel Supply Pump”.
16. Install the cylinder head.
LNW21BSH022601
Refer to the “Cylinder Head”.
17. Install the camshaft ASM.
Refer to “Camshaft ASM”.
18. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
19. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.
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1A-150 ENGINE MECHANICAL (4HK1, 6HK1)
Torque Specifications
Special Tool
Tool Number/Description/ Tool Number/Description/
Illustration Illustration
Special Tool Rank Special Tool Rank
4
8-9439-6818-0 8-9439-6819-0
EN-47684 J-41222
Crankshaft gear remover Crankshaft gear installer
Rank B Rank B
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-151
Tool Number/Description/
Illustration
Special Tool Rank
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Rank B
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1A-152 ENGINE MECHANICAL (4HK1, 6HK1)
Cylinder Block
Components
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-153
9. Remove the water pump. If the cylinder liner cannot be pulled free by hand,
Refer to the “Water Pump” in the Cooling System tap around the lower side of the liner with a
Section. hammer grip or similar object loosen it.
10. Remove the front cover.
Refer to the “Front Cover”.
Inspection
11. Remove the timing gear train.
Refer to the “Timing Gear Train”. 1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
12. Remove the oil pump.
Refer to the “Oil Pump”. • Be careful not to damage the cylinder block.
13. Remove the piston and connecting rod. 2. Carefully remove the liquid gasket on the
Refer to the “Pistons and Connecting Rod”. crankcase mounting surface.
14. Remove the crankshaft. 3. Clean up the cylinder block.
Refer to the “Crankshaft”.
4. Visually inspect the cylinder block.
15. Remove the piston oil jet
• Conduct color check and hydraulic (or pneumatic)
test and if you find crack or other damage, replace
the cylinder block.
LNW21BSH026701
LNW21BSH026401
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1A-154 ENGINE MECHANICAL (4HK1, 6HK1)
Caution:
You need not select cylinder liner bore grade since the
liners are only available in one size.
6. Cylinder block upper face warpage
• Pull out the cylinder liners and remove water stains
on the cylinder block.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-155
(Reference)
When replacing liners, a “liner set” let you obtain a
piston of proper grade for a given liner bore
diameter only by specifying a liner outside
diameter grade.
2. Install the cylinder liners.
• Install the cylinder liners perpendicular to the
cylinder block.
Caution:
Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
6HK1
LNW21BSH027101
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1A-156 ENGINE MECHANICAL (4HK1, 6HK1)
Caution:
Be sure to measure the cylinder liner extrusion
whenever you have replaced cylinder liners.
LNW21BSH026401
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-157
Lubrication System
Precautions on Service Work • Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the start and end of the application should
and apply the specified new fluid gasket at each be overlapped.
location.
Explanations on functions and operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating system diagram
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1A-158 ENGINE MECHANICAL (4HK1, 6HK1)
Function Check
Oil pressure check
1. Check whether the engine oil is contaminated with
dirt, light oil, or water. If contaminated with dirt,
light oil, or water (after examining the cause and
taking the appropriate measures for light oil or
water contamination), replace the oil.
2. Check the engine oil level. The oil level should be
between the two holes of the level gauge. If the oil
level is insufficient, replenish it.
3. Remove the oil pressure switch on the oil filter
body.
4. Install the oil pressure gauge on the oil filter body.
Special tool
Oil pressure gauge: J43620-20
Hose: J43630
Connector (4HK1 only): J43630-14
Oil pressure testing adapter (4HK1 only): EN-46333 Name
1. 4HK1 Oil Pressure (Oil Port)
2. 4HK1 Oil Pressure (Oil Gallery)
3. 6HK1 Oil Pressure (Oil Port)
4. 6HK1 Oil Pressure (Oil Gallery)
Engine oil
• Ensure the engine is at a level ground.Before
starting the engine or when 5 minutes or more
have elapsed after stopping the engine, check the
engine oil volume using the level gauge. The
volume is appropriate if the engine oil is between
the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lower
limit. Also, check for contamination of the engine
oil.
Name
1. Oil Port
2. Oil Gallery
3. Hose
4. Oil Pressure Gauge
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-159
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
J-43620-20
Oil pressure gauge
Rank B
J-43630
Hose
PNW56ASH001601
Rank B
* 4HK1 is shown for illustration.
J-43630-14
Connector
(4HK1)
Rank A
1 2
J-46333
Oil pressure gauge
testing adapter
(4HK1)
Rank A
LNW21BSH000401
Name
1. Upper Limit
2. Lower Limit
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1A-160 ENGINE MECHANICAL (4HK1, 6HK1)
Name
1. Oil Pressure Switch 3. O-Ring
2. Oil Port Cover
Removal
1. Remove the oil pressure switch.
2. Remove the oil port cover. 1
3. Remove the O-ring.
Installation
1. Install the O-ring on the oil port cover.
PNW56ASH004401
Name
1. O-Ring
2. O-Ring
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-161
2. Install the oil port cover on the cylinder block and
tighten it to the specified torque.
Tightening torque:
4HK1 48 N-m (4.9 kg-m/35 lb ft)
6HK1 39.2 N-m (4.0 kg-m/29 lb ft)
PNW56ASH004501
Name
1. Bolt M10X L = 80
2. Bolt M10X L = 25
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1A-162 ENGINE MECHANICAL (4HK1, 6HK1)
Oil Cooler
Components
4HK1
Name
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Common Rail
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-163
6HK1
W SHK0038
Name
1. EGR Cooler Water Return Pipe 4. Fuel Supply Pump
2. Oil Cooler 5. Suction Pipe
3. Common Rail
Removal
1. Remove the common rail.
Refer to the “Common Rail” in the fuel system
section.
2. Remove the fuel supply pump.
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1A-164 ENGINE MECHANICAL (4HK1, 6HK1)
4. Remove the EGR cooler water feed pipe. (4HK1) • Screw the removed fixing bolt of the oil cooler into
5. Remove the clip on the head side of the water the replacer hole at the location 1 of the figure and
bypass hose (4HK1) and remove the hose from remove the oil cooler.
the suction pipe ASM.
4HK1
LNW46ASH003401
Name
1. Bypass Hose Disassembly
2. EGR Cooler Water Return Pipe 1. Remove the element mounting bolts.
3. EGR Cooler Water Feed Pipe
2. Remove the element.
4. Suction Pipe
3. Remove the O-ring.
6HK1
LNW21HSH001201
Name Name
1. Suction Pipe 1. Element
2. EGR Cooler Water Return Pipe 2. O-Ring
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-165
3. Tighten the element fixing bolts using the specified
m m (in)
torque.
Tightening torque: 20 N-m (2.0 kg-m/15 lb ft)
o o X
ST 2~4 1(0.04)
Uxj:
(0 .0 8 -0 .1 6 )
*■
Q.j<, ^ «, 5 -^ ^ 3
WSHK0242
Name
LNW21HSH001201
1. O-Ring
* 4HK1 is shown for illustration. 2. O-Ring
3. Liquid Gasket
Name
1. Element - Align the oil cooler holes with the cylinder block
2. O-Ring studs.
- Install the oil cooler and glow plug controller
bracket to the cylinder block.
Installation - Tighten the bolts to the specified torque in the
1. Install the oil cooler ASM. order shown in the illustration.
• Apply liquid gasket (ThreeBond 1207B or Tightening torque: 24 N-m (2.4 kg-m/18 lb ft)
equivalent) to the flange surface groove (cylinder • Liquid gasket quickly hardens.
block). Bead diameter must be between 2 and 4 Make it complete within 7 minutes after
mm (0.08 and 0.16 in). applying the liquid gasket.
Refer to the illustration for the offset position (no
more than 1 mm {0.04 in}). 4HK1
LNW46ASH003301
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1A-166 ENGINE MECHANICAL (4HK1, 6HK1)
o O X
PNW56ASH004701
2-5 1(0.04)
6^ (0.08-0.2) 3. Install the EGR cooler water feed pipe. (4HK1)
• Install the O-ring on the EGR cooler water feed
! , * C=^£=3
o pipe.
LNW21HSH001401
• Install at the position shown in the figure and
tighten using the specified torque.
Name
1. Liquid Gasket
Tightening torque: 24 N m (2.4 kg m/18 lb ft)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-167
4HK1
PNW56ASH004801
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1A-168 ENGINE MECHANICAL (4HK1, 6HK1)
Oil Pan
Components
Removal
1. Drain engine oil.
2. Remove the oil pan.
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-169
3. Remove the Oil strainer. 4HK1
Installation
1. Install the oil strainer with new O-ring to the crank
case.
Tightening torque:
M8 Bolt (4HK1): 32 N-m (3.3 kg-m/24 lb ft)
M8 Bolt (6HK1): 24 N-m (2.4 kg-m/18 lb ft)
M10 Bolt: 48 N-m (4.9 kg-m/35 lb ft)
WSHK0042
WSHK0181
• Apply the liquid gasket and install the oil pan within
7 minutes.
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1A-170 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
PNW56ASH005101
6HK1
6HK1 • Fastening the oil pan from the part of A or B in
clock wise order.
• It tightens again by specified torque.
Tightening torque: 24.5 N-m (2.5 kg-m/18 lb ft)
WSHK0195
Name
1. Oil Pan
2. Gasket
4HK1
• Tighten the locations (1), (2), (3), and (4) as shown
in the figure and then tighten others. (In any
sequence)
Tightening torque: 30 N-m (3.1 kg-m/22 lb ft)
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-171
Oil Pump
Components
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1A-172 ENGINE MECHANICAL (4HK1, 6HK1)
11. Remove the flywheel housing.
• Make sure you remove the bolts shown in the
figure.
LNW21HSH001801
LNW21BSH053601
Disassembly
* 4HK1 is shown for illustration. 1. Remove the driven gear and shaft.
12. Remove the idle gear A. 2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin and fold it according to (1).
LNW21HSH005501
LNW21HSH006201
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-173
• Measure the clearance between the gear surface
and the upper surface of the oil pump body using
the thickness gauge and square.
LNW21HSH002401
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Measure the clearance between the gear and oil
pump body using a thickness gauge.
LNW21HSH001901
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1A-174 ENGINE MECHANICAL (4HK1, 6HK1)
3. Install the idling gear A.
• Install the idling gear shaft at the position shown in
the figure and apply engine oil on the shaft.
LNW21HSH002101
Standard 0 .0 4 -0 .0 7 (0.0016-0.0028)
Limit 0.20 (0.0079)
LNW21HSH002601
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-175
• Apply the liquid gasket (ThreeBond 1207B) Tightening torque: (6HK1)
uniformly on the inside surface of the bolt holes
Bolt holes marked with “1” =
(excluding the bolt holes indicated by arrows) as
96 N-m (9.8 kg-m/71 lb ft)
shown in the figure.
Bolt holes marked with “2” =
• After applying the liquid gasket, quickly install it. 86 N-m (8.8 kg-m/63 lb ft)
Bolt holes marked with “3” =
4HK1
119 N-m (12.1 kg-m/88 lb ft)
Bolt holes marked with “4” =
53 N-m (5.4 kg-m/39 lb ft)
Bolt holes marked with “5” =
73 N-m (7.4 kg-m/54 lb ft)
Bolt holes marked with “6” =
26 N-m (2.7 kg-m/19 lb ft)
• The seal is tightened from the cylinder block side.
6HK1
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1A-176 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1
6HK1
WSHK0044
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ENGINE MECHANICAL (4HK1, 6HK1) 1A-177
5. Install the oil pan.
Refer to “Oil Pan”.
6. Install the rear seal of the crankshaft.
Refer to “Rear Oil Seal of Crankshaft”.
7. Install the flywheel.
Refer to the “Flywheel”.
8. Install the fuel supply pump ASM.
Refer to “Fuel Supply Pump” in the Fuel System
section.
9. Install the cylinder head ASM.
Refer to “Cylinder Head Cover”.
10. Install the camshaft ASM.
Refer to “Camshaft ASM”.
11. Install the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
12. Tighten the cylinder head cover.
Refer to “Cylinder Head Cover”.
