Isuzu WSM

WORKSHOP MANUAL
N SERIES
∗R99.00.01-01-E
PubNo. N∗
THIS MANUAL INCLUDES FOLLOWING SECTIONS:
G. Export 99.00MY
SECTION CONTENTS
0 GENERAL INFORMATION
1 HEATING,VENTILATION AND AIR CONDITIONING
2 FRAME AND CAB
3 STEERING,SUSPENSION WHEELS AND TIRES
4 PROPELLER SHAFT AND AXLE
5 BRAKES
6 ENGINE (4H SERIES)
6 ENGINE (4J SERIES)
7 AUTOMATIC TRANSMISSION (450-43LE)
7 MANUAL TRANSMISSION AND CLUTCH
(MSB TYPE)
(MXA TYPE)
(MBP TYPE)
8 CAB AND CHASSIS ELECTRICAL
(LEFT HAND DRIVE MODEL)
(RIGHT HAND DRIVE MODEL)
POWER TAKE OFF
Europe 00MY
SECTION CONTENTS
0 GENERAL INFORMATION (EUROPE)
2 FRAME AND CAB
5 BRAKES
(MSB TYPE)
(MXA TYPE)
(MBP TYPE)
Europe 01MY
SECTION CONTENTS
0 GENERAL INFORMATION (EUROPE)
2 FRAME AND CAB
5 BRAKES
5A4 ANTI-LOCK BRAKE SYSTEM (ABS)
(MSB TYPE)
(MXA TYPE)
(MBP TYPE)
(ANTI-LOCK BRAKE SYSTEM<ABS>SUPPLEMENT)
Australia 00MY
SECTION CONTENTS
2 FRAME AND CAB
5 BRAKES
(MXA TYPE)
(MBP TYPE)
WORKSHOP MANUAL
N-SERIES
POWER TAKE OFF

(with oil pump)
International Service & Parts

Tokyo, Japan
NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
“GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS
MANUAL”.
All material contained in this Manual is based on the latest

product information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.
Applicable Model :
N-Series
This manual is applicable to 1994 year model and later vehicles.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION NO. CONTENTS

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POWER TAKE OFF
CONTENTS
PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
On-Vehicle Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection and Supply of The Hydraulic Operating Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Supply Procedure of Hydraulic Operating Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
If the Dump Rise Operation is Disabled by Itself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Total Replacement of Hydraulic Operating Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Bleeding Procedure of Hydraulic Operating Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Cable (For Rear Dump Truck). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil Pump Unit (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PTO (with Oil Pump) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Main Data and Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 POWER TAKE-OFF
GENERAL DESCRIPTION
The side with an oil pump PTO integrates the PTO The oil pump section consists of the gear pump
and the oil pump and installed in the left side of a part and the hydraulic circuit switching part, and
transmission. The shift rod for switching the "ON" the gear pump section fixs efficiency by selecting
and "OFF" of the hydraulic circuit of the PTO is and assembling the side plate. Further, the
provided at the bottom of the PTO and the oil hydraulic circuit switching portion switches the
pump main unit. three positions of "Up", "Neutral", and "Down" by
The "ON" and "OFF" of the PTO uses a gear slide the spool provided on the rod extension.
system and turn on and off the power by sliding The dump control system uses a cable system.
the output gear.
The idle gear bearing uses a needle bearing and
the output shaft uses a ball bearing to ensure
durability.
CROSS-SECTION VIEW
* This illustration is based on a rear dump truck model.
Idle gear Needle bearing
Output shaft
Output gear
Oil seal (output shaft side)
Oil pump (gear pump section)
PTO oil pump assembled point assembly drawing

PTO side Section A-A, Pump side Section C-C (Illustrated by rotating by 90 degrees counterclockwise)
PTO Rear ball bearing Bolt (oil pump to PTO)

Front ball bearing
Flow control
Shift arm (decompression valve)
Check valve B
(swing check valve)
Control cable C
connector Shift cap
A
A
D
D
Cable C
connector Spool Stopper adapter
Inner rod
Shift rod
Oil seal
O-ring Oil pump
(shift rod side) B
(hydraulic circuit switching section)
PTO oil pump hydraulic switching assembly drawing)
PTO side Section B-B, Pump side Section D-D
281LX00090
HYDRAULIC CIRCUIT DIAGRAM
Dump cylinder
Check valve Flow control valve

(swing check valve) (decompression valve)
Operation lever
(PTO interlocking)
Down Neutral Up
Spool valve
Oil pump
Oil reserve tank
D08LX00103
Dump cylinder

Operation lever
(PTO interlocking)
Neutral
Down Up
Spool valve
Oil pump
Oil reserve tank
D08LX00104
4 POWER TAKE-OFF
Dump cylinder

Operation lever
(PTO interlocking)
Down
Neutral Up
Spool valve
Oil pump
Oil reserve tank
D08LX00105
SYMBOL FOR HYDRAULIC CIRCUIT
Symbol Meaning of symbol Symbol Meaning of symbol
Check valve (swing check

Spring
valve)
D08LX151 D08LX156
Detent (position stop

Cylinder
system)
D08LX152 D08LX157
Flow control valve

Manual lever (dump lever) (decompression valve)
(internal pilot method)
D08LX153 D08LX158
Hydraulic switching valve

Oil tank
(three-position valve)
D08LX154 D08LX159
Oil pump (unidirectional

flow)
D08LX155
ON-VEHICLE SERVICE
Inspection and Supply of The Hydraulic
Operating Fluid
NOTE:
When inspecting and supplying hydraulic operating fluid,
you might have incurred danger. In that case, inspect and
supply hydraulic operating fluid after having fully checked
safety.
Symptoms Due to Insufficient Hydraulic

Operating Fluid
The following symptoms might have occurred. In that
case, inspect and supply hydraulic operating fluid because
it may be insufficient.
(1) The body (cargo deck) is raised only immediately.
(2) The body (cargo deck) is lugged during rise.
(3) While the body (cargo deck) is being raised, the oil
pump portion causes a large abnormal sound (such as
caterwaul or grate).
(4) After the body (cargo deck) has been raised, it drops
generating a knock.
Preparing for Hydraulic Operating Fluid Supply

If there is loading, pull down the loading. Then supply
hydraulic operating fluid after having safely and more
carefully raised the body (cargo deck) and having firmly
held the body (cargo deck) by the "safety rod" and the
"safety strut" in accordance with the following "How to
raise the body (cargo deck)".
How to Raise the Body (Cargo Deck)

(1) Put a truck at a horizontal place.
NOTE:
Never raise the body (cargo deck) on tilted ground,
soft ground, and unleveled ground. A truck may be
inverted or warp may be generated in functional
components.
At a horizontal place
F05LX00008
(2) Set the shift lever to the "Neutral" position.

Be sure to set
neutral position N.
F05LX00009
6 POWER TAKE-OFF
(3) Firmly actuate the parking brake and apply a scotch to

Release button
the rear tire.
Parking brake lever
F05LX00010
(4) Start the engine and depress the clutch pedal to the
floor. Push in the lock button of the dump lever and
release the lock to set the "Up" position.
NOTE:
"Up" Fully check that there is no person or hindrance
around a truck.
When the dump lever is operated, observe the notes
of the Note label attached to the driver's seat.
Clutch pedal
F05LX00011
(5) When the clutch pedal is slowly returned, the body

(cargo deck) is raised.
• Adjust raised speeds according to the pedal feel of
the accelerator.
• When raising the body (cargo deck), be sure to
check the lock of the dump lever.
Adjust speeds
according to the • After having raised the body (cargo deck), held the
pedal feel. body by the safety rod and the safety strut and
stop the engine.
F05LX00012 NOTE:
Suddenly returning the clutch pedal is very dangerous.
Use the engine at about 1,000 to 1,500 rpm, and do
not perform high-speed rotation, sudden acceleration
and deceleration, and unnecessary idle rotation.
NOTE:
Vertically Raise the body (cargo deck) paying full attention to
as much safety and firmly hold the body (cargo deck) by the
Firmly touch as possible
not to slide. safety rod and safety strut.
Safety Provide slight
strut clearance.
Safety
rod
Scotch
F05LX00015
Oil tank
Supply Procedure of Hydraulic Operating
Fluid
Oil filler port
NOTE:
Be sure to supply a specified amount (check it by the
Oil level level plug) of hydraulic operating fluid using a cleaned
oil supply container paying full attention so that dust
or foreign matter will not be mixed in. After having
supplied oil, firmly tighten each plug.
When replacing the total amount of hydraulic
F05LX00014 operating fluid, request a service network (SS store)
of a body manufacturer.
(1) Remove the oil supply plug and level plug of the oil
Oil filler port tank in the engine stopped state.
(2) While supplying hydraulic operating fluid from the oil
Oil tank filler port, supply it until the hydraulic operating fluid
flows out from the level plug.
Oil level (3) Remove the "Safety strut" once and raise the body
(cargo deck) to the most raised position, then re-hold
it by the "Safety strut and safety rod".
(4) Additionally supply hydraulic operating fluid. When
the hydraulic operating fluid flows out from the level
F08LX00003
plug, install and firmly tighten the level plug and the
oil filler port plug.
(5) After having supplied hydraulic operating fluid,
remove the "Safety strut" and store the "safety rod".
Subsequently firmly drop the body (cargo deck) and
stop the engine.
NOTE:
Supply the hydraulic operating fluid used with
reference to the following table.
Hydraulic Operating Fluid (Turbine Oil)

0 to 30°C: VG32
Manufactured by
ShinMaywa Industries 20°C or more: VG56
Co., Ltd.
less than 10°C: VG22
8 POWER TAKE-OFF
If the Dump Rise Operation is Disabled by

Itself
If the body (cargo deck) is kept being dropped and the
"Rise" operation of the body (cargo deck) is disabled by
itself, inspect the cause of rise disabled, fully identify the
status, and execute maintenance and repair in accordance
with the flowchart of the "Defect 1". Dump body rise
disabled" (Page 52) of Chapter "Troubleshooting".
After maintenance and repair, if there is a hindrance in
subsequent work advance because the "Rise" operation is
disabled by itself or when the hydraulic circuit is in the
following states (1) and (2) after maintenance and repair,
raise the body (cargo deck), take safety measures for
preventing drop, and continue the work according to the
following (item of the existence of hoist or crane
equipment) methods.
(1) The body (cargo deck) rise is disabled due to the air
mixture into the hydraulic circuit resulting from
insufficient hydraulic operating fluid immediately after
repair for oil pump replacement
(2) The body (cargo deck) rise is disabled due to the air
mixture into the hydraulic circuit resulting from
insufficient hydraulic operating fluid immediately after
repair for leak of hydraulic operating fluid.
When hoist or crane equipment is provided
(1) Firmly actuate the parking brake and apply a scotch to

Wire the rear tire.
(2) Set the engine to the stopped state.
(3) Set the dump lever to the "Up" position and apply a
wire with ample strength to the front of the body
(cargo deck).
(4) Slowly hang a wire (tensile strength of 1,000 kg
(9,807N)) by a hoist or crane.
(5) After having drawn up the body (cargo deck) to the
most raised position, prevent the drop of the body
(cargo deck) by the safety rod and the safety strut and
check safety.
NOTE:
For the subsequent work procedure, supply hydraulic
operating fluid or perform air bleeding of the
hydraulic operating fluid in accordance with each
item of the text in the "Supply Procedure of Hydraulic
Operating Fluid" (Page 7) or the "Air Bleeding
F08LX00004
Procedure of Hydraulic Operating Fluid" (Page 12) in
the next chapter.
If neither hoist nor crane is provided
If the body (cargo deck) is kept being dropped and the

"Up" operation of the dump is disabled by itself or if
neither hoist nor crane is provided, raise the body (cargo
deck) according to the following work procedure.
Oil tank Pipe

Low-pressure hose
Piston
High-pressure hose Hoist cylinder
PTO with oil pump
Hydraulic operating Low-pressure hose

fluid container
Oil tank
Pipe
Hydraulic
operating fluid
Piston
Test hose Hoist cylinder

High-pressure hose
Test hose joint
320LX00003
Preparation
(1) Because removal of a spare tire makes work easier
according to a truck, previously check the truck.
(2) Remove the intermediate fixed clip on the truck side
between the oil pump and the oil tank of the low-
pressure side hose and set the low-pressure hose free.
(3) Prepare a cleaned hydraulic operating fluid container
(a 20ll can will do), a funnel, hydraulic operating fluid,
a test hose for a special tool, and a test hose joint.
(4) Prepare the hydraulic operating fluid of about 10ll in
the cleaned hydraulic operating fluid container.
Hydraulic Operating Fluid (Turbine Oil)

0 to 30°C: VG32
Manufactured by
ShinMaywa Industries 20°C or more: VG56
Co., Ltd.
less than 10°C: VG22
10 POWER TAKE-OFF
NOTE:
Carefully control the prepared hydraulic operating
fluid so that dust or foreign matter will not be mixed
in it. Besides, if the dust or foreign matter is mixed in
the hydraulic operating fluid, carefully handle it
because it becomes the first cause of a dump
mechanism fault.
Hydraulic operating Low-pressure hose Work Procedure

fluid container
Oil tank (1) With reference to the piping rough sketch on the
preceding page, remove the low-pressure side hose of
Hydraulic the oil pump and insert the port for removal in the
operating
fluid prepared hydraulic operating fluid container.
NOTE:
Hoist cylinder Be sure to install the hydraulic oil fluid container at a
High-pressure hose higher position than the tank pump. If it is installed
PTO with oil pump at a lower position, the oil pump may be damaged
320LX00004 because the hydraulic operating fluid applied in Item
(4) flows in the hydraulic operating fluid container
Low-pressure hose
and air is mixed in the hose.
To oil tank Funnel
Hydraulic
Insert NOTE:
Test hose When inserting the removed low-pressure hose in the
operating fluid
container hydraulic operating fluid, remove the hose band, be
Hydraulic High-pressure sure to clean the hose port, and handle the hose so
operating fluid hose that dust or foreign matter will not be mixed in the
hydraulic operating fluid.
PTO with oil pump (2) Remove the low-pressure side hose joint of the oil
320LX00005
pump.
(3) Install the test hose and connecting joint on the low-
pressure side of the oil pump.
Joint (low-pressure side): 5-8840-2439-0

Test hose: 5-8840-2435-0
(4) Use the funnel from the fluid container insertion side
of the test hose to fill the hose with the hydraulic
operating fluid and insert the hose port in the
hydraulic operating fluid container.
NOTE:
The test hose is filled with hydraulic operating fluid to
minimize the mixture of air in the hydraulic circuit.
Further, fix the two hoses inserted in the fluid
container not to jump out from the hydraulic
operating fluid.
(5) Start the engine and depress the clutch pedal in the
idling state, then set the dump lever to the "Up"
position.
(6) When slowly releasing the clutch pedal and operating
the oil pump, the body (cargo deck) starts being
raised.
NOTE:
At this time, check that the air mixed in the hydraulic
circuit is discharged in the hydraulic operating fluid as
blow holes.
(7) Raise the body (cargo deck) up to the most raised

position in the idling state and apply the safety rod
and the safety strut to the body (cargo deck). Then
prevent drop and check safety.
(8) After having the body (cargo deck), stop the engine
and remove the test hose installed in Item (3) from the
oil pump, then release it from the fluid container.
(9) Remove the test hose connecting joint from the low-
pressure side of the oil pump and install the joint for
connecting the original low-pressure hose.
(10) Release the low-pressure side hose removed from the
oil pump and soaked in the fluid container in Item (1)
and install it on the low-pressure side of the oil pump
as before, then firmly tighten the hose band.
NOTE:
For the subsequent work procedure, supply hydraulic
operating fluid or perform the air bleeding of
hydraulic operating fluid in accordance with each
item of the text in the "Supply Procedure of Hydraulic
Operating Fluid" (Page 7) or the "Air Bleeding
Procedure of Hydraulic Operating Fluid" (Page 12) in
the next chapter.
Be careful of excessive supply of hydraulic operating
fluid.
If an excessive amount of hydraulic operating fluid
exceeding the specified amount is supplied when
supplying the hydraulic operating fluid at the rise of
the body (cargo deck), the hydraulic circuit will be
filled with the hydraulic operating fluid because the
volume of the fluid in the oil tank is increased more
than necessary at the drop of the body (cargo deck).
According, the body (cargo deck) will not be dropped
from a predetermined place. If it is dropped forcibly,
excessive pressure applies to the hydraulic circuit
(consisting of the hose, pipe, and tank) resulting in its
damage or a leak of oil.
Total Replacement of Hydraulic