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1A-178 ENGINE MECHANICAL (4HK1, 6HK1)
Circuit check
1. Turn the key switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
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Cooling System
ENGINE
Cooling System
TABLE OF CONTENTS
Cooling System.........................................................1B-2
Precautions on Service W ork............................... 1B-2
Function C h e c k .................................................... 1B-5
A List of Defective Phenom ena...........................1B-8
Main Data and Specifications............................... 1B-8
Water Pump (4 H K 1 )................................................ 1B-9
Components...........................................................1B-9
Removal................................................................. 1B-9
Inspection.............................................................1B-10
Installation........................................................... 1B-11
Torque Specifications..........................................1B-12
Water Pump (6 H K 1 ).............................................. 1B-13
Removal............................................................... 1B-13
Installation...........................................................1B-15
Torque Specifications..........................................1B-17
Disassembly.........................................................1B-18
Inspection and R e p a ir........................................1B-19
Reassembly.........................................................1B-20
T herm ostat.............................................................1B-23
Components.........................................................1B-23
Removal 1 B-23
Inspection 1 B-23
Installation...........................................................1B-24
Drive Belt................................................................. 1B-25
Components.........................................................1B-25
Inspection 1 B-25
Torque Specifications..........................................1B-27
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Cooling System
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Cooling System 1B-1
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1B-2 Cooling System
Cooling System
Precautions on Service Work Explanations on functions and operation
WARNING: Cooling water system
Do not remove the radiator cap when the cooling water The cooling water system, which is the forced
is at high temperature. Steam or boiling water will gush circulation system, consists of a water pump,
out and you may be burnt. To open the radiator cap, thermostat, and radiator as its main components.
cover the cap with a thick cloth when the cooling water
is cool, release the pressure by slowly turning the cap,
and then remove the cap.
4HK1
Name
1. Water Jacket 10. Reservoir Tank
2. Drain Plug 11. Air Bleeding Plug
3. Oil Cooler 12. Water Outlet Pipe
4. Water Pump 13. Thermostat (2 units)
5. Drain Cock 14. Thermometer Unit
6. Radiator 15. Bypass Route
7. Cooling Fan 16. Turbocharger
8. Radiator Cap 17. EGR Cooler
9. Heater Core
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Cooling System 1B-3
6HK1
WSHK0045
Name
1. Water Jacket 8. Radiator Cap
2. Drain Plug 9. Reservoir Tank
3. Oil Cooler 10. Water Outlet Pipe
4. Water Pump 11. Thermostat (2 units)
5. Drain Cock 12. Thermometer Unit
6. Radiator 13. Bypass Route
7. Cooling Fan 14. EGR Cooler
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1B-4 Cooling System
Water pump
The water pump, which uses the centrifugal impeller
system, is driven by the engine fan belt.
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Cooling System 1B-5
Thermostat
The thermostat is a wax pellet type and consists of two
units, in which one unit (bottom bypass type) has an
valve initial opening temperature of 82 °C (180 °F) and
the second (inline type) has an valve initial opening
temperature of 85 °C (185 °F). It is designed such that
the water temperature can be adjusted finely and it is
mounted within the thermostat-housing unit.
Name
1. Jiggle Valve 4. Gasket
2. Stamp Mark (Valve Initial Opening Temperature) 5. Piston
3. Valve
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1B-6 Cooling System
Inspection location
• Radiator ASM, water pump ASM, radiator hose,
heater hose
Coolant
1. About the engine coolant concentration
• Take the concentration corresponding to the
minimum temperature because the freezing
temperature varies according to the
concentration of the engine coolant.
• Use only genuine engine coolant.
• Use engine coolant with a mix ratio in the range
of 30 to 60% because over heating is likely to
occur if the ratio is greater than 60% and
corrosion prevention is inadequate if the ratio is
less than 30%.
LNW46BSH001301
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Cooling System 1B-7
EGR cooler air bleeding procedure
When replacing the coolant, bleed air from the EGR
cooler with the following procedure.
Caution:
Be sure to replace the coolant when it is cooled.
Loosen the air bleeder plug (1) on the EGR cooler.
Caution:
• Take care to prevent the spilt coolant from getting
the exhaust system parts wet.
• Be sure to wipe off the spilt coolant.
Tightening torque: 24.5—30.5 N-m (2.5— 3.1 kg-m/
18—23 lb ft)
• Pour coolant into the radiator via its opening again
until it is filled.
• Bleed air from the engine body coolant with idling
the engine.
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1B-8 Cooling System
A List of Defective Phenomena
• Engine overheats
• Engine overcools
Engine overheats
Engine overcools
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Cooling System 1B-9
Name
1. Fan 4. Fan Belt
2. Spacer 5. Water Pump ASM
3. Water Pump Pulley 6. Gasket
Removal
1. Drain the coolant.
2. Remove the four mounting bolts and then the fan
ASM and spacer, water pump pulley.
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1B-10 Cooling System
Name Name
1. Fan 1. Water Pump
2. Spacer
3. Water Pump Pulley 5. Remove the gasket.
4. Bolt
3. (2) and (3) that tighten the setting plate and water Inspection
pump together. Loosen the adjusting bolts (1) in 1. Appearance check
the generator and remove the fan belt.
• Check for cracks or damage in the pump body.
• Check for cracks and corrosion in the impeller.
• Check for water leakage from the seal unit.
• If you find abnormalities, replace with the water
pump ASM.
2. Bearing nut check
• Rotate the fan center while pushing it along the
radial direction. Confirm that there is no
abnormal noise and no excessive play.
• If you find abnormalities, replace with the water
pump ASM.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
LNW21CSH001001
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Cooling System 1B-11
Installation
1. Install the gasket.
2. Install the water pump ASM.
• Mount the water pump to match with the studs
of the front cover.
3. Temporarily fit the bolts until the water pump pulley
and the spacer and fan are properly seated in the
water pump ASM.
4. Mount the fan belt, tighten the adjusting bolts of
the generator, and adjust the tension.
• Refer to the “Drive Belt”.
5. After fan belt adjustments, tighten the generator
using the specified torque.
Name
1. Fan ASM
2. Spacer
3. Water Pump Pulley
4. Bolt
7. Pour coolant.
Name
1. Adjusting Bolt
2. Lock Nut
3. Bolt
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1B-12 Cooling System
Torque Specifications
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Cooling System 1B-13
Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
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1B-14 Cooling System
5. Remove the adapter and fan pulley.
Name
1. Adapter 4. Bypass hose
2. Fan pulley 5. Water duct
3. Water pump 6. Water duct
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Cooling System 1B-15
Installation 6. Clamp the bypass hose.
1. Install the water pump with new gaskets to the 7. Install the fan pulley and adaptor to the water
front plate. Use the locating pin. pump.
Tighten the fixing bolts to the specified torque.
2. Tighten the fixing nuts and bolts to the specified
torque. Tightening torque: 52 N-m (5.3 kg-m/38 lb ft)
Tightening torque:
Nut A: 39 N-m (4.0 kg-m/29 lb ft)
Bolt: 20 N-m (2.0 kg-m/15 lb ft)
Tightening torque:
Bolt (1) : 221.6 N-m (22.6 kg-m/163 lb ft)
Bolt (2) : 24.5 N-m (2.5 kg-m/18 lb ft)
WSHK0214
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1B-16 Cooling System
10. Install the cooling fan.
Tighten the fixing nuts to the specified torque.
Tightening torque: 52 N-m (5.3 kg-m/38 lb ft)
WSHK0207
Name
1. Bolt
2. Washer
3. Rubber mount
4. Rubber mount
5. Guide tube
6. Fan guide
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Cooling System 1B-17
Torque Specifications
F06E100076
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1B-18 Cooling System
Disassembly
15
WSHK0215
Name
1. Center 9. Shaft
2. Dust cover 10. Water pump body
3. Snap ring 11. Dowel pin
4. Bearing 12. Seal unit
5. Bearing 13. Impeller
6. Spacer 14. Gasket
7. Bearing 15. Cover
8. Washer 16. Bolt
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Cooling System 1B-19
1. Remove the rear cover from the water pump body. Inspection and Repair
2. Use a remover 1-8521-0062-0 to remove the Make the necessary adjustments, repairs and part
impeller from the water pump. replacements if excessive wear or damage is
3. Use a puller to remove the water pump center. discovered during inspection.
4. Remove the dust cover and snap ring.
Water pump impeller
5. Remove the water pump shaft with ball bearings.
• Use a plastic hammer to lightly tap on the water 1. Check the impeller for corrosion.
pump shaft from the impeller side.
WSHK0217
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1B-20 Cooling System
2. Carefully wipe away any bearing grease. • Use a bench press to gradually press the water
3. Listen for excessive bearing operating noise. pump shaft down until the bearings are seated
correctly.
WSHK0222
severe bearing wear. 2. Install the water pump shaft with bearings to the
water pump body.
• Repack the bearings with multipurpose grease.
Reassembly
1. Install the ball bearing to the water pump shaft.
• Apply engine oil to the water pump shaft.
• Place the water pump shaft and the bearings
on the base plates.
• Install the washer (4), ball bearing (3), spacer
(2), and bearings (1).
WSHK0223
NOTE :
To prevent damage to the water pump shaft, place soft
brass or copper sheets between the base plates and
the water pump shaft.
WSHK0221
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Cooling System 1B-21
• Position the pump shaft with bearings to the 4. Install the seal unit to the water pump body.
water pump body. • Press in the seal unit to the specified position
• Use a bench press to gradually press the water using a bench press and installer 1-85220-047
pump shaft into the water pump body. 0.
Seal unit installation position A:
NOTE :
11.0 - 11.6 mm (0.433 - 0.457 in)
Do not drive the bearing into position with a hammer or
similar object. Bearing damage will result.
shaft.
• Use pliers to install the snap ring into water • Use a bench press to press in the impeller.
pump body groove. • The impeller must be flush with the water pump
• Install the dust cover with the flange facing out. shaft end.
6. Use a bench press to gradually press the water
pump center onto the water pump shaft to the
specified dimension.
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1B-22 Cooling System
Special tool
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Cooling System 1B-23
Thermostat
Components
Removal
1. Drain the coolant. Prepare the container for
discharging and use it for replenishment when
mounting the thermostat. Set the discharge of
cooling water such that the water does not flow out
of the thermostat housing.
2. Disconnect the water outlet pipe.
3. Remove the thermostat.
4. Remove the gasket from the thermostat.
Inspection
• Place the thermostat in water and increase the
temperature while stirring it sufficiently.
• Measure the temperature when the valve is just
opened and when it is fully open.
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1B-24 Cooling System
Installation 6HK1
1. Mount the gasket on the thermostat and mount it at
the position shown in the figure.
• The thermostat with the jiggle valve (A) is
installed to the left side of the engine. The jiggle
valve faces the rear of engine.
• Fit the thermostat gasket ensuring that it does
not come out of and on top of the external
housing on the cylinder head side.
WSHK0024
Name
1. Thermostat
\ )
PNW56ASH001301
1 2
* 4HK1 is shown for illustration.
3. Replenish the cooling water stored during the
LNW21CSH000201 discharge, and check the volume of the cooling
water.
Name
1. Thermostat
2. Cylinder Head
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Cooling System 1B-25
Drive Belt
Components
Name
1. Crankshaft Pulley 5. Adjusting Bolt
2. Generator Drive Belt 6. Lock Nut
3. Bolt 7. Adjusting Plate
4. Generator 8. Water Pump Pulley
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1B-26 Cooling System
PNW56BSH000301
Name
1. Crankshaft Pulley
2. Bolt
3. Generator
4. Adjusting Bolt
5. Lock Nut
6. Water Pump Pulley
7. Generator Drive Belt
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Cooling System 1B-27
Torque Specifications
N -m (kgm /lb-ft)
24 (2 .4 /1 7 )
6 9 (7 .0 /5 1 )
WSHK0230
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1B-28 Cooling System
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Fuel System
ENGINE
Fuel System
TABLE OF CONTENTS
Fuel S y s te m .............................................................1C-2
Precautions on Service W ork...............................1C-2
Special T o o l........................................................ 1C-12
Fuel Filter A S M .......................................................1C-13
Components.........................................................1C-13
Removal............................................................... 1C-13
Installation...........................................................1C-13
Fuel Filter E le m e nt............................................... 1C-14
Removal...............................................................1C-14
Installation...........................................................1C-14
Special T o o l........................................................ 1C-14
Fuel In je c to r...........................................................1C-15
Components........................................................ 1C-15
Removal...............................................................1C-16
Installation...........................................................1C-19
Torque Specifications.........................................1C-22
Special T o o l........................................................ 1C-23
Fuel Supply Pump.................................................. 1C-24
Components........................................................ 1C-24
Removal...............................................................1C-25
Installation...........................................................1C-26
Torque Specifications.........................................1C-29
Gauze filte r.............................................................1C-30
Removal...............................................................1C-30
Installation...........................................................1C-30
Electromagnetic Pump Filter................................ 1C-31
Removal............................................................... 1C-31
Installation...........................................................1C-31
Common R a il........................................................ 1C-32
Components........................................................ 1C-32
Removal...............................................................1C-33
Disassembly........................................................ 1C-35
Reassembly........................................................ 1C-36
Installation...........................................................1C-36
Torque Specifications.........................................1C-39
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Fuel System
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Fuel System 1C-1
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1C-2 Fuel System
Fuel System
Precautions on Service Work
Parts of the fuel system such as the internal part of the
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter
and the entry of foreign matter could cause damage to
the fuel passage. Therefore, effective measures should
be taken to prevent the entry of foreign matter.