Operating Fluid
Request a service network (SS store) of a body
manufacturer of the total replacement of hydraulic
operating fluid.
12 POWER TAKE-OFF
Air Bleeding Procedure of Hydraulic

Operating Fluid
NOTE:
Be sure to supply a specified amount of hydraulic
operating fluid using a cleaned oil supply container
paying full attention so that dust or foreign matter will
not be mixed in. After having supplied oil, firmly
tighten each plug.
[Rear Dump Truck]

<Manufactured by Shin Maywa Industries, Co., Ltd.>
Hydraulic Operating Fluid Supply
(1) Raise the body (cargo deck) in accordance with the
Piston rod "How to raise the body (cargo deck) (Page 5)
3 Oil filler port described previously.
A (2) Remove oil filler plug 1 and level plug 2 of the oil
tank and supply oil from the oil filler port until the
hydraulic operating fluid flows out from level plug 1,
Hoist cylinder
then tighten plug 2.
1 Oil filler port B
(3) Remove oil filler port plug 3 from the cylinder head,
Oil tank
supply the hydraulic operating fluid to "Chamber A"
so that no air will be left to fill the chamber with the
fluid, and tighten oil filler port plug3.
C
Air Bleeding Method
2 Level plug Oil pump "How to raise the body (cargo deck) (Page 5)
described previously.
(2) At the maximum rise, cylinder shaded portions
"Chamber A" and "Chamber B" shown in the drawing
are fully filled with hydraulic operating fluid and
Section "C" is filled with the hydraulic operating fluid
320LX00006
up to its level position.
NOTE:
Supplying hydraulic operating fluid more than
necessary will cause a fault.
(3) First remove the oil tank oil filler port plug of 1. Then
start the engine, operate the dump lever, and drop
and raise the body (cargo deck) several times.
Consequently, air is naturally released usually.
(4) Tighten the oil tank oil filler port plug of 1.
NOTE:
If the work of Item 2 is performed with plug 1
tightened, air may not be released.
NOTE:
When air is mixed in hydraulic operating fluid and
becomes whitely foamy, the air will not be released.
So raise the body (cargo deck) and remove plugs 1
and 3. When the hydraulic operating fluid is left
alone about for 30 to 60 minutes, the air is naturally
separated. Re-supply oil in accordance with the
procedure of Items (2) and (3) of the "Supply
Procedure of Hydraulic Operating Fluid" (Page 7).
Principles Under Which Air iIs Released

Between "B" and "C"
For Chamber "B" filled with hydraulic operating fluid,
when the body (cargo deck) is dropped, the piston rod is
dropped and the hydraulic operating fluid in "Chamber B"
passes through the oil pump and is returned to the oil
tank. At this time, if air is mixed in, it is discharged from
"Surface C" in the oil tank as blow holes.
Between "A" and "C"

The hydraulic operating fluid pressurized and sent via the
oil pump is sent from "Chamber C" to "Chamber B". The
piston cylinder is raised and the hydraulic operating oil in
"Chamber A" is sent to "Chamber C", and then the air is
discharged for the same reason as between "B" and "C".
[Three-Rotation Dump Truck]

1 Oil filler port <Manufactured by Shin Maywa Industries, Co., Ltd.]
Hydraulic Operating Fluid Supply
2 Level plug "How to raise the body (cargo deck) (Page 5)
described previously.
(2) Remove oil filler plug 1 and level plug 2 of the oil
Oil tank
tank and supply oil from the oil filler port until the
hydraulic operating fluid flows out from level plug 2,
F08LX00005
then tighten plug 2.
NOTE:
Supplying hydraulic operating fluid more than
necessary will cause a fault.
(3) Set the dump lever to the "Up" position with the
3 Air bleeding plug engine in the idling state.
(4) When loosening the air bleeding plug 3 of the
cylinder about once or twice, air is discharged and
then hydraulic operating fluid is ejected. So quickly
From oil pump
tighten the plug.
(high pressure)
To oil tank NOTE:
When air is mixed in hydraulic operating fluid and
Cylinder main unit Bypass valve becomes whitely foamy, the air is not released. So
raise the body (cargo deck) and leave the hydraulic
F08LX00006
operating fluid alone about for one hour. The air in
the hydraulic operating fluid is naturally separated
and subsequently air can be released.
Even when performing air bleeding work, raise the
body (cargo deck) in accordance with the "How to
Raise The Body (cargo deck") (Page 5) described
previously.
14 POWER TAKE-OFF
CONTROL CABLE (FOR REAR DUMP TRUCK)

REMOVAL AND INSTALLATION
Cable stopper clip 6
Cab inside
Lock button
Oil pump
Dump lever
PTO
6
1 3 4 5 Shift cap
281LX00002
Removal Steps Installation Steps

1. Lock nut (dump lever side) To install, follow the removal steps in the reverse
2. Clip (inside cap) order.
3. Lock nut (PTO side)
4. Special nut
5. Cable holder
6. Control cable
Removal Steps
NOTE:
Because a three-rotation dump truck differs in the
wiring of a control cable from a rear dump truck, refer
to the notes on the replacement and adjustment of
the control cable for the three-rotation dump truck.
1. Lock Nut (Dump Lever Side)

Cab inside
• Set the dump lever to the "Down" position and
Clip firmly lock the lever.
• Loosen the lock nut of the control cable and
remove the cable tip from the boss portion of the
dump lever.
2. Clip (Inside Cab)
• Remove the clip from the instrument panel bottom
Control cable Lock nut inside the cab.
Boss portion
281LX00003
3. Lock Nut (PTO Side)

PTO side
• Loosen the lock nut and move it toward the truck
Control cable
Cable holder front.
Truck front
Lock nut Special nut PTO
281LX00004
4. Special Nut
Lock nut • Loosen the special nut and move it toward the
truck front.
Special nut
281LX00005
5. Cable Holder
Rod end ball portion
Truck front • Remove the bolt and remove the cable holder from
the PTO.
• Move the cable holder to the truck front and
provide clearance between the cable holder and
PTO.
Cable holder Shift rod
PTO
Bolt
281LX00006
16 POWER TAKE-OFF
6. Control Cable
Cable holder Rod end ball portion PTO • Because the tip portion (PTO side) of the control
cable is of a rod end ball type as shown in the
drawing, remove the cable end portion from the
cable connector groove on the PTO side sliding it
along the groove.
Cable connector groove
281LX00007
• Remove the cable holder from the control cable.

Control cable Rod end ball portion • Remove the control cable assembly from the truck.
Lock nut
Cable holder
Special nut
281LX00008
Installation Steps
Control cable Special nut
6. Control Cable
• Set the dump lever to the "Down" position and lock
it.
• Install the control cable assembly in the truck.
• Move the lock nut (PTO side) and special nut of the
Truck front Lock nut cable top the truck front side.
281LX00009
5. Cable Holder
Rod end ball portion
• Assemble the cable holder in the control cable.
Control cable
Cable holder
281LX00010
• Coat the rod end ball of the cable tip with a small
Rod end ball amount of grease and assemble it in the groove of
(apply a small amount of grease)
the control cable connector on the PTO side.
Cable holder Shift rod
Cable connector PTO

281LX00011
• Install the cable holder in the PTO and temporarily

Lock nut Cable holder tighten the bolt.
NOTE:
Tighten the bolt after having adjusted it in
accordance with the work procedure of the "Control
Cable Adjustment" (Page 18) in the next item.
Special nut Bolt PTO
281LX00012
4. Special Nut
Control cable • Tighten the special nut to the cable holder at a
Cable holder
specified torque pressing down the control cable
Truck front L to the PTO side lightly.
Special Nut Torque N·m (kg·m / lb·ft)

147 (15 / 108)
Lock nut Special nut PTO
• At this time, check that the "L" dimension is
281LX00013
34±1 mm (1.339±0.039 inch.)
• If the "L" dimension does not satisfy the specified
value, remove the cable holder from the PTO and
rotate the cable holder to adjust the dimension.
NOTE:
Both "clockwise rotation" and "counterclockwise
rotation" indicate that the cable moves by about 0.75
mm (0.0295 inch) every time the cable holder rotates
by 180 degrees.
• Re-install the cable holder on the PTO and

temporarily tighten the bolt.
3. Lock Nut (PTO Side)
• After having checked the specified value
Lock nut
dimensions of the cable outer threaded portion,
temporarily tighten the lock nut.
NOTE:
Tighten the special nut and lock nut after having
adjusted it in accordance with the work procedure of
Special nut the "Control Cable Adjustment" (Page 18) in the next
item.
281LX00014
18 POWER TAKE-OFF
2. Clip (Cab Inside)

• Draw the control cable in the instrument panel
Clip bottom inside the cab and firmly install the
grommet.
• Firmly install and fix the clip in the cable flange
portion groove.
1. Lock Nut (Dump Lever Side)
• Assemble the control cable tip in the boss portion
Control cable Lock nut
Boss portion
of the dump lever and tighten the lock nut at a
specified torque.
281LX00015
Lock Nut Torque N·m (kg·m / lb·in)

6 (0.6 / 52)
NOTE:
Double nut If the double nut position of the control cable is not
Lock nut fixed, it is fixed to a reference value.
Control Cable Length (Reference) mm(in.)
18±1 (0.709±0.039)
Control cable
Reference value
281LX00016
Spool
Control Cable Adjustment
Shift cap
Inspecting the Amount of Spool Extrusion
After having installed the control cable, inspect the
amount of spool extrusion according to the following
procedure.
Bolt (1) Remove the shift cap tightening bolt of the oil pump
rear and remove the shift cap.
Oil pump rear end
281LX00017
(2) Repeat the "Up" and "Down" operations of the dump

Oil pump lever twice or three times and slowly set the dump
lever to the "Up" position as much as possible.
(3) Measure the amount of spool extrusion of the oil
pump rear and check that it is a specified amount.
24mm Amount of Spool Extrusion mm(in.)
or more
24 (0.945) or more
Spool extrusion
281LX00018
(4) Repeat the "Up" and "Down" operations of the dump

Oil pump lever twice or three times and slowly set the dump
lever to the "Up" position as much as possible.
(5) Measure the amount of spool extrusion of the oil
pump rear and check that it is a specified amount.
2mm Amount of Spool Extrusion mm(in.)
Less than
less than 2 (0.0787)
Spool extrusion
NOTE:
281LX00019
Both amounts of spool extrusion at "Up" and "Down"
shall be within a standard value.
(6) If the amount of spool extrusion is within a specified

Shift cap
dimension, install the shift cap and tighten the bolt at
a specified torque.
Shift Cap Fixing Bolt Torque N·m (kg·m / lb·ft)
24 (2.4 / 17)
NOTE:
Bolt If the groove is not installed facing downward, the
Make groove face water intruded in the shift cap is not ejected but
downward
281LX00020
collected. Rusting and freezing will cause an incorrect
actuation.
Cable holder
Cable Adjustment (PTO Side)
Lock nut If no specified extrusion dimensions can be obtained as a
result of measuring the amount of spool extrusion
described previously, adjust (PTO side) the cable so that
the specified amount of spool extrusion can be obtained
according to the following procedure.
(1) Loosen the lock nut of the control cable.
PTO
Bolt (2) Remove the tightening bolt of the cable holder.
281LX00021
(3) Adjust the cable rotating the cable holder.

PTO
• If the amount of spool extrusion is improper
(insufficient) at "Dump lever Up", rotate the cable
holder toward "Counterclockwise rotation" shown
by the arrow mark of the drawing.
• If the amount of spool extrusion is improper
(excessive) at "Dump lever Down", rotate the cable
holder toward "Clockwise rotation" shown by the
Counterclockwise Clockwise
rotation rotation arrow mark of the drawing.
281LX00022
NOTE:
Both "clockwise rotation" and "counterclockwise
rotation" indicate that the cable moves by about
0.75 mm (0.0295 inch) every time the cable holder
rotates by 180 degrees.
20 POWER TAKE-OFF
(4) If the cable is adjusted in the aforementioned method

and the amount of spool extrusion cannot be
Lock nut Bolt obtained, repeat Items (2) and (3) and adjust the cable
so that the amount of spool extrusion will reach a
specified extrusion dimension.
(5) If a spool extrusion dimension can be obtained,
tighten the cable holder tightening bolt and lock nut at
a specified torque in this order.
Special nut
Cable Holder Bolt Torque N·m (kg·m / lb·ft)
23 (2.3/ 17)
231LX00023
Lock Nut Torque N·m (kg·m / lb·ft)

21 (2.1 / 15)
Operability of the dump lever, rise of the body (cargo

deck), and inspection and adjustment of the rise and fall
reference times
(1) Check that the engine revolution per minute is 1,250

rpm and the rise and fall operations of the body
(cargo deck) are performed within the following
reference times.
Rise Time And Fall Time Sec.

Rise Fall
Single Cab within within 20
Double Cab 20 within 25
(2) Inspection of the dump lever control force and

moderation
• Inspect that the operation of the dump lever can
lightly and smoothly be performed.
Basic Value
(On the Dump Lever Knob) kgf (N)
10 (98)
Direction of forward rotation PTO • When the dump lever is in the "Up" and "Down"
Oil pump positions, inspect that the lock operation can be
performed without a feeling of physical disorder.
(3) After having repeated the "Up" and "Down" positions
of the dump lever and slowly set them to the "Down"
position as much as possible, inspect the shaft
(driving shaft) between the PTO and oil pump.
• Inspect that the shaft (driving shaft) rotates
Direction of
forward or backward.
Shaft (drive shaft)
backward rotation If the shaft slowly rotates backward, it is normal.
231LX00024
Cable Adjustment (Dump Lever Side)

If a defect is found as a result of the inspection of the
Loosen
aforementioned items (1) to (3), adjust the control cable in
Dump lever the dump lever portion inside the cab according to the
following procedure.
1 (1) Set the dump lever to the "Down" position.
Squeeze 2 Dump cable
Pull out (2) Loosen the lock nut of the control cable and adjust the
cable as follows:
231LX00025
When the rise time is improper or when the shaft is

inverted at "Down" time or when the dump lever is hard to
Oil pump Oil pump lock at "Down" time, move the inner cable to Direction (1)
of the drawing.
When the fall time is improper or when the dump lever is

hard to lock at "Up" time or when the shaft rotates forward
at "Down" time, move the inner cable to Direction (2) of
Spool extrusion Spool extrusion the drawing.
NOTE:
231LX00026
If the cable is adjusted on the dump lever side, be
sure to re-inspect the amount of spool extrusion.
(3) After adjustment, tighten the lock nut at a specified

torque.