If water removal agent is used in the fuel then it will
absorb moisture in the light oil and may cause rust.
Therefore, do not use water removal agent in the fuel
tank.
When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/or
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• Always replace the high-pressure pipe in fuel
system with new one if it has been removed.
Reuse of it causes damage the seal surface,
resulting in fuel leakage.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with
new ones.
Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and common rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, after
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage after
starting the engine.
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Fuel System 1C-3
Explanations on functions and operation
Name
1. Common Rail 6. Supply Pump
2. Fuel Filter 7. Fuel Injector
3. Electromagnetic Pump 8. Leak-Off Pipe
4. Pre-fuel Filter 9. Fuel Return Pipe
5. Fuel Tank
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1C-4 Fuel System
W1GR-01-01-001
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Fuel System 1C-5
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1C-6 Fuel System
Caution:
• Be careful foreign material does not into the fuel
system, because the precise fuel system is used.
Common rail
4HK1
Name
1. Flow Damper 3. Pressure Sensor
2. Pressure Limiter
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Fuel System 1C-7
6HK1
Name
1. Flow Damper 3. Fuel Inlet
2. Pressure Limiter 4. Pressure Sensor
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1C-8 Fuel System
Fuel supply pump
4HK1
Name
1. Fuel Temperature Sensor 4. Camshaft Key
2. Suction Control Valve 5. Camshaft Nut
3. High Pressure Pipe
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Fuel System 1C-9
6HK1
WSHK0046
Name
1. Fuel Temperature Sensor 3. High Pressure Pipe
2. Suction Control Valve 4. Camshaft Key
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1C-10 Fuel System
Fuel injector Fuel filter
Name Name
1. Terminal Stud 1. Priming Pump
2. Part for Mounting Leak Off Pipe 2. Air Bleed
3. O-ring 3. Case
4. Part for Mounting Injection Pipe 4. Drain Plug
5. Parts Number
6. ID Plate
Function check
Air bleeding
1. Before starting the engine
a. Fit a tray below the fuel filter (below the air
bleed plug).
b. Turn the key switch to ON, and activate the
electromagnetic pump. (on the machine with
electromagnetic pump)
c. Loosen the plug adequately and operate the
priming pump more than 20 times until the fuel
near the plug overflows.
d. Tighten the plug, and operate the priming pump
more than 10 times until it is filled with fuel.
After waiting for approximately a minute, loosen
the plug and bleed out the air in the fuel filter.
(This work must be repeated a minimum of
three times until no more air comes out from the
plug.)
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Fuel System 1C-11
e. Tighten the plug firmly and wipe the fuel in the
surrounding area. Operate the priming pump
(10 to 15 times) till it is filled with fuel and then
send fuel to the engine.
2. After starting the engine
a. Start the engine, but do not control the engine
speed on machine side.
b. After starting, maintain the idling rotation for 5
seconds.
c. Increase the engine speed slowly and keep this
for three minutes.
d. Operate the engine speed to maximum on the
machine side. (Repeat this operation several
times)
e. Return to idling speed.
Caution:
If the air bleeding work is insufficient then it could lead
to faults in the engine. Therefore, the procedures after
starting the engine should always be implemented.
Water drain
It is designed that the float inside of the water
sedimenter floats when water accumulates.
When the float level goes up to the aluminum body
section, be sure to drain the water.
PNW56AMH000301
Fuel system vacuum check 4. Loosen the air bleeding plug on the supply pump.
Use this procedure to measure the vacuum (negative 5. Use your hand to operate the fuel filter priming
pressure) discharge side the fuel system. pump. Operate the pump until all the air has been
bled from the system.
Important:
6. Start the engine and allow it to idle.
The fuel pressure/vacuum gauge ASM (gauge (1)) and
the fuel pressure/vacuum gauge adapter (adapter (5)) 7. Note the gauge (1) reading. If the reading is
must be cleaned before connecting to the fuel line. normal, go to Step 8. If the fuel vacuum is greater
Otherwise, foreign material adherent to the tools may than the specified value, there is a problem in the
damage the fuel supply pump. fuel system. Perform the procedures outlined
below.
1. Disconnect the fuel hose from the fuel filter Standard fuel vacuum Less than 17 kPa (170 mbar)
housing. (fuel supply pump side). • Replace the cartridge fuel filter element.
2. Install the adapter. • Check the fuel delivery pipe. If it is clogged, it must
be replaced.
Special tool
• Remove the fuel pipe at the fuel filter inlet. Use
Fuel pressure/vacuum gauge adapter (4HK1 only):
high-pressure air forced through the fuel pipe to
EN-47667
clean the fuel system.
3. Connect the gauge (1) with hose to the adapter
(3). Caution:
• Remove the fuel filler cap before applying high-
Special tool
pressure air.
Fuel pressure/vacuum gauge ASM:
J-44638
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1C-12 Fuel System
• Do not perform this procedure if the fuel tank is
nearly full (fuel approaching or flowing into the fuel
filler neck). The forced air will spray fuel from the
fuel filler neck.
8. Remove the gauge (1) and hose from the adapter
(3).
9. Remove the adapter (3).
10. Connect the fuel hose.
11. Use your hand to operate the fuel filterpriming
pump. Operate the pump until all the airhas been
bled from the system.
12. Start the engine and allow it to idle.
13. Inspect the fuel system for fuel leakage.
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
EN-47667
Fuel pressure/vacuum
gauge adapter
(4HK1)
Rank B
L J-44638
Fuel pressure/vacuum
gauge ASM
Rank B
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Fuel System 1C-13
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Removal
1. Remove the feed hose and the return hosefrom
the fuel filter and plug it so that the fuel does not
flow out.
2. Remove the bolts for mounting the fuel filter.
3. Remove the fuel filter ASM.
Installation
1. Install the fuel filter ASM.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Bleed out the air.
• Refer to “Fuel System”.
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1C-14 Fuel System
8-9801-3170-0
Main filter wrench
Rank A
PNW56AMH000201
Name
1. Priming Pump
2. Air Bleed
3. Case
4. Drain Plug
Installation
1. Assemble the Fuel Filter element.
2. To simplify air bleed, fill light oil in the case.
3. Tighten the case by hand. During this process take
adequate care that the light oil that is inside does
not flow out.
4. Use the filter wrench and tighten rotating by 1/3 to
2/3.
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Fuel System 1C-15
Fuel Injector
Components
4HK1
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1C-16 Fuel System
6HK1
Name
1. Fuel Injection Pipe Clip 7. EGR Adapter
2. Fuel Injection Pipe 8. EGR Cooler
3. Fuel Injector Leak-Off Pipe 9. EGR Valve
4. Fuel Injector 10. Cylinder Head Cover
5. Fuel Injector Clamp 11. Fuel Injector Harness Bracket
6. Fuel Injector Clamp Bolt 12. Fuel Injector Terminal
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Fuel System 1C-1 7
3. Tape the EGR case holes shut to prevent the entry
of foreign material.
4HK1
PNW56ASH000101
Name
1. Cylinder Head Cover
WSHK0163
Name
1. EGR Adapter
2. EGR Valve
2 4
PNW56ASH002501
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal
4. Fuel Leak Off Pipe
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1C-18 Fuel System
9. Remove the fuel injection pipe clips and the Caution:
injection pipes. Do not remove the fuel injector sleeve.
4HK1
6HK1
Name
1. Sliding Hammer
2. Remover
3. Fuel Injector ASM
Caution:
• Do not tamper with the electromagnetic portion of
Name the fuel injector. Reduced electromagnetic function
1. Fuel Injection Pipe will result in injector failure.
2. Pipe Clip
Recording Injector ID Code Information from the
10. Loosen the fuel injector clamp fixing bolts and Injector ID plate on the replaced fuel injector
remove the fuel injectors. housing;
If the fuel injectors are difficult to remove, use the fuel Record all numbers of replaced fuel injector's from ID
injector remover. Install the fuel injector remover to the plate.
leak-off pipe attachment part on the fuel injector. Use a
sliding hammer to force the fuel injector clamp off the
fuel injector.
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Fuel System 1C-1 9
3. Install the fuel injector clamps to the cylinder head.
4. Temporarily tighten the clamp bolts.
5. Apply a thin coat of engine oil to the outer surface
of the fuel injector side sleeve nuts.
6. Install the fuel injector pipes to the position shown
in the illustration.
Important:
Replace the high-pressure pipe in fuel system with new
one if it has been removed.
Name
1. Injector ID Plate
2. Injector ID Code
3. Fuel Injector
Installation
Important:
Install each of the fuel injectors on its original position.
(the cylinder from which it was removed)
1. Install a new gasket and O-ring to each of the fuel
injector clamps. Refer to the illustration.
PNW56ASH001801
Name
1. Fuel Injection Pipe
2. Pipe Clip
Name
1. Gasket
2. Fuel Injector
3. Bolt
4. Fuel Injector Clamp
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1C-20 Fuel System
4HK1
PNW56ASH002701
11. Install the nozzle leak off pipes together with the
new gaskets. Tighten the pipes to the specified
torque.
Caution:
Do not overtighten the nuts. Damage to the terminal
LNW21DSH003401
studs will result.
* 4HK1 is shown for illustration.
12. Install the fuel injector harness connectors. Work
from the inside out.
13. Install the harness bracket and tighten the bolts to
the specified torque.
Tightening torque: 4HK1: 48 N-m (4.9 kg-m/35 lb ft)
6HK1: 22 N-m (2.2 kg-m/16 lb ft)
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Fuel System 1C-21
Tightening torque: 24 N-m (2.4 kg-m/18 lb ft)
LNW46CSH000801
PNW56ASH002201
Name
1. Fuel Injector * 4HK1 is shown for illustration.
2. Harness
Name
3. Terminal Nut
1. EGR Adapter
2. EGR Valve
16. Install the gasket to the cylinder head cover.
17. Install the cylinder head cover and tighten the bolts 20. Attach the engine harness connectors. Each
to the specified torque. composite connector should make a loud click
Tightening torque: 4HK1: 18 N-m (1.8 kg-m/13 lb ft) when it is securely attached.
6HK1: 13 N-m (1.3 kg-m/9.6 lb ft) Before Programming the Injector ID Code
Important:
DO NOT program the fuel injector ID code data unless
you are directed by a service procedure or you are
directed by a service bulletin. Programming the fuel
injector at any other time will not permanently correct a
customers concern.
Ensure the following conditions are met before
programming the ECM.
• System voltage for machine
- There is no charging system concern. All
charging system concerns must be repaired
before programming the ECM.
- Battery voltage is 12 volts or 24 volts (varies
depending on the machine). The battery must
be charged before programming the ECM if the
battery voltage is low.
- A battery charger is NOT connected to the
PNW56ASH000101
machine's battery. Incorrect system voltage or
* 4HK1 is shown for illustration. voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
Name
- Turn OFF or disable and system that may put a
1. Cylinder Head Cover
load on the machine's battery.
18. Install the gasket to the EGR valve and tighten the • The key switch is in the proper position. DO NOT
bolts to the specified torque. change the position of the key switch during the
programming procedure, unless instructed to do
Tightening torque: 24 N-m (2.4 kg-m/18 lb ft) so.