6 (0.6 / 52)
22 POWER TAKE-OFF
NOTES ON REPLACING AND ADJUSTING CONTROL CABLE FOR

THREE-ROTATION DUMP TRUCK
1. The control cable between the "Dump lever selector main unit and the aforementioned
and selector" of the three-rotation dump truck control cable.
is manufactured by ISUZU MOTORS LIMTED. 3. First adjust the control cable at the dump lever
This control cable is sent for (at replacement) bottom, adjust the control cable in the cable
in the Isuzu Motors Service Network, and holder portion of the PTO (oil pump portion),
because the selector need be disassembled, and check that the shaft (driving shaft) of the
assembled, and adjusted, request a service oil pump will not rotate concurrently. Then
network (SS store) of a body manufacturer of because the adjustment of the selector main
the replacement work. unit is necessary (only at down lever down, the
2. The selector main unit for the three-rotation ejection direction of the cargo deck can be
dump truck and the control cable between the selected. If this adjustment is improper, the
"Selector and PTO (with oil pump) are cargo deck may fall off.), request a service
manufactured by a body manufacturer. network of a body manufacturer of the
Request a service network (SS store) of a body adjustment.
manufacturer of the replacement work of the
Control Cable Rough Layout Drawing for Three-Rotation Dump Truck
Cab
Dump lever
Dump (ejection)
position switching lever
PTO Transmission
Isuzu control cable
Oil pump
Frame
Control cable
(between selector and oil pump)
Selector
F08LX00008
CONTROL CABLE ADJUSTMENT FOR THREE-ROTATION DUMP TRUCK
Cab Inside
Lock button
Dump lever
PTO Oil pump
Control cable
Control cable
Stopper adapter
Cable connector
Inner rod assembly Spool
281LX00028
Truck front
Replacement
Inner rod
(1) The control cable between the "Dump lever and
Shift cap
selector" of the three-rotation dump truck is
manufactured by Isuzu Motors Ltd. This control cable
is sent for (at replacement) in the Isuzu Motors
Bolt
Service Network, and because the selector need be
disassembled, assembled, and adjusted, request a
Spool extrusion PTO tip portion
service network (SS store) of a body manufacturer of
portion the replacement work.
231LX00029
(2) The selector main unit for the three-rotation dump
truck and the control cable between the "Selector and
PTO (with oil pump) are manufactured by a body
manufacturer. Request a service network (SS store) of
a body manufacturer of the replacement work of the
selector main unit and the aforementioned control
cable.
24 POWER TAKE-OFF
Measurement of the Amount of Spool Extrusion

(PTO Tip Portion)
Less than
(1) Remove the shift cap tightening bolt of the PTO tip
7 mm
portion and remove the shift cap.
(2) Operate the dump lever twice or three times and
slowly set it to the "Up" position as much as possible,
then firmly lock the dump lever.
(3) Measure the amount of spool extrusion at "Up" time
at the PTO tip portion and check that it is a basic
231LX00030 value.
Amount of Spool Extrusion mm (in.)

less than 7 (0.276)
(4) Operate the dump lever twice or three times and

slowly set it to the "Down" position as much as
27 mm
possible, then firmly lock the dump lever.
or more (5) Measure the amount of spool extrusion at "Down"
time at the PTO tip portion and check that it is a basic
value.
Amount of Spool Extrusion mm (in.)

27 (1.063) or more
231LX00031
NOTE:
Be sure check that both amounts of spool extrusion
at "Up" and "Down" times are within basic values.
(6) As a result of measurement, if the amount of spool

Truck front extrusion is within a basic value, install the shift cap
Shift cap
and tighten the bolt at a specified torque.
Bolt • Install the shift cap so that the groove on the
locating plane can locate downward.
Shift Cap Bolt Torque N·m ( kg·m / lb·ft)
24 (2.4 / 17)
Make groove face downward NOTE:

If the groove is not installed facing downward, the
231LX00032
water intruded in the shift cap is not ejected but
collected. Rusting and freezing will cause an
incorrect actuation.
Adjustment of the Amount of Spool Extrusion

(Control Cable Adjustment)
NOTE:
As a result of the "Measurement of The Amount of
Spool Extrusion" described previously, if a specified
extrusion dimension cannot be obtained, adjust the
control cables on the dump lever side inside the cab
and the dump lever side according to the following
Control cable
procedure.
Boss portion Lock nut
231LX00033
Control Cable Adjustment (Dump Lever Side Inside Cab)
(1) Operate the dump lever twice or three times with the
engine in the stopped state and slowly set it to the
"Up" position, then firmly lock the dump lever.
(2) Measure the length "L1" on the control cable tip and
Double nut double nut side shown in the drawing and check that
Lock nut it is within the following basic value.
Length "L1" mm (in.)

14±1 (0.55±0.039)
(3) As a result of measurement, if the length "L1" does

Control cable L1 not satisfy a basic value, loosen the lock nut and
adjust the control cable so that the length "L1" will be
231LX00034
set to a specified length "L1", then tighten the lock nut
at a specified torque.

6 (0.6 / 52)
Truck rear
Control Cable Adjustment (Oil Pump Side)
Cable holder (1) Tighten the special nut in the cable holder loosening
Control cable the lock nut, moving it to the truck rear, and lightly
L2
pushing the control cable against the PTO side.
(2) Measure the length "L2" between the outer screw tip
portion and special nut end of the control cable shown
in the drawing and check that it is within a basic value.
Outer threaded
portion
Oil pump Lock nut Length "L2" (Reference) mm (in.)
portion Special nut
24 +1 (0.945 +0.039 )
231LX00035 –0 –0
• As a result of check, if the length "L2" is satisfied,

tighten the lock nut at a specified torque.
Lock Nut Torque N·m ( kg·m / lb·ft)

20 (2.0 / 14)
26 POWER TAKE-OFF
Truck rear 3) As a result of measurement, if the length "L2" does

not satisfy a basic value, adjust the control cable
Cable holder
Control cable according to the following procedure.
Special nut
Lock nut
Oil pump portion
231LX00036
Truck rear 1 Loosen the special nut and move it toward the
truck rear, then set the control cable free.
Cable holder
Control cable 2 Manually holding the control cable, take in and out
L3 the cable to the front and rear. Obtain the length
"L3" and temporarily tighten the special nut
securing the control cable manually.
"L3" = "L2" basic value + Special Nut Thickness (10 mm)

Special nut
Lock nut
Oil pump portion
231LX00037
Truck rear 3 Measure the length "L2" in the state of 2. If the

dimension does not satisfy a basic value, repeat
Cable holder
Control cable Items 2 and 3 and adjust so that the "L2" will be
set to the basic value.
L2 4 After having the length "L2", tighten the special nut
Outer threaded Special Nut Torque N·m ( kg·m / lb·ft)

Bolt portion
Special nut
Lock nut 142 (14.5 / 105)
Oil pump portion
281LX00038
5 After having tightened the special nut, tighten the

Special nut lock nut at a specified torque.
Lock Nut Torque N·m ( kg·m / lb·ft)

20 (2.0 / 14)
Oil pump portion Lock nut
281LX00039
(4) After having adjusted the control cable, slowly

operate the dump lever twice or three times and
recheck the spool extrusion dimension.
less than
(Refer to the item of Measurement of The Amount of
7 mm Spool Extrusion on Page 24.)
27 mm
or more
281LX00040
(5) After having completed all measurement and

adjustments, set the dump lever to the "Down"
position and start the engine.
Operability of the Dump Lever, Rise of the Body

(Cargo Deck), and Inspection and Adjustment of
the Rise and Fall Reference Times
(1) Check that the engine revolution per minute is 1,250
rpm and the rise and fall operations of the body
(cargo deck) are performed within the following
reference times.
Rise time = within 20 seconds
Fall time = within 20 seconds
(2) Inspection of the dump lever control force and

moderation
• Inspect that the operation of the dump lever can
lightly and smoothly be performed.
Basic value = less than 10 kgf (98N) on the dump
lever knob
• When the dump lever is in the "Up" and "Down"

positions, inspect that the lock operation can be
performed without a feeling of physical disorder.
Direction of forward (3) After having repeated the "Up" and "Down" positions
PTO
rotation Oil pump of the dump lever and slowly set them to the "Down"
position as much as possible, inspect the shaft
(driving shaft) between the PTO and oil pump.
• Inspect that the shaft (driving shaft) rotates
forward or backward.
If the shaft slowly rotates backward, it is normal.
Shaft (drive shaft)

Direction of backward
rotation
281LX00041
28 POWER TAKE-OFF
(4) If a defect is found as a result of the inspection of the

aforementioned items (1) to (3), adjust the control
Loosen cable in the dump lever portion inside the cab
Dump according to the following procedure.
lever
1 Set the dump lever to the "Down" position.
1 2 Loosen the lock nut of the control cable and adjust
2 Dump
Push in the cable as follows:
Pull out cable
When the rise time is improper or when the dump

lever is hard to lock at "Down" time, move the inner
281LX00042
cable to Direction 2 of the drawing on the preceding
page.
When the fall time is improper or when the dump

lever is hard to lock at "Up" time or when the shaft
rotates forward at "Down" time, move the inner cable
to Direction 1 of the drawing on the preceding page.
NOTE:
If the cable is adjusted on the dump lever side, be
sure to re-inspect the amount of spool extrusion.
After adjustment, tighten the lock nut at a specified

torque.
6 (0.6 / 52)
∗ Selector
The selector is adjusted so that the ejection direction of
the cargo deck can be selected only at dump lever "Down".
If this adjustment is improper, the cargo deck may slide
from the truck at rise. Accordingly, because the
adjustment of the selector main unit is also needed after
the replacement, adjustment, and inspection of the control
cable, request a nearest service network (SS store) of a
body builder of the adjustment.
OIL PUMP UNIT (REPLACEMENT)

10
9
PTO
6
4 7
5 8
1
3 9
281LX080

1. Bolt (shift cap) To install, follow the removal steps in the reverse
2. Shift cap order.
3. Bolt (cable holder)
4. Cable holder
5. Control cable
6. Low-pressure hose
7. High-pressure hose
8. Inner rod assembly
9. Bolt (oil pump)
10. Oil pump
30 POWER TAKE-OFF
Removal Steps
Oil pump
NOTE:
Set the dump lever inside the cab to the "Down"
position and check the lever lock.
1. Bolt (Shift Cap)

2. Shift Cap
• Remove the bolt and remove the shift cap from the
oil pump.
Bolt Shift cap

285LX00001
3. Bolt (Cable Holder)

Cable holder
4. Cable Holder
5. Control Cable
NOTE:
Before removing the control cable, be sure to refer to
Control cable Items 3 to 6 of "Removal" of the "Control Cable
Replacement and Adjustment for Rear Dump Truck"
described previously and perform work in accordance
PTO with the items.
Bolt
285LX00002
6. Low-Pressure Hose
Low-pressure
hose • Loosen the hose band and remove the hose from
the oil pump.
7. High-Pressure Hose
• Loosen the hose joint and remove the hose from
the oil pump.
NOTE:
For the high-pressure hose, the joint may not be
High-pressure
hose removed in the oil pump fixed state according to the
285LX00003 type of the truck and equipment. In that case, slightly
loosen the joint to set the state. At the stage where
the rear oil pump is removed (Item 10), remove the
high-pressure hose rotating the oil pump.
Low-pressure hose High-pressure hose NOTE:

Because hydraulic operating fluid flows out when the
Wire Left frame hose is removed, quickly make the hose port face
upward and protect the hose so that dust or foreign
matter will not be mixed in, then fix it to the frame
with a wire.
Truck front
285LX00004
Oil pump
8. Inner Rod Assembly
PTO
• To remove the inner rod assembly, as shown in
the drawing, press the stopper adapter side by a
wrench and insert a Phillips screwdriver (large) in
the groove of the control cable connector. Then
rotate it counterclockwise, loosen it, and remove it.
NOTE:
Inner rod assembly Fixed Be sure to press the stopper adapter side and loosen it
on the control cable connector side. (Press the stopper
adapter side not to rotate the spool valve. Besides, the
281LX00044
three-rotation dump truck is in contrast with this.)
9. Bolt (Oil Pump)
10. Oil Pump
• Remove three oil pump tightening bolts and strike
them with a plastic hammer (or a wooden
hammer) from the truck front side, then remove
the oil pump from the PTO.
• Remove the joint from the oil pump.
NOTE:
PTO Bolt Oil pump If the high-pressure hose could not be removed in
281LX00045 Item 7 described previously, remove the oil pump
from the high-pressure hose rotating the oil pump at
this time.
Installation Steps
10. Oil Pump
PTO 9. Bolt (Oil Pump)
• Fully coat the oil pump shaft tip groove portion
and PTO shaft tip with lithium grease (BESCO L-2
or equivalent).
• Install the oil pump in the joint.
NOTE:
Coat shaft tip Coat shaft tip If the oil pump is rotated and removed from the high-
portion Oil pump portion
with grease. with grease. pressure hose when the oil pump is removed, install
281LX00046 the oil pump in the high-pressure hose rotating the
oil pump and slightly tighten it.
• Align and install the oil pump groove and the shaft
width across flats of the PTO and tighten the bolt
PTO Bolt Torque N·m ( kg·m / lb·ft)

53 (5.4 / 39)
NOTE:
Be fully careful so that dust or foreign matter will not
PTO Bolt Oil pump be mixed in from the hose installation port of the oil
281LX00045 pump.
32 POWER TAKE-OFF
Oil pump 8. Inner Rod Assembly

PTO
• Coat the threaded portion of the inner rod
assembly tip with liquid gasket (LOCTITE 242 or
equivalent) and insert and screw the tip from the
front side of the PTO, then tighten it at a specified
torque.
• When tightening the inner rod assembly, insert a
Inner rod assembly
Phillips screwdriver (large) in the control cable
connector groove, press it so that the spool valve
Fixed will not rotate, then apply a wrench to the stopper
281LX00047 adapter on the oil pump side to tighten it.
(Besides, the three-rotation dump truck is in
contrast with this.)
Inner Rod Torque N·m ( kg·m / lb·ft)

19 (1.9 / 14)
Low-pressure 7. High-Pressure Hose

hose • Install the high-pressure hose in the oil pump and
firmly tighten the joint.
NOTE:
If the oil pump is rotated and installed in the high-
pressure hose in Item 10 described previously, firmly
tighten the joint.
High-pressure 6. Low-Pressure Hose

hose
• Install the hose and firmly tighten the hose band.
285LX00003
NOTE:
When installing both the high-pressure and low-
pressure hoses, be fully careful so that dust or foreign
matter will not be mixed in the hose port and oil pump.
Joint Torque N·m ( kg·m / lb·ft)

Item Size Torque
High-pressure side PF1/2 103 (10.5 / 76)
Low-pressure side PF3/4 147 (15 / 108)
* After having tightened the joint using a

recommended value, additionally tighten it if
there is a leak of oil.
5. Control Cable
Cable holder
4. Cable Holder
NOTE:
Install the control cable and cable holder in the PTO in
accordance with Items 6 to 3 of "Installation Steps"
Control cable
(Page 16) of Removal and Installation of Control Cable
for Rear Dump Truck, and after installation, inspect
PTO
Bolt
and adjust the spool amount in accordance with the
285LX00002
"Amount of Spool Extrusion" (Page 18) described
previously.
• After having adjusted the control cable and having

inspected or adjusted the amount of spool
Loosen extrusion, tighten the bolt and the special nut and
Dump lock nut of the control cable at a specified torque.
lever
Tightening Torque N·m ( kg·m / lb·ft)
Bolt 24 (2.4 / 17)
1
2 Dump
Push in Special Nut 206 (21 / 152)
Pull out cable
Lock Nut 21 (2.1 / 15)
281LX00042
Oil pump 2. Shift Cap

1. Bolt (Shift Cap)
• Install the shift cap in the oil pump making its
grooved side face upward and tighten the bolt at a
specified torque
24 (2.4 / 17)
Bolt Shift cap

NOTE:
If the groove is not installed facing downward, the
285LX00001
water intruded in the shift cap is not ejected but
collected. Rusting and freezing will cause an
incorrect actuation.
Supply and Air Bleeding of Hydraulic Operating