19. Install the gasket to the EGR adapter and tighten • All tool connections are secure.
the bolts to the specified torque. - RS-232
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1C-22 Fuel System
- The connection at the data link connector - Electromagnetic interference (EMI) on the tool
(DLC) is secure. harness and ECM may cause the programming
- Voltage supply circuit failure or ECM damage.
• DO NOT disturb the tool harness while Injector ID Code Programming Procedure
programming. If an interruption occurs during the Programming of the injector ID code is refered to
programming procedure, programming failure or “Injector Replacement” in the EMPS or EMPSIII
ECM damage may occur. operating instructions manual.
• Surrounding environment
- Surrounding temperature must be between 0
and 50°C (32 and 122°F) during the
programming procedure. Excessively low or
high temperature may cause the programming
failure or ECM damage.
Torque Specifications
N-m(kg-m/lb -ft)
W S H K 0047
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Fuel System 1C-23
Special Tool
Tool Number/Description/
Illustration
Special Tool Rank
5-8840-0019-0
J-23907
Sliding hammer
Rank B
-
5-8840-2826-0
EN-46720
Injector remover
Rank A
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1C-24 Fuel System
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Fuel System 1C-25
Removal
1. Remove the intake pipe and case ASM.
2. Remove the fuel pipe and fuel leak-off pipe.
Important:
Do not reuse the high-pressure pipe in fuel system if it
has been removed.
4HK1
LNW46CSH003001
6HK1
LNW21DSH004801
Caution:
• Do not hold the high pressure pipe, during the
supply pump removal procedure.
• Do not grasp the high pressure pipe, when moving
the supply pump form one location to another.
4. Disconnect the connector of fuel temperature
sensor and the common rail pressure regulator
from the fuel supply pump.
5. Remove the fuel supply pump.
Note:
A single bolt (1) secures the pump and the flywheel
housing.
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1C-26 Fuel System
Name Name
1. Fuel Supply Pump 1. Fuel Supply Pump
2. O-ring 2. O-ring
3. Fuel Supply Pump Bracket 3. Fuel Supply Pump Bracket
Caution:
Take care not to twist the O-ring.
Name
1. Fuel Supply Pump
2. Fuel Supply Pump Gear
3. Nut
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Fuel System 1C-27
4. Apply white paint to the top of the fuel supply pump 6HK1
gear tooth directly above the stamped ‘O’ mark.
Refer to the illustration.
W SHK0049
6. Remove the oil drain adapter.
7. Install the O-ring to the fuel supply pump.
* 4HK1 is shown for illustration.
8. Align the slits as shown in the illustration.
5. Turn the crankshaft in the normal direction of
9. Insert the stud bolts into the guides and
engine rotation until the No. 1 or No. 4 cylinder is
temporarily tighten them.
at TDC on the compression stroke.
Refer to the illustration. Caution:
4HK1 • If the stud bolts (cylinder block side) have been
loosened or replaced, apply Loctite 262 to the
recessed portion of the bolts.
PNW56ASH003101
LNW46CSHQ02001
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1C-28 Fuel System
14. Install the case ASM.
• Apply the liquid gasket and mount within 7
minutes.
1
Tightening torque: 24 N-m (2.4 kg-m/18 lb ft)
4HK1
LNW21DSH003001
Name
1. Plug Hole
2. Alignment Mark
LNW46CSH000901
Important:
Do not reuse the high-pressure pipe in fuel system if it
* 4HK1 is shown for illustration. has been removed.
Name
1. Oil Drain Adapter 16. Start and idle the engine.
2. O-ring
Important:
In order to make the fuel supply pump characteristic
12. Connect the fuel temperature sensor and the
learn into the ECM, let the engine idle until warm-up. If
suction control valve connectors to the fuel supply
the fuel system DTC' stored in the meantime, once
pump.
clear DTD and warm-up the engine again.
13. Connect the fuel feed hose.
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Fuel System 1C-29
Torque Specifications
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1C-30 Fuel System
Gauze filter
4HK1
6HK1
WSHK0250
Name
1. Fuel Supply Pump 3. Gauze Filter
2. Eyebolt
Removal Installation
1. Remove the eyebolt. 1. Attach the gauze filter to the eyebolt, then secure it
2. Disconnect the C-ring from the eyebolt and detach using a C-ring.
the gauze filter. 2. Install the eyebolt to the supply pump.
3. Clean the gauze filter with solvents, then blow dust
Tightening torque: 14.6 — 24.6 N-m
particles off with compressed air.
(1.5 — 2.5 kg-m/11 — 18 lb ft)
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Fuel System 1C-31
Name
1. Electromagnetic Pump 3. Pump Cover
2. Filter Element 4. Ground Cable
Removal Installation
1. Remove the ground cable that is installed on the 1. Insert the filter element to the pump, then attach
electromagnetic pump cover. the cover.
2. Turn the pump cover with your hand to remove it 2. Install the ground cable to the cover.
and take out the filter element. 3. Bleed out the air.
3. Clean the filter element with solvents, then blow • Refer to "Fuel System".
dust particles off with compressed air.
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1C-32 Fuel System
Common Rail
Components
4HK1
Name
1. Fuel Leak Off Pipe 6. Injection Pipe Clip
2. Fuel Pipe 7. Injection Pipe (#1 to #4)
3. EGR Valve 8. Common Rail
4. EGR Cooler 9. Common Rail Bracket
5. EGR Adapter
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Fuel System 1C-33
6HK1
Name
1. Fuel Leak Off Pipe 5. EGR Adapter
2. Fuel Pipe 6. Injection Pipe Clip
3. EGR Valve 7. Injection Pipe (#1 to #6)
4. EGR Cooler 8. Common Rail
Parts of the fuel system such as the internal part of the • Cover the removed fuel hose with a lid, keep it
fuel injector, holes and clearances that form passages facing upward and secure it using wire, etc.
for fuel are finished to a very high degree of accuracy.
They are therefore highly sensitive to foreign matter Note:
and the entry of foreign matter could cause damage to Cover the areas exposed during part removal to
the fuel passage. Therefore, effective measures should prevent the entry of foreign material into the fuel
be taken to prevent the entry of foreign matter. system.
3. Disconnect the connected of common rail pressure
sensor, and all the connectors.
Removal
4. Remove the EGR valve and the EGR adapter.
1. Remove the air intake pipe. 5. Tape the EGR case holes shut to prevent the entry
• Disconnect the connector for the intake air of foreign material.
temperature sensor.
2. Remove the fuel leak off hose from the leak off
pipe.
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1C-34 Fuel System
4HK1 4HK1
Name Name
1. EGR Adapter 1. Fuel Injection Pipe
2. EGR Valve 2. Pipe Clip
6. Remove the injection pipe clip and remove the 7. Remove the fuel pipe.
injection pipes.
Note:
Important: Cover the areas exposed during part removal to
Do not reuse the high-pressure pipe in fuel system if it prevent the entry of foreign material into the fuel
has been removed. system.
8. Remove the clip and the fuel leak off pipe.
Note:
Cover the areas exposed during part removal to Note:
prevent the entry of foreign material into the fuel Cover the areas exposed during part removal to
system. prevent the entry of foreign material into the fuel
system.
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Fuel System 1C-35
4HK1
LNW46CSH001601
Name Name
1. Fuel Leak Off Pipe 1. Common Rail Bracket (4HK1)
2. Common Rail
6HK1
Disassembly
1. Remove the fuel pressure limiter.
4HK1
WSHK0051
Name 3 2
1. Fuel Leak Off Pipe
Caution:
• Do not grasp the pressure sensor, during the
common rail removal procedure.
• Take care not to damage the connector unit of the
pressure sensor.
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1C-36 Fuel System
6HK1 6HK1
3 3
WSHK0168 WSHK0168
Name Name
1. Common Rail 1. Common Rail
2. Pressure Sensor 2. Pressure Sensor
3. Pressure Limiter 3. Pressure Limiter
Reassembly Installation
1. Install the fuel pressure limiter. 1. Tighten the common rail bracket to the specified
Tightening torque: 172 N-m (17.5 kg-m/127 lb ft) torque. (4HK1)
Tightening torque: 19 N-m (1.9 kg-m/14 lb ft)
4HK1
2. Tighten the common rail to the specified torque.
Tightening torque: 4HK1: 19 N-m (1.9 kg-m/14 lb ft)
6HK1: 25 N-m (2.5 kg-m/18 lb ft)
Caution:
• Do not grasp the pressure sensor, during the
common rail reassembly procedure.
• Take care not to damage the connector unit of the
pressure sensor.
3 2
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Fuel System 1C-37
4HK1
Important:
Replace the high-pressure pipe in fuel system with new
one if it has been removed.
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1C-38 Fuel System
4HK1 4HK1
Name Name
1. Fuel Injection Pipe 1. EGR Adapter
2. Pipe Clip 2. EGR Valve
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Fuel System 1C-39
Torque Specifications
4HK1
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1C-40 Fuel System
6HK1
39 (4.0 / 2 9 )
WSHK0172
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Engine Electrical
ENGINE
Engine Electrical
TABLE OF CONTENTS
Service Precautions................................................ 1D-2
General Procedure................................................1D-2
Charging System...................................................... 1D-3
General Description..............................................1D-3
Generator (4H K 1).................................................... 1D-5
Removal................................................................. 1D-5
Installation.............................................................1D-6
Torque Specifications............................................1D-6
Specifications........................................................ 1D-7
Generator (6H K 1).................................................. 1D-14
Specifications...................................................... 1D-14
Charging C ircuit.................................................. 1D-14
Structure...............................................................1D-15
Disassembly and Inspection of Generator. . . .1D-16
Inspection.............................................................1D-20
Assem bly.............................................................1D-22
Bench Testing...................................................... 1D-23
Trouble D ia g no sis..............................................1D-24
Specifications...................................................... 1D-24
Starting System...................................................... 1D-25
General Description............................................1D-25
On-machine Service: Starting System 1D-26
Starter (4HK1)........................................................ 1D-27
Removal...............................................................1D-27
Installation...........................................................1D-28
Torque Specifications..........................................1D-28
Main Data and Specifications.............................1D-29
Starter (6HK1)........................................................ 1D-37
Specifications...................................................... 1D-37
Sectional view (reference)................................. 1D-38
Output Characteristic (reference)..................... 1D-39
Disassembly and Inspection of Starter 1D-40
Assembly of S ta rte r............................................1D-46
No Load T e s t...................................................... 1D-50
Specifications...................................................... 1D-50
Preheating S ystem ................................................ 1D-51
Glow Plug Replacement..................................... 1D-51
Precautions on Service W ork.............................1D-52
A List of Defective Phenom ena....................... 1D-52
Main Data and Specifications.............................1D-53
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Engine Electrical
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1D-1 Engine Electrical
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1D-2 Engine Electrical
Service Precautions
General Procedure
When fasteners are removed, always reinstall them at
the same location from which they were removed. If a
fastener needs to be replaced, use the correct part
number fastener for that application. If the correct part
number fastener is not available, a fastener of equal
size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking
compound will be called out. The correct torque value
must be used when installing fasteners that require it. If
the above conditions are not followed, parts or system
damage could result.
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Engine Electrical 1D-3
Charging System
General Description
The main charging system components are the
batteries, the generator and the battery discharge
indicator light circuit. The generator is a selfrectifying
type with a built-in regulator.
Name
1. Generator 8. Plate
2. Lower Mount Bolt 9. Bolt
3. Nut 10. ACG Adjust Bolt
4. Spring Washer 11. Sliding Piece
5. Washer 12. Washer
6. Bracket 13. Adjust Nut
7. Bracket Mount Bolt
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1D-4 Engine Electrical
Maintenance Notice:
The most common indication of charging system To avoid damage to the vehicle electrical system,
troubles is an undercharged or overcharged battery. always observe the following precautions:
Since the battery itself may be defective, the first step • Do not polarize the generator.
should be to check its condition. In the case of an • Do not short across or ground any of the terminals
undercharged battery, check for battery drain caused in the charging circuit except as specifically
by grounds or by accessories left turned on. instructed herein.
Keep the generator and all other electrical system • NEVER operate the generator with the output
terminals clean and tight. A loose or badly corroded terminal open-circuited.
terminal connection will create excessive resistance in
the system and result in hard starting, dim lights etc. • Be sure the generator and battery have the same
Inspect the generator system at regular intervals and ground polarity.
correct any potential causes of trouble before machine • When connecting a charger or booster battery to
performance is affected. the battery, connect negative to negative and
positive to positive.
Diagnosis of Charging System
1. With the engine control switch “ON” and engine not
Trouble in the charging system will be evidenced as
running, connect a voltmeter from terminal “E” to
one or more of the following three conditions:
ground. The voltmeter should show 0 volts.
1. The battery discharge warning light will stay on.
2. With the engine control switch “ON,” and engine
2. An undercharged battery as evidenced by slow not running, connect a voltmeter from terminal “B”
cranking. to ground. The voltmeter should read at least 24
3. An overcharge, or overvoltage, condition. volts.
3. With the engine control switch “ON” and the engine
Undercharged Battery not running, connect a voltmeter from white wire
Inspection side of the connector to ground. The voltmeter
should show 24 volts.
1. Accessories to be sure none were left on for
extended periods. 4. With the engine control switch “ON” and the engine
not running, the “charge” light should be on. This
2. Drive belt for proper tension.
shows that the other circuit in the connection is
3. The ECM main relay has been ON stuck at the key working.
switch OFF position. (Battery voltage is
5. With the engine running and the headlight high
consumed.)
beams (if equipped) turned on, read the voltage at
4. Wiring and connections for corrosion or looseness. the “B” post on the generator. The voltmeter should
Overcharge (or Overvoltage) condition read at least 24 volts.
A charging rate in excess of 29.5-volts for a prolonged 6. If steps 1 through 4 are not OK, check connectors
period may cause early electrical system failure. in the harness for looseness or corrosion and
Blown fuses. light bulbs burned out, and even battery retest.
failure may result. If this condition exists, test the 7. If step 5 voltage is low, substitute a known good
generator as described under “Generator Output Test” regulator and test again. If the voltage is still low,
later in this section. bench test the generator.
Noisy Generator
Inspection
1. Drive pulley for looseness.
2. Mounting bolts for looseness.
3. Bearings for dirt, damage, or wear.
• Generator noise may also be caused by worn or
damaged diodes and/or starter.
Electrical Tests
Before performing the following generator electrical
tests on the vehicle, be certain that the system wiring is
not defective and generator belts are not slipping. Also,
the battery must be fully charged for a valid test of the
charging system.
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Engine Electrical 1D-5
Generator (4HK1)
80
1 2 3 4 5 x1 0 0 0
[r/m in ]
PNW56 AS H004301
Removal
• Battery negative cable.
1. Electrical wiring at the generator.
2. Loosen the adjust nut.
3. Loosen the ACG adjust bolt.
4. Loosen the lower mount bolt.
5. Drive belt
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1D-6 Engine Electrical
6. Generator. 2. ACG Adjust bolt.
3. Adjust nut.
Installation Tightening torque:
Adjust Nut 68 N-m (6.9 kg-m/50 lb ft)
1. Generator.
Tightening torque: 4. Electrical wiring at the generator.
Lower Mount Bolt 127 N-m (13.0 kg-m/94 lb ft) • Battery negative cable.
Torque Specifications
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Engine Electrical 1D-7
Specifications Connector terminal
Name
1. R Terminal
2. L Terminal
Internal connections
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1D-8 Engine Electrical
Disassembly of generator
Disassembly Procedure
1. Screw 13. Collar
2. Cover 14. Ball Bearing
3. Through Bolt 15. Rotor Assembly
4. Rotor, Front Bracket Assembly 16. Screw
5. Nut, Washer 17. Field Coil Assembly
6. Pulley 18. Stator Assembly
7. Fan 19. Holder
8. Collar 20. Regulator Assembly
9. Screw 21. Bolt (B terminal)
10. Retainer 22. Condenser
11. Ball Bearing 23. Rectifier Assembly
12. Front Bracket Assembly is the reverse order of disassembly.
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Engine Electrical 1D-9
Inspection and repair of generator 3. Diode for initiating excitation, Resistor
Check the continuity between connector terminals
1. Diode
R and L with a tester (at Q x 100 range). Normal
Check the continuity of forward and inverse
diodes and resistors show low resistance in
directions with a tester. Normal diodes show low
forward direction and high resistance in inverse
resistance in forward direction and high resistance
one.
in inverse one.
Judge that they are faulty other than those above.
Judge that they are faulty other than those above.
_____________________________________________________________________________ W SHK0106
4. Field coil
Charge the condenser with a tester (at Q x 1000 • To judge the insulating condition of field coil,
range), and connect a tester lead inversely. Judge measure between the protrusion portions and core
it as normal if the needle on a meter deflects a little of the coil with a tester (at Q x 1000 range). Judge
and returns to the original position. as faulty if it has continuity.
Judge that they are faulty other than those above.
W SHK0107
W SHK0105
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1D-10 Engine Electrical
• Measure between the protrusion portions of field • Judge as normal if there is continuity between N
coil with a tester, and judge as normal if the lead of stator coil and three leads.
resistance is about 6.7Q (20°C {68°F}).
W SHK0110
_____________________________________________________________________________ W SHK0108 6. Bearing
5. Stator coil • Check if the bearing rotates smoothly or has no
• To judge the insulating condition of stator coil, noise.
measure between the stator coil and core with a If the result of the inspection is unsatisfactory,
tester (at Q x 1000 range). Judge as faulty if it has replace the bearing.
continuity.
W SHK0109
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Engine Electrical 1D-11
Performance test
In the performance test of generator, connect as
follows and measure the regulated voltage and output
current.
Actual wiring diagram for performance test of IC regulator built-in generator
W SHK0112
Disassembly Procedure
1. Voltmeter 5. Clamp Tester Ammeter
2. R Terminal 6. Battery 24 V
3. L Terminal 7. Variable Resistor
4. Charging Lamp 24 V-3 W
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1D-12 Engine Electrical
Handling of generator
Be careful with the following when handling a
generator.
• Connecting the polarities of battery inversely
causes generator diode to be broken.
• While the engine runs, NEVER disconnect the
wiring of battery terminal and charging circuit.
• Wiring connection to terminal must be performed
properly according to terminal symbol.
• Do not perform megger test on semiconductor
device.
• Be sure to disconnect the battery terminal (-)
before inspection on equipment.
• Do not open/close the battery relay switch while
the engine runs.
• Disconnect the battery terminal when charging
from external source such as quick charge.
• Do not pour steam cleaner or water directly on it.
• After connecting to B terminal and E terminal,
tighten them to the following torque.
B terminal 4.9 N-m {50 kgf-cm/43 lb in}
E terminal 4.9 N-m {50 kgf-cm/43 lb in}
• Refer to “Belt Adjustment” for tension adjustment
of V-belt.
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Engine Electrical 1D-13
Trouble and Action
Action to be
Trouble symptom Trouble location Trouble cause
taken
Charging is Wiring and Open or short circuit, disconnection
Repair
impossible. ammeter
Generator. Open circuit, short to ground, short circuit in each coil Replace
Broken diode Replace
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Insufficient Wiring Open or short circuit, looseness in connection Repair
charging
Generator. Looseness of generator driven belt Repair
Layer or short circuit in field coil Replace
Layer or short circuit in stator coil Replace
Defective diode Replace
Poor contact in each terminal Repair
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Excessive Regulator Defective regulator.
Replace
charging
Unstable charging Wiring Intermittent contact or nearly disconnected connection
Repair
current in wiring
Generator. Looseness of generator driven belt Repair
Short circuit or nearly disconnected connection in field
Repair
coil
Short circuit or nearly disconnected connection in stator
Repair
coil
Poor contact in each terminal Repair
Regulator Defective regulator. Replace
Poor contact in terminal of regulator Repair
Noisy generator Generator. Improper installation of generator Repair
Defective bearing Replace
Contact of rotor core and stator core Repair
Defective diode Replace
Short circuit in stator coil Replace
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1D-14 Engine Electrical
Generator (6HK1)
Specifications
Charging Circuit
Name
1. Field Coil 5. Key Switch
2. Stator Coil 6. Battery 24 V
3. Diode Trio 7. IC Regulator
4. Charging Lamp 8. Generator
Charging circuit and internal circuit are shown in the illustration above.
Charging system consists of IC regulator built-in generator, battery, charging lamp and wires to connect them.
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Engine Electrical 1D-15
Structure
W SHK0092
Name
1. Rear Bracket 6. Rotor
2. IC Regulator 7. Bearing
3. Bearing 8. Pulley
4. Rectifier 9. Front Bracket
5. Stator 10. Coil Assembly (Field Coil)
This generator has no brush. terminal (for direct current output), L terminal and R
Main parts are a rotor, stator, rectifier assembly, front terminal.
bracket, rear bracket, IC regulator, bearing, pulley and The L terminal is connected to field coil. Therefore, as
so on. well as R terminal, it becomes input terminal for
Moving parts are a rotor and pulley. A field coil is initiating excitation current until the generator starts to
secured to rear bracket. generate electric power.
Six main diodes and two additional diodes are used to It also provides function as output terminal. (Current
convert three-phase alternating current, generated in capacity is 1 A.)
stator coil, into direct current. Among six main diodes, The charging lamp will be off if the voltage on L
there are three positive diodes and three negative terminal reaches battery voltage.
diodes. Both bearings are sealed, therefore periodic lubricant is
In addition, three tiny diodes, called trio diode, are used not necessary.
to supply field current. IC regulator cannot be disassembled. Handle it as
This generator has three terminals, which are B assembly.
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1D-16 Engine Electrical
Name
1. Nut Washer 9. Ball Bearing
2. Pulley, Fan 10. Screw
3. Collar 11. Cover
4. Through Bolt 12. Rectifier Assembly
5. Front Bracket 13. Regulator Assembly
6. Ball Bearing 14. Stator Assembly
7. Retainer 15. Field Coil Assembly
8. Rotor Assembly
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Engine Electrical 1D-17
Name
1. Nut Washer 10. Ball Bearing
2. Pulley, Fan 11. Field Coil Assembly
3. Key 12. Connector Set
4. Collar 13. Screw
5. Through Bolt 14. Terminal Set
6. Front Bracket 15. Cover
7. Ball Bearing 16. Rectifier Assembly
8. Retainer 17. Regulator Assembly
9. Rotor Assembly 18. Stator Assembly
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1D-18 Engine Electrical
5. To remove the coil assembly from rear bracket,
firstly remove the screw A (which fixes coil terminal
portion to IC regulator).
Removing a screw B (which fixes the coil assembly
to rear bracket) prior to screw A may cause
damage to terminal portion.
Hold the coil assembly by hand not to damage to
terminal portion.
Then, remove the screw B and remove the coil
assembly.
W SHK0093
Name
1. Ball
Caution:
Do not remove it if not necessary. Do not reuse the
removed bearing.
4. If the rotor bearing needs to be removed, it can be Name
done by a general bearing puller. 1. Connector
Caution:
Do not lose the tube.
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Engine Electrical 1D-19
12
10
W SHK0095
Name
1. IC Regulator 8. Cap
2. Rectifier 9. Nut
3. B terminal 10. Terminal Bolt
4. Terminal Bolt 11. Terminal Bolt
5. B terminal 12. Terminal Bolt
6. Cap 13. Rectifier
7. Nut
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1D-20 Engine Electrical
W SHK0159
Name
1. IC Regulator 4. B terminal
2. Terminal Bolt 5. Tube
3. Nut 6. Rectifier
Caution:
Lead wires of stator coil are soldered (melting point:
230°C {446°F}) on rectifier terminal.
Disconnect them quickly (within five seconds) not to
heat the rectifier causing damage to diode.
Inspection
1. Stator
Check visually for damage, loose connection and
discoloration of coil.
• Check the continuity between two lead wires of Name
stator coil with a circuit tester. Replace the stator if 1. Stator Coil Lead
no continuity is present. -------------------------------
• Check the continuity between lead wire of stator
coil and core with a circuit tester. Replace the
stator if continuity is present.