Fluid
After having installed the oil pump, supply hydraulic
operating fluid and release air as requested. Supply the
hydraulic operating fluid and release air in accordance
with the "Inspection and Supply of The Hydraulic
Operating Fluid" (Page 5) and the "Air Bleeding Procedure
of Hydraulic Operating Fluid" (Page 12) described
previously.
34 POWER TAKE-OFF
PTO (With OIL PUMP) ASSEMBLY

10
Oil pump
6 8
5 4 PTO 1 2
281LX00048

1. Drain plug, filler plug To install, follow the removal steps in the reverse
2. Bolt (shift cap) order.
3. Shift cap
4. Bolt (cable holder) NOTE:
5. Cable holder For the three-rotation dump truck, refer to the
6. Control cable notes of the "Control Cable Adjustment for Three-
7. Low-pressure hose Rotation Dump Truck" (Page 23) in the preceding
8. High-pressure hose chapter before that.
9. Bolt (PTO)
10. PTO (with oil pump)
Removal Steps
Oil pump
NOTE:
Set the dump lever inside the cab to the "Down"
position and check the lever lock.
1. Drain Plug, Filler Plug

• Remove the drain plug and filler plug of the
transmission and remove the transmission oil.
2. Bolt (Shift Cap)
3. Shift Cap
Bolt Shift cap • Remove the bolt and remove the shift cap from the
285LX00001
oil pump.
Cable holder
5. Cable Holder
6. Control Cable
NOTE:
Before removing the control cable, be sure to refer to
Items 3 to 6 of "Removal Steps" (Pages 15 and 16) in
Control cable
the "Removal and Installation of Control Cable for
Rear Dump Truck" in the chapter described previously
PTO and perform work in accordance with the items.
Bolt
285LX00002
Low-pressure 7. Low-Pressure Hose

hose • Loosen the hose band and remove the hose from
the oil pump.
• Loosen the hose joint and remove the hose from
the oil pump.
NOTE:
High-pressure For the high-pressure hose, a part of the joint may
hose not be removed according to the type of the truck
285LX00003 and equipment. In that case, slightly loosen the joint
to set the state. At the stage where the rear PTO is
removed (Item 10), remove the high-pressure hose
rotating the PTO (with oil pump).
Low-pressure hose High-pressure hose NOTE:

Because hydraulic operating fluid flows out when the
Wire Left frame
hose is removed, quickly make the hose port face
upward and protect the hose so that dust or foreign
matter will not be mixed in, then fix it to the frame
with a wire.
Truck front
285LX00004
36 POWER TAKE-OFF
9. Bolt (PTO)
PTO Oil pump 10. PTO (with Oil Pump)
Bolt
• Remove the six tightening bolts around the PTO
and remove the PTO (with oil pump) from the
transmission.
NOTE:
If the high-pressure hose could not be removed in
Item 8 described previously, remove the PTO (with oil
pump) from the high-pressure hose rotating the PTO
281LX00049
at this time.
Besides, because this PTO (with oil pump) weighs
15kg (147N), be fully careful of its drop at attachment
and detachment.
Installation Steps
NOTE:
Before installing the PTO, cleanly remove the liquid
gasket left on the PTO installation side of the
transmission case and clean and degrease the
transmission case by waste cloth so that oil will not
adhere to it.
10. PTO (with Oil Pump)

Apply liquid
• After having cleaned and fully degreased the
gasket
transmission installation side of the PTO, coat it
with liquid gasket (LOCTITE 17430 or equivalent).
281LX00050
NOTE:
PTO Oil pump When removing the PTO side from the high-pressure
Bolt
hose rotating the PTO side at PTO (with oil pump)
removal, install the PTO (with oil pump) in the high-
pressure hose and lightly tighten it.
9. Bolt (PTO)
• Install the PTO (with oil pump) in the transmission
and tighten the bolt at a specified torque.

281LX00049
45 (4.6 / 33)
Low-pressure
hose • Install the high-pressure hose in the oil pump and
firmly tighten the joint.
NOTE:
When the PTO (with oil pump) is installed in the high-
pressure hose rotating the PTO in Item 10 described
previously, firmly tighten the joint.
High-pressure 7. Low-Pressure Hose

hose • Install the hose and firmly tighten the hose band.
285LX00003
NOTE:
When installing the high-pressure hose and the low-
pressure hose, be fully careful so that dust or foreign
matter will not be mixed in the pose port and the oil
pump.
6. Control Cable
Cable holder
5. Cable Holder
NOTE:
Install the control cable and cable holder in the PTO in
accordance with Items 6 to 3 of "Installation Steps"
Control cable
(Pages 16 and 17) in the "Removal and Installation of
Control Cable for Rear Dump Truck", and after
PTO installation inspect and adjust it in accordance with
Bolt
285LX00002
the "Amount of Spool Extrusion" (Page 18).
• After having adjusted the control cable and having
inspected or adjusted the amount of spool
Lock nut Bolt extrusion, tighten the bolt and the special nut and
lock nut of the control cable at a specified torque.
Tightening Torque N·m ( kg·m / lb·ft)
Bolt 24 (2.4 / 17)
Special Nut 147 (15 / 108)
Special nut Lock Nut 20 (2.0 / 14)
281LX00023
Oil pump 3. Shift Cap

2. Bolt (Shift Cap)
• Install the shift cap in the oil pump making its
grooved side face upward and tighten the bolt at a
specified torque.
24 (2.4 / 17)
Bolt Shift cap

285LX00001
1. Drain Plug, Filler Plug

• Firmly tighten the drain plug of the transmission.
• Supply the transmission oil (BESCO gear oil trans-
axle (5W-30) or equivalent) until it flows out from
the filler plug hole and firmly tighten the filler plug.
Amount of Oil (Reference) Liters (US gal / Imp. gal)
5 speed 3.2 (0.85 / 0.70)
6 speed 4.0 (1.06 / 0.88)
Drain Plug and Filler Plug Torque N·m ( kg·m / lb·ft)

49 (5.0 / 36)
38 POWER TAKE-OFF
Supply and Air Bleeding of Hydraulic Operating

Fluid
After having installed the oil pump, supply hydraulic
operating fluid and release air as requested. Supply the
hydraulic operating fluid and release air in accordance
with the "Inspection and Supply of The Hydraulic
Operating Fluid" (Page 5) and the "Air Bleeding Procedure
of the Hydraulic Operating Fluid" (Page 12) described
previously.
UNIT REPAIR
PTO ASSEMBLY
DISASSEMBLY
5
21 2
Oil pump
12
11
Shift cap
28
4 29
10 20
18
9 23
8
24
7
27 22
15 17
25 14 19
26
1 13 16
Cable holder
281LX00051
Disassembly Steps
1. Inner rod assembly 16. Interlock plug
2. Bolt 17. Interlock pin
3. Spring pin 18. Shift rod
4. Idle gear shift 19. Shift arm
5. Idle gear 20. Oil seal (output shaft side)
6. Needle bearing 21. Rear ball bearing
7. Bolt 22. O-ring
8. Case cover 23. Oil seal (shift rod side)
9. Front ball bearing 24. Gear case
10. Output shaft 25. Spring pin
11. Output gear 26. Cable connector
12. Thrust collar 27. Inner rod
13. Spring set bolt 28. Spring pin
14. Spring 29. Stopper adapter
15. Ball
40 POWER TAKE-OFF
Disassembly Steps
1. Inner Rod Assembly
• Press the stopper adapter side by a wrench and
insert a Phillips screwdriver (large) in the groove of
the control cable connector. Then rotate it
counterclockwise, loosen it, and remove it.
Fixed
NOTE:
Be sure to press the stopper adapter side and loosen
Oil pump
Inner rod assembly it on the control cable connector side. (Press the
PTO stopper adapter side not to rotate the spool valve.
Besides, the three-rotation dump truck is in contrast
281LX00052
with this.)
2. Bolt
PTO
• Remove three bolts and separate the oil pump and
PTO striking the oil pump by a plastic hammer (or
wooden hammer).
Oil pump
281LX00053
3. Spring Pin
• Punch the spring pin in the idle gear shaft.
(After having removed the idle gear shaft, punch
the spring pin from the shaft.)
Spring pin Spring pin bar: 9-8529-2201-0
281LX00054
4. Idle Gear Shaft