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Engine Electrical 1D-21
2. Rotor 4. Rectifier assembly
• Check the bearings for noise, rattle or grease • Check the continuity between positive diode,
leakage (wipe off if tiny amount of grease). additional diode positive heat sink on positive side
Replace it if faulty. It is easier to check for noise and four diode terminals with a circuit tester.
and rattle when it is press-fitted into shaft than The positive diode has short circuit if continuity is
when it is a single unit. present in both directions. Replace the rectifier
assembly.
The positive diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.
• Negative diode and additional diode on negative
side
Check the continuity between negative heat sink
and four diode terminals with a circuit tester.
The negative diode has short circuit if continuity is
present in both directions. Replace the rectifier
assembly.
The negative diode has open circuit if no continuity
is present in both directions. Replace the rectifier
assembly.
• Diode trio (three tiny diodes)
Check the continuity in both directions with a circuit
tester.
The diode is faulty if continuity is present in both
directions or no continuity is in both directions.
Name Replace the rectifier assembly.
1. Stator Coil Lead
2. Core
3. Coil assembly
Measure the resistance between terminal portions
with a circuit tester.
Replace the coil assembly if the value is out of
specified value.
Name
1. Diode Terminal Portion
2. Positive Diode
3. A Part of Negative Diode
5. Front bearing
W SHK0098 Check the bearings for noise, rattle or grease
leakage (wipe off if tiny amount of grease).
Name Replace them if faulty. It is easier to check for
1. Terminal noise and rattle when the bearing is press-fitted
2. Terminal Portion into bracket than when it is a single unit.
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1D-22 Engine Electrical
6. Regulator
The regulator cannot be checked with a circuit
tester. After re-assembling the generator, check it
to make sure that regulator controls the voltage for
generator.
Assembly
Assembly can be performed in the reverse order of
disassembly. However, be careful with the following.
1. Lubrication is not necessary. Bearing is filled with
grease and is sealed.
Caution:
Keep a bearing with resin band for rotor shaft away
from oil. Wipe off oil on bearing box area of rear
bracket. Oil may cause creep.
2. Use a high temperature solder (melting point:
230°C {446°F}).
Using a soldering iron (with 180 — 270 watt),
soldering must be performed quickly (within five
seconds) not to heat the rectifier.
3. Tightening torque
• Pulley fixing nut:
132 — 162 N-m {13.5 — 16.5 kg-m/97 — 119 lb
ft}
• Through bolt:
12.8 — 18.6 N-m {1.3 — 1.9 kg-m/9 — 14 lb ft}
• Bearing retainer fixing screw:
2 — 5.3 N-m {20 — 54 kgf-cm/18 — 47 lb in}
• Coil assembly fixing screw:
2 — 5.3 N-m {20 — 54 kgf-cm/18 — 47 lb in}
• Rectifier fixing screw:
2 — 5.3 N-m {20 — 54 kgf-cm/18 — 47 lb in}
• Regulator fixing screw:
2 — 5.3 N-m {20 — 54 kgf-cm/18 — 47 lb in}
• Nut for B terminal bolt:
4.9 — 8.7 N-m {50 — 88 kgf-cm/43 — 77 lb in}
4. Assembly of rear bracket to stator assembly and
front bracket to rotor assembly
• The rotor bearing and rear bracket are engaged
tightly. Heat the bearing box area of rear bracket to
50 — 60°C (122 — 140°F) prior to assembly.
• After re-assembling the generator, rotate the pulley
to confirm that the rotor rotates smoothly.
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Engine Electrical 1D-23
Bench Testing 4. Set the generator speed to approx. 5000 rpm and
read an ammeter. If the value is 5 A or less, read
Bench testing is performed as follows.
indication on a voltmeter. This is regulated voltage.
If an ammeter shows 5 A or more, keep charging
Regulated voltage check
for a while until it shows below 5 A or replace the
1. Wire as shown in the illustration. battery with full-charged one.
Use an ammeter with 100 A rating and a voltmeter If regulated voltage is out of specified value,
with 30 V rating. replace the regulator.
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1D-24 Engine Electrical
Trouble Diagnosis
Specifications
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Engine Electrical 1D-25
Starting System
General Description
Name
1. Starter 3. Ground Cable
2. Nut 4. Bolt
Maintenance
Keep the starter’s exterior clean. Remove corrosion
from the terminals, leads, and connectors.
Tighten the starter to engine mounting bolts and the
electrical cable retaining nuts.
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1D-26 Engine Electrical
Diagnosis of Starting System On-machine Service: Starting System
No Cranking, No Sound Maintenance
• Discharged batteries. Check for the cause of the Keep starter terminals and all other terminals in the
discharged batteries. electrical system clean tight. A loose or corroded
• Sulfated battery terminals. Clean all the battery connection or terminal will cause excessive resistance
terminals and cable ends. in the system that will result in hard starting. At regular
• A starter that draws too much current. intervals, inspect the starting system to locate and
correct potential causes of trouble before the system
• Starter relay won’t work. Attempt to start and listen
performance is affected. Starting motors do not require
for a “click” at the starter relay. If there is no “click,”
lubrication.
check the starter relay control terminals with a test
light. If the test light shows that power is getting to
the starter relay, check the ground circuit with the
test light. If the ground circuit is OK, replace the
starter relay.
• Engine control switch start circuit won’t close.
With the engine control switch turned to start,
check the starter relay with a test light. If the test
light doesn’t come on, check the starter circuit at
the engine control switch with the test light. If the
test light comes on, check the harness for an open
and repair. If the test light does not come on,
replace the engine control switch.
• Starter relay power circuit isn’t closing. Attempt to
start. The starter relay “clicks.” Check the
secondary terminals with a test light. If the test light
lights on the battery side only, replace the starter
relay. If the test light lights on both terminals, check
for an open at the starter.
• Starter clicks when start is attempted. Check all
power connections for corrosion. Clean
connections if corrosion is present. Terminal on
starter should have at least 18 volts on it when
cranking the engine. If voltage is OK, replace the
starter.
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Engine Electrical 1D-27
Starter (4HK1)
16 80 4 I N
>/
\
\ /
/ NA
12 3 /\ / N
60
\/ / \
8 40 2
\
/ \\ X
i. V ”
/
4 20 1 \
/ \
0 0 0
0
// 200 400 600, . . , 800 1000 1200
I fA]
Removal
1. Battery negative cable from the battery.
2. Cables and electrical leads from the starter.
3. Two mount nuts.
4. Starter.
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1D-28 Engine Electrical
Installation 3. Cables and electrical leads to the starter.
1. Starter 4. Battery negative cable to the battery.
2. Two mount nuts.
Tightening torque:
Mount nuts 82.4 N-m (8.4 kg-m/61 lb ft)
Torque Specifications
N -m {kg m /lb-ft}
82.4{8.4 / 60}
82 .4{8.4 / 60}
PNW56ALF002601
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Engine Electrical 1D-29
Main Data and Specifications
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1D-30 Engine Electrical
Connections (Nikko Electric Industry Co., Ltd)
Name
1. Starter Relay 3. Motor
2. Battery 4. Magnetic Switch
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Engine Electrical 1D-31
Disassembly of starter
24 V 5.0KW (Nikko Electric Industry Co., Ltd)
Name
1. Clip Ring 15. Ball
2. Pinion Stopper, Pinion, Spring 16. Rubber Bushing
3. Lead Wire 17. Plate
4. Bolt 18. Spring
5. Magnetic Switch 19. Pin
6. Screw 20. Holder
7. Bolt 21. Shift Lever
8. Rear Bracket 22. E Clip
9. Brush Holder ASM 23. Overrunning Clutch ASM
10. Yoke ASM 24. Internal Gear
11. Armature 25. Washer
12. Cover 26. Drive Shaft ASM
13. Packing 27. Front Bracket ASM
14. Idle Gear Assembly is the reverse order of disassembly.
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1D-32 Engine Electrical
Inspection and repair of starter Contact Point Check
Service limit of contact point is judged by damaged
1. Magnetic switch
condition on contact surface in the following procedure.
Never perform operational check on magnetic
Measure the load current on starter. Replace it if
switch as single unit.
voltage drop between terminals B and M is 0.3 V or
Inspection of coil more per 100 A.
• Check the pressure coil C1 and holding coil C2 for
open circuit using a tester. Caution:
Check the continuity between magnetic switch and Use a digital voltmeter to measure voltage drop. Using
M terminal. It has open circuit if no continuity. an analog voltmeter may damage itself.
(Resistance approx. 1.6Q)
W SHK0115
• Supply 24 V between M terminal of magnetic Bentness measurement of shaft
switch and case, push the plunger by hand, and Measure with a dial gauge, and repair or replace if
then release it. It is normal if it is not sucked. Coil is bentness is 0.05 mm (0.0020 in) or more.
defective if it is sucked.
Caution:
Perform this while the magnetic switch is set up.
W SHK0118
W SHK0116
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Engine Electrical 1D-33
Inspection of commutator Inspection of armature coil
• Check the surface of commutator. File the • Using a growler tester, put probe on a armature
surface smooth with No.400 to 600 sand paper core. It is normal if probe does not vibrates.
if it is rough. Repair with a lathe if deflection is • Check with a tester. It is normal if there is no
0.1 mm (0.004 in) or more. continuity between commutator and shaft.
(0.02-0.03)
WSHK0120
Name
1. Repair is needed
2. Improper repair
3. Good
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1D-34 Engine Electrical
6. Bearing
• Check if the bearing outer race rotates smoothly by
hand.
mm (in)
Standard Limit
17 — 18 (0.669 — 0.709) 10 (0.394)
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Engine Electrical 1D-35
Handling of starter
1. Precautions on handling
• Improper gap between pinion and ring gear causes
faulty mesh. (Gap 2 — 5 mm {0.079 — 0.197 in})
• Also, the front bracket is installed on the engine
side securely.
• Be sure to turn off the battery switch before
removal/installation of stater.
• Tightening/inserting wiring must be performed
properly. Improper work causes starting trouble
due to high contact resistance.
2. Precautions on starting
• Be careful with charging status of battery.
Insufficiently-charged battery causes starting
trouble.
• After checking engine starting, turn off the stater
switch immediately.
• One continuous use should be less than 10
seconds. If re-starting is needed, wait until the
pinion stops completely.
• If the starter does not stop rotating when the starter
switch is turned off, turn off the battery switch
immediately. In this case, check the wiring, switch,
etc.
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1D-36 Engine Electrical
Trouble countermeasure
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Engine Electrical 1D-37
Starter (6HK1)
Specifications
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1D-38 Engine Electrical
W SHK0069
Name
1. Through Bolt 8. Pinion
2. Bearing 9. Bearing
3. Rear Bracket 10. Front Bracket
4. Brush Holder 11. Gear
5. Magnetic Switch 12. Yoke
6. Shift Lever 13. Armature
7. Gear Shaft
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Engine Electrical 1D-39
Output Characteristic (reference)
Current (A) — ►
WSHK0070
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1D-40 Engine Electrical
W SHK0071
Name
1. Snap Ring 16. Plate
2. Stop Ring 17. Packing
3. Pinion 18. Packing
4. Pinion Spring 19. Plate
5. Lead Wire with Terminal 20. Planetary Gear
6. Screw 21. Lever
7. Magnetic Switch 22. E-shaped Retaining Ring
8. Screw 23. Overrunning Clutch
9. Through Bolt 24. Internal Gear
10. Rear Bracket 25. Washer
11. Yoke Assembly 26. Gear Shaft
12. O-Ring 27. Front Bracket
13. Brush Holder 28. Bearing
14. Armature 29. Washer
15. Ball 30. Brush
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Engine Electrical 1D-41
Disassembly
Caution:
• Before disassembling the starter, put alignment
marks on each magnet switch, yoke front bracket
and rear bracket to facilitate re-assembly.
• In normal condition, if tap the pinion or stop ring
toward the front bracket side, the front bracket will
be broken. Therefore, tap the stop ring when the
pinion come out to cranking position.
1. Connect the starter to battery as shown in the
illustration.
When closing the switches SW1 and SW2, the
pinion move forward to the cranking position and
the armature rotates.
Then, open the switch SW2 to stop the armature
rotating.
Caution:
Remove the pinion within 10seconds since heat is Name
generated during electric discharge. 1. Pinion
2. Clutch Shaft
3. Snap Ring
4. Stop Ring
5. Pipe
6. Pinion Spring
Caution:
Tightening screw is tight. Use a shock driver to loosen.
4. Remove the brush holder-tightening screw and
through bolt.
Then, remove the rear bracket and O-ring
W iring diagram to move pinion forward
together.
Caution:
Do not reuse the removed O-ring.
WSHK0072 Also, do not reuse also O-ring on tightening screw.
2. Apply the pipe, which just fits the stop ring, on the 5. Apply a socket (outside diameter 32 mm
ring and tap the pipe with a hammer to remove the {1.260 in}) on a commutator of armature.
stop ring toward the pinion side once. Then, slide the brush on the socket to yoke
Then, remove the snap ring and remove the stop assembly and O-ring.
ring, pinion and pinion spring. This facilitates to re-assemble.
Caution: Caution:
Do not reuse the snap ring. Do not reuse the removed O-ring.
6. Remove the brush from brush holder by pulling up
the brush spring, and then remove the brush
holder.
7. Remove the armature.
Remove a bearing using a general puller.
8. Remove the plate in planetary gear and remove
the packing.
Then, remove the packing and plate on the lever
support.
9. Remove the internal gear, gearshift, overrunning
clutch and lever as a unit from front bracket.
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1D-42 Engine Electrical
10. Remove the lever. • Check the armature coil for grounding (faulty
insulating) with a circuit tester.
Caution: Replace the armature if grounding is present.
Remember the direction of lever.
11. Remove the two E-shaped retaining ring.
To remove the overrunning clutch, rotate the spline
by one tooth to remove it from gearshift assembly.
Caution:
Do not reuse removed E-shaped retaining ring.
12. Remove the internal gear.
In this time, take out one washer which adjusts
axial play of gearshift.
W SHK0076
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Engine Electrical 1D-43
• Check the depth (undercut) of insulating mold of • Check the coil for grounding (faulty insulating) with
commutator. a circuit tester.
Remove abrasion powder on brush, and repair if Repair or replace the yoke assembly if grounding
faulty. is present.
Name
1. Good • Measure the length of the brush.
2. Insulating If it is worn to the limit, replace the brush holder
3. Commutator Segment assembly on the brush holder as a unit and only
4. Defective brush on the yoke assembly side.
• Make sure the brush moves smoothly in the brush
• Check the gears for wear or damage. holder. Also, check the brush spring pressure.
Replace the armature if fault is present.
• Check the bearings for noise, rattle or grease
leakage.
2. Field coil
• Check the coil for open circuit with a circuit tester.
Replace the yoke assembly if open circuit is
present.
W SHK0078
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1D-44 Engine Electrical
• Check the brush holder for grounding (faulty
insulating) with a circuit tester.
Clean the brush holder before checking.
Replace the brush holder assembly if the
continuity is present when putting one probe of
circuit tester to brush holder plate (metal part) and
another one to insulated holder.
Caution:
Grease is present in overrunning clutch. Do not use
wash oil or cleaning agent for cleaning.
Wipe off stain on overrunning clutch with a cloth.
Name
1. Worn Part
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Engine Electrical 1D-45
8. Magnetic switch
Check the continuity between the M terminal and
the body, and replace the magnet switch if no
continuity is present.
Then, make sure that no continuity is present
between B terminal and M terminal. Replace the
magnet switch if continuity is present.
Name
1. M Terminal
2. S Terminal
3. B Terminal
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1D-46 Engine Electrical
Assembly of Starter
Assembly diagram: Assemble in the order of the numbers.
24
WSHK0084
Name
1. Brush 16. Ball
2. Washer 17. Armature
3. Bearing 18. Brush Holder
4. Front Bracket 19. O-Ring
5. Gear Shaft 20. Yoke Assembly
6. Washer 21. Rear Bracket
7. Internal Gear 22. Through Bolt
8. Overrunning Clutch 23. Screw
9. E-shaped Retaining Ring 24. Magnetic Switch
10. Lever 25. Screw
11. Planetary Gear 26. Lead Wire with Terminal
12. Plate 27. Pinion Spring
13. Packing 28. Pinion
14. Packing 29. Stop Ring
15. Plate 30. Snap Ring
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Engine Electrical 1D-47
1. Lubricant locations and tightening torque
Shown in
the Lubricant locations Lubricant agent
illustration
A Sleeve bearing and ball Molycote® AG650
B Clutch shaft sliding surface MULTEMP 6129
C Spline portion and sliding portion of gearshift MULTEMP 6129
D Sliding portion of lever and overrunning clutch Molycote® AG650
E Armature shift gear, planetary gear, internal gear Molycote® AG650
F Under pinion MULTEMP 6129
G Outer surface of armature bearing (tiny amount) MULTEMP 6129
H Oil seal MULTEMP 6129
I Surface of plunger (tiny amount) MULTEMP 6129
2. Axial play of armature shift Pass the gear shaft through washer, internal gear
Adjustment is unnecessary (assemble the ball into and overrunning clutch. Then move the
a tip of shaft.) overrunning clutch by one tooth of spline to make
3. Axial play of gear shaft sure that the clutch cannot be pulled out.
Adjustment is unnecessary Assemble the E-shaped retaining ring.
Appropriate gap will be obtained automatically
Caution:
when one washer (removed in step 12 of
disassembly procedure) is inserted between • Do not reuse removed E-shaped retaining ring.
internal gear and gearshift.
4. Assembly of gearshift
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1D-48 Engine Electrical
• If assembling the E-shaped retaining ring prior to
the overrunning clutch, the clutch cannot be
assembled. Be careful with it.
W SHK0087
Name
1. Pinion
2. Clutch Shaft
Name 3. Snap Ring
1. Overrunning Clutch 4. Stop Ring
2. Washer 5. Pinion Spring
3. Gear Shaft
4. E-shaped Retaining Ring 6. Check of the pinion protruded position
5. Internal Gear After assembling the starter, check the protruded
position of pinion.
5. Assembly of pinion How to measure and adjust
Assemble the pinion spring, pinion and stop ring to • Connect the starter to battery.
clutch shaft in this order, then assemble the snap When closing the switches SW1 and SW2, the
ring to the groove of clutch shaft at the end. pinion move forward to the cranking position
Then, pull strongly the stop ring toward the snap and the armature rotates.
ring side with a gear puller and fix both of them. Then, open the switch SW2 to stop the
armature rotating.
Caution:
• Assemble the pinion before assembling the
magnet switch to front bracket.
• Do not reuse the removed snap ring.
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Engine Electrical 1D-49
• Push into or pull back a tip of the crankshaft
lightly by hand and measure the moving
distance of it.
Adjust by using one or two packings (0.5 mm
{0.020 in}) of magnet switch and front bracket
so that this measurement value is between 0.5
— 2.0 mm (0.020 — 0.079 in).
If this adjustment cannot be done, replace the
lever.
W SHK0088
Name
1. Battery 24 V
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1D-50 Engine Electrical
No Load Test
1. After adjusting the protruded position of pinion,
connect the starter as shown in the illustration
above.
Caution:
Use a thick electric wire and tighten the connected
portion securely.
2. Close the switch and read the speed, current and
voltage.
If the measured values are out of specified value,
disassemble and inspect again.
W SHK0090
Name
1. Battery 24 V
2. Ammeter
3. Voltmeter
Specifications
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Engine Electrical 1D-51
Preheating System
Glow Plug Replacement
LNW21BSH055301
Installation Procedure
1. Install the glow plug.
Tightening torque: 20 N-m (2.0 kg-m/15 lb ft)
2. Install and tighten the glow connector with the
designated torque.
Tightening torque: 1.2 N-m (0.1 kg-m/11 lb in)
3. Install the EGR valve and the EGR adapter.
PNW56ASH002201
Name
1. EGR Adapter
2. EGR Valve
PNW56ASH002201
Name
1. EGR Adapter
2. EGR Valve
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1D-52 Engine Electrical
Precautions on Service Work
Adequate care should be taken as over-tightening the
glow plug could lead to damage.
Explanations on functions and operation
The preheating system consists the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and make the engine easy to start.
Glow plug check
• Use the circuit tester and measure the resistance
of the glow plug.
• If the measured value deviates from the specified
value, then replace the glow plug.
• Resistance value of glow plug is approximately
less than 5Q.
Caution:
Use glow plugs from the same manufacturer.
LNW21KSH000701
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Engine Electrical 1D-53
Trouble Shooting
Item Model
Preheating device model Glow plug
Glow plug rated voltage/ current (V-A) 23 - 3.5
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1D-54 Engine Electrical
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Exhaust System
ENGINE
Exhaust System
TABLE OF CONTENTS
EGR System ............................................................. 1F-2
Precautions on Service W ork............................... 1F-2
Explanations on Functions and Operation ......... 1F-2
EGR Valve and EGR Cooler .................................. 1F-3
Components.......................................................... 1F-3
Removal ................................................................ 1F-3
Inspection............................................................... 1F-4
Installation ............................................................ 1F-4
Torque Specifications............................................ 1F-5
Exhaust S y s te m .......................................................1F-6
A List of Defective Phenom ena........................... 1F-6
Troubleshooting.....................................................1F-6
Turbocharger (6 H K 1 ).............................................. 1F-7
Table of Specifications..........................................1F-7
Turbocharger Structured D iagram .......................1F-8
Disassembly and Inspection of Turbocharger . . 1F-9
Assembly of Turbocharger................................. 1F-15
Turbocharger (4 H K 1 )............................................ 1F-20
Measurement Tool...................................................1F-21
Other M aterial.........................................................1F-21
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Exhaust System and Turbocharger
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Exhaust System and Turbocharger 1F-1
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1F-2 Exhaust System
EGR System
Precautions on Service Work Explanations on Functions and Operation
Perform EGR related assembly according to the usual Re-circulate a part of the exhaust gas of the EGR
procedure of temporarily fitting and then permanently system in the intake manifold. Reduce the combustion
tightening the parts so that unnecessary stresses are temperature and inhibit NOx generation since inert
not applied on the parts. gases may be mixed up in the intake air.
An electronic control system is used in this EGR to
balance the requirements of operability and low
emissions. A DC motor is operated using the control
current of the Engine Control Module (ECM) to control
the EGR.
Refer to the chapter on Engine Control System for
details on fault diagnosis of the EGR system.
Name
1. EGR Cooler 3. EGR Valve DC Motor
2. Engine Control Module (ECM)
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Exhaust System 1F-3
PNW56ALF002001
Name
1. EGR Adapter 4. EGR Pipe
2. Cooling Water Pipe (out) 5. Cooling Water Pipe (in)
3. EGR Cooler 6. EGR Valve
Removal
1. Drain the coolant.
2. Disconnect the EGR valve connector.
3. Remove the EGR pipe.
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1F-4 Exhaust System
2. Install the EGR cooler.
• Temporarily fit the EGR cooler to the bracket.
Notice:
Temporarily tighten the bolts.
3. Install the EGR adapter.
• Temporarily fit the EGR adapter between the EGR
cooler and exhaust manifold.
Notice:
Temporarily tighten the bolts.
4. Install the EGR pipe.
• Insert the gasket between the two ends of the EGR
pipe and temporarily fit it.
Notice:
Temporarily tighten the bolts.
During temporary assembly, tighten the nuts
* 4HK1 is shown for illustration. and bolts to the specified torque in the order
shown in the illustration.
Name
1. EGR Adapter
2. Cooling Water Pipe (out)
3. EGR Cooler
4. EGR Pipe
5. Cooling Water Pipe (in)
Caution:
After removing the EGR valve and EGR adapter, seal
so that foreign matter does not enter.
Inspection
Name
Installation
1. Mount the EGR valve. 1 ~ 9 Show the Order of Tighten Bolts and Nuts.
• Insert the gasket and temporarily fit the EGR valve. Tightening torque
1, 2: 28 N-m (2.9kg-m/21 lb ft)
Notice:
Temporarily tighten the bolts. 3, 4, 5, 6: 24 N-m (2.4 kg-m/18 lb ft)
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Exhaust System 1F-5
Torque Specifications
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1F-6 Exhaust System
Exhaust System
A List of Defective Phenomena
• Vibration or rattling noise from the exhaust system
• Clogging of exhaust system
• Exhaust leakage or noise
Troubleshooting
Vibration or rattling noise from the exhaust system
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Exhaust System 1F-7
Turbocharger (6HK1)
Table of Specifications
Assembly
Item Service limit
specifications
Turbine shaft Axial play mm (in) 0.06 — 0.09
0.11 (0.00433)
(0.00236 — 0.00354)
Radial play mm (in) 0.10 — 0.17
0.205 (0.00807)
(0.00394 — 0.00669)
Journal outside diameter (A) mm (in) — 11.380 (0.44803)
Sealing groove width (B) mm (in) — 1.33 (0.05236)
Runout mm (in) — 0.11 (0.00433)
Sealing Turbine side (bearing housing) (F) mm (in) — 17.03 (0.67047)
insertion part Compressor side (seal plate) (H) mm (in) — 14.05 (0.55315)
Oil thrower Sealing groove width (G) mm (in) — 1.52 (0.05984)
Bearing Bearing housing inner diameter (B) mm (in) — 16.11 (0.63425)
housing Thrust bearing inside diameter for (L) mm (in)
— 23.020 (0.90630)
press-fit portion
Thrust Bearing pad height at compressor side (J) mm (in) 0.0 — 0.060
—
bearing (0.0 — 0.00236)
Thrust collar thickness (K) mm (in) — 2.950 (0.11614)
E G
W SHK0126
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1F-8 Exhaust System
Turbocharger Structured Diagram
Name
1. Turbine Housing 6. Seal Plate
2. Heat Protector 7. Compressor Impeller
3. Floating Metal 8. Seal Ring
4. Oil Thrower 9. Seal Ring
5. Compressor Housing 10. Turbine Shaft
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Exhaust System 1F-9
Disassembly and Inspection of Turbocharger
Disassembly diagram: disassemble in the order of the numbers.
Name
1. Compressor Housing 10. Seal Ring
2. Nut 11. Gasket
3. Compressor Impeller 12. Heat Protector
4. Seal Plate 13. Thrust Bearing
5. Oil Thrower 14. Thrust Collar
6. Seal Ring 15. Snap Ring
7. G Coupling 16. Floating Metal
8. Turbine Housing 17. Thrust Bearing
9. Turbine Shaft 18. Bearing Housing
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1F-10 Exhaust System
Disassembly
Caution:
If you perform inspection with the turbocharger
removed from the engine, plug the oil port opening
before work.
turbine shaft
Insert a thickness gauge into the gap between the
compressor impeller and housing, and measure
the clearance.
The thickness gauge to be inserted must be 0.2
mm (0.0078 in) or less.
1. Compressor housing
• Put alignment marks between the compressor
housing and the seal plate, and tap the
compressor housing to drive it out.
• Liquid gasket is applied to the mating surfaces of
the compressor and the seal plate.
Caution:
Take care not to damage the impeller during removal of
W SHK0129 the compressor housing.
• Measurement of radial play of turbine shaft
W SHK0131
Name
1. Alignment Mark
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Exhaust System 1F-11
2. Compressor impeller 4. Oil thrower
• Attach the box spanner to the turbine-side shaft • Remove the oil thrower from the seal plate.
end of the turbine shaft, and remove the nut. The 5. G coupling
nut is left-hand screw.
• Loosen the nut and remove the G coupling from
• Remove the impeller from the turbine shaft. the turbine housing and the center housing.
• Washing of impeller 6. Turbine housing
Soak in the cleaning solvent until the foreign
• Remove the center housing from the turbine
matters soften, and clean it with a plastic scraper
housing.
or hard brush.
• Washing of turbine housing
Caution: Soak in the cleaning solvent to remove the foreign
Do not use a wire brush. matters.
Name
• Hold the heat protector lightly by hand, and take
1. Left-hand Thread
out the turbine shaft.
3. Seal plate • If it is hard to remove, lightly tap the compressor-
side shaft end with a wooden hammer.
• Loosen the pot small screw.
• Washing of turbine shaft
• Lightly tap the bearing housing in the seal plate
Soak in the cleaning solvent until the foreign
with a wooden hammer.
matters soften, and clean it with a plastic scraper
• Liquid gasket is applied to the mating surfaces of or hard brush.
the seal plate and the bearing housing.
Caution:
• Do not use a wire brush.
• Foreign matters remaining on the surface causes
the unbalance of weight. Therefore, wash it
thoroughly.
• Take care not to damage the floating metal contact
surface of the shaft and the seal ring groove.
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1F-12 Exhaust System
Inspection
Compressor housing
• Check the compressor housing for crack or
damage, and replace if defective.
Caution:
While pushing out with a bar, take care that they do not
run on to damage the snap ring.
12. Snap ring
• Remove the 2 snap rings from the bearing housing
with snap ring pliers.
13. Seal ring
• Remove the seal rings from turbine shaft and oil
thrower.
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Exhaust System 1F-13
Heat protector • Measurement of turbine shaft runout
• Check the heat protector for damage, thermal
Turbine shaft runout mm (in)
deformation or corrosion.
Service limit 0.011 (0.00043)
Oil thrower
Name • Inspection of damage on the oil thrower sliding
1. Journal outer diameter surface, measurement of the seal ring groove
2. Ring groove width width
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1F-14 Exhaust System
Thrust collar
• Measure the thrust collar thickness (K), and
replace with new one if it exceeds the service limit.
W SHK0143
G coupling
• Replace with new one.
Seal ring
• Replace with new one.
Others
• Check the bolts for deformation, and replace with
new ones if faulty. Also, replace the Plate small
screw with new one.
Thrust bearing
• Replace the compressor-side and the turbine-side
thrust bearings with new ones.
Floating metal
• Replace the floating metal with new one.
Bearing housing
• Check the casting surface for peeling from
oxidation-deterioration, dent or crack. Replace with
new one if faulty.
mm (in)
Location Service limit
Bearing housing inner diameter (B) 16.11
(0.6343)
Turbine-side seal ring insertion (F) 17.03
part (0.6705)
Turbine-side thrust bearing (L) 23.02
press-fit part inner diameter (0.9063)
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Exhaust System 1F-15
Assembly of Turbocharger
Assembly diagram: Assemble in the order of the numbers.
Assembly Procedure
1. Bearing Housing 10. Gasket
2. Snap Ring 11. Turbine Housing
3. Floating Metal 12. G Coupling
4. Thrust Bearing 13. Seal Ring
5. Seal Ring 14. Oil Thrower
6. Heat Protector 15. Seal Plate
7. Turbine Shaft 16. Compressor Impeller
8. Thrust Collar 17. Nut
9. Thrust Bearing 18. Compressor Housing
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1F-16 Exhaust System
Assembly
1. Bearing housing
• Check that the bearing housing is free of damage
and foreign matters.
2. Snap ring
• Install the 2 snap rings to the bearing housing with
snap ring pliers.
• After assembling the floating metal (turbine side),
install the snap ring at the position shown in the
figure.
W SHK0146
Name
1. Apply Oil.
4. Thrust bearing
a. Press-fitting of turbine-side thrust bearing
• Press-fit the turbine-side thrust bearing into the
bearing housing.
• Position the pawl of the turbine-side thrust
bearing for more than 2 mm (0.0787 in) apart
from the existing press-fitting part.
• Do not press the thrust bearing pad surface
Name
during press-fitting.
1. Turbine-Side Floating Metal
• The press-fit pressure must be between 215.6
3. Floating metal N {22.0 kgf} and 1862 N {190 kgf}.
• Apply oil to the floating metal, and assemble it to • After press-fitting, remove the dust powder
the bearing housing. using vacuum.
After securing it with a snap ring, assemble the
compressor-side floating metal.
Caution:
• Place the snap ring with its rounded-side facing to
the floating metal.
• Assemble the inner snap ring with its end gap
facing to the oil outlet-direction of the housing, to
prevent it from blocking the oil path.
• Assemble the turbine-side snap ring to the housing
with its end gap facing to the direction as shown in
the illustration.
• Apply oil to the floating metal before assembly.
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Exhaust System 1F-17
b. After press-fitting, check the depth and flatness
of the turbine-side thrust bearing.
(Depth 3.08±0.02 mm {0.1213±0.0008 in},
Flatness is below 0.01 mm {0.0004 in}: See
illustration)
Name
1. Apply Oil.
8. Thrust collar
• Apply engine oil to the thrust collar, and install ti to
Name the turbine shaft.
1. Common Tolerance
9. Thrust bearing
5. Seal ring • Apply engine oil to the metal portion of the thrust
bearing, and insert it to the bearing housing.
• Insert the seal ring to the turbine shaft.
• Apply Loctite to the Plate small screw threads, and
• Use new seal ring.
install it using torque screwdriver.
6. Heat protector
Tightening torque: 3.7 N-m (0.38 kgf-m/33 lb in)
• Install the heat protector to the bearing housing.
7. Turbine shaft
• Apply engine oil to the journal portion of the turbine
shaft, and insert it from the turbine side of the
bearing housing.
• Take care not to damage the floating metal with the
turbine shaft. Also, insert with the end gap of the
seal ring facing to the oil inlet side so that its core
matches with the turbine shaft.
W SHK0150
Name
1. Apply Oil.
10. Gasket
• Set the gasket to the turbine housing, and install it
to the bearing housing.
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1F-18 Exhaust System
11. Turbine housing
• Assemble by aligning the phase of the turbine
housing and the bearing housing with the turbine
housing positioning pin and the bearing housing
hole.
Name
1. Approx. 60°
2. Approx. 60°
3. Torque Wrench
Hammering procedure
a. Check that it does not run on the turbine 1) Using a metal hammer (Approx. 250g in
housing or the bearing housing. weight), lightly tap 2 to 3 times (same place),
b. Tighten temporarily to the specified torque from the outer portion toward the center.
using a torque wrench. 2) Do not hammer the G coupling directly. Place
Tightening torque: 83 N-m (8.5 kgf-m/61 lb ft) brass bar between as shown in the illustration.
Name
1. Approx. ^ 13 mm (0.5 in)
2. Hammer
3. G Coupling
4. Bearing Housing
5. Gasket
6. Heat Shield Plate
7. Turbine Housing
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Exhaust System 1F-19
13. Seal ring • Align the alignment marks that marked during the
• Install the seal ring to the oil thrower. disassembly, and assemble the compressor
housing to the seal plate.
• Use new one.
14. Oil thrower Tightening torque: 7.9 N-m (0.81 kgf-m/70 lb in)
W SHK0154
16. Compressor impeller
• Insert the compressor impeller to the turbine shaft.
17. Nut
• Attach the box spanner to the turbine-side shaft
end of the turbine shaft, and tighten the nut.
• The nut is left-hand thread. Make sure the turning
direction.
Tightening torque: 7.8 N-m (0.80 kgf-m/69 lb in)
18. Compressor housing
• Apply liquid gasket to the compressor-side flange
surface of the seal plate. Illustration shown in the
previous page (A)
Application thickness 0.1 — 0.2 mm (0.004 —
0.008 in)
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1F-20 Exhaust System
Turbocharger (4HK1)
Inspection of Turbocharger
Inspection
Caution:
Turbocharger on 4HK1 engine cannot be overhauled
structurally.
____________________________________________________________________________W SHK0129
• Inspection of radial play of turbine shaft
Insert a thickness gauge into the gap between the
compressor impeller and housing, and measure
the clearance.
The thickness gauge to be inserted must be 0.2
mm (0.0078 in) or less.
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Exhaust System 1F-21
Measurement Tool
r 5 .............
—
diameter
Measurement of thrust bushing groove
clearance
W SHK0157 Measurement of thrust bearing thickness
Measurement of floating metal inner/outer
diameter
Measurement of inner diameters of the center
housing metal portion and ring portion
Dial gauge Measurement of turbine shaft axial gap, radial
gap and runout
c
eI Y —
W SHK0158
Other Material
Name Usage
Besco super engine oil Floating metal sliding portion
Thrust bushing sliding portion
Thrust bearing sliding portion
Turbine shaft journal portion
ThreeBond No. 1207 Housing installing surface of the seal plate
Flange of the compressor housing
Loctite No. 242 Seal plate tightening screw thread
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1F-22 Exhaust System and Turbocharger
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