Idle gear shaft 5. Idle Gear
6. Needle Bearing
• Strike and remove the idle gear shaft and remove
the idle gear, then remove the needle bearing.
Idle gear
281LX00055
7. Bolt
Case cover
8. Case Cover
• Remove the bolt and remove the case cover.
Bolt
281LX00056
9. Front Ball Bearing

10. Output Shaft
• Strike the end face of the output shaft from the
rear side and remove the front ball bearing while it
Front ball bearing is being installed in the output shaft.
Output shaft
281LX00057
• Remove the front ball bearing from the output

shaft.
Front ball bearing
F08LX00002
11. Output Gear

Output gear
12. Thrust Collar
• Remove the output gear and the thrust collar from
Thrust collar the gear case.
NOTE:
Check the orientation of the output gear and the
thrust collar. The side in which the shift arm groove
of the gear and the taper of the thrust collar exist is
the rear side.
Shift arm
281LX00058
13. Spring Set Bolt

14. Spring
15. Ball
Spring set bolt • Remove the spring set bolt and remove the spring
and ball.
Spring
Ball
281LX00059
42 POWER TAKE-OFF
16. Interlock Plug

17. Interlock Pin
• Remove the interlock plug and remove the
Interlock plug interlock pin from the shift arm.
Interlock pin
281LX00060
18. Shift Rod

19. Shift Arm
• Pull out the shift rod to the rear side of the gear
Alignment mark
case and remove the shift arm from the inside of
Alignment the gear case.
mark
NOTE:
When removing the shift arm, be sure to check the
Shift arm installation direction of the arm and apply the
Shift rod assignment mark. In that case, incorrect assembly
281LX00061
can be prevented at subsequent assembly.
20. Oil Seal (Output Shaft Side)
21. Rear Ball Bearing
• Pry the oil seal by a screwdriver and remove it,
then strike the rear ball bearing from the rear side
Rear ball bearing of the gear case and remove it.
Bearing installer : 5-8840-2432-0
281LX00062
22. O-Ring
O-ring • Remove the O-ring from the shift rod hole of the
gear case.
O-ring groove
281LX00063
Oil seal
23. Oil Seal (Shift Rod Side)
• Remove the oil seal from the gear case.
Rear case 24. Gear Case
281LX00064
25. Spring Pin

26. Cable Connector
27. Inner Rod
28. Spring Pin
29. Stopper Adapter
• Remove the cable connector or stopper adapter
from the inner rod as requested.
44 POWER TAKE-OFF
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage, or any other abnormal conditions are
found through inspection.
Gear Case
Gear case • Inspect that there is a crack, a wear, or a scratch in
each portion of the gear case and replace the gear
case if there is a remarkable wear or scratch.
281LX00065
Bearings
• Inspect each bearing, and replace it if the following
Ball bearing Needle bearing defects are found.
(1) The rotation is not smooth.
(2) A remarkable noise is generated.
(3) There is damage or rust in the inner and outer
laces.
(4) There is an abnormal play in the thrust direction.
(5) There is discoloration, remarkable wear, or hitting
on the body of rotation and surface of rotation of
281LX00066 the needle roller.
NOTE:
If the ball bearing is removed, replace it by a new one.
Gears and Thrust Collar

Thrust collar • Inspect the tooth surface of each gear and replace
what has remarkable wear or damage. Further,
correct lightly staged wear or a rough surface with
an oil stone.
• Inspect both surfaces of the thrust collar and
replace the thrust collar if there is a remarkable
Output gear surface roughness or wear.
Idle gear
281LX00067
Shafts
• Inspect the damage and wear on the external
surface of each shaft and the wear and damage of
Idle gear shaft the spline portion and replace them if there are
remarkable.
Output shaft
281LX00068
Inner rod assembly

Shift Mechanism
• Inspect each portion of the shift mechanism and
Shift arm
Shift rod
replace it if there is remarkable damage, deflection,
or staged wear.
Spring set bolt (1) Deflection and wear of the shift rod
Spring (2) Deformation and wear of the shift rod
Ball Shift Arm Thickness mm (in.)

Standard Limit
Interlock pin Interlock plug
9.0 (0.354) 8.5 (0.335)
281LX00069
(3) The backlash or operation between the shift rod

and gear case is not smooth.
(4) Wear of the ball for a detent of the shift rod and
the fatigue of the spring
(5) Wear of the lock pin sliding portion for the lock pin
and plug
(6) Deflection of the inter rod and wear of the cable
connector portion
Oil Seal and O-ring

• Replace the oil seal and O-ring if there is damage,
O-ring
wear, or aging in the lip portion of the oil seal and
Oil seal
the O-ring.
NOTE:
If the PTO is disassembled, replace the oil seal and
the O-ring by new ones in principle. Further, if the oil
seal and the O-ring are removed, they cannot be
reused.
281LX00070
Spring Pin
NOTE:
Be sure to replace the spring pin by a new one.
281LX046
46 POWER TAKE-OFF
REASSEMBLY
19
4 23
Oil pump
13
12
Shift cap
18
21
28
27
20
22
14
6
15
2
16
1
17
3
24
9 7
26 10 5
25
29 8
11
Cable holder
281LX00072
Reassembly Steps
1. Gear case 16. Case cover
2. Oil seal (shift rod side) 17. Bolt
3. O-ring 18. Needle bearing
4. Rear ball bearing 19. Idle gear
5. Shift arm 20. Idle gear shaft
6. Shift rod 21. Spring pin
7. Interlock pin 22. Oil seal (output shaft side)
8. Interlock plug 23. Bolt
9. Ball 24. Inner rod
10. Spring 25. Cable connector
11. Spring set bolt 26. Spring pin
12. Output gear 27. Stopper adapter
13. Thrust collar 28. Spring pin
14. Output shaft 29. Inner rod Assembly
15. Front ball bearing
Reassembly Steps
1. Gear Case
2. Oil Seal (Shift Rod Side)
• Coat the lip portion of the oil seal with lithium
Oil seal
grease (BESCO L-2 or equivalent), the periphery
Gear case portion of the seal with liquid gasket (LOCTITE 518
or equivalent).
• Install the lip portion of the oil seal in the shift rod
side (front side) of the gear case so that the lip
portion will not be damaged.
281LX00073 Oil seal installer : 5-8840-2433-0

3. O-Ring
O-ring • Thinly coat the O-ring and the O-ring groove of the
gear case with lithium grease (BESCO L-2 or
equivalent) and firmly assemble them in the
groove so that there will be no damage and
torsion.
O-ring groove
281LX00063
4. Rear Ball Bearing

• Strike and install the rear ball bearing in the gear
case from the inner side of the case.
Rear ball bearing

281LX00074
5. Shift Arm
• Assemble the shift arm in the gear case.
Alignment mark 6. Shift Rod
• Thinly coat the shift rod with lithium grease
Alignment (BESCO L-2 or equivalent) and insert it in the gear
mark case, then assemble it in the shift arm.
Shift arm NOTE:

Shift rod Align the assembly direction of the shift arm to the
alignment mark at disassembly.
281LX00075
48 POWER TAKE-OFF
• Align the position between the lock pin hole of the

Shift rod shift arm and the lock pin groove of the shift rod.
Alignment mark
Shift arm
Align the position.
281LX00076
7. Interlock Pin
8. Interlock Plug
• Assemble the interlock pin in the shift arm and
Interlock plug coat the interlock plug threaded portion with liquid
gasket (LOCTITE 242 or equivalent), then tighten
the interlock plug at a specified torque.
Interlock Plug Torque N·m ( kg·m / lb·ft)

Interlock pin 60 (6.1 / 44)
281LX00077
NOTE:
After having tightened the interlock plug, do not
move the shift rod. Moving the shift rod may remove
the interlock pin.
9. Ball
10. Spring
11. Spring Set Bolt
Spring set bolt • Assemble the ball and spring in the gear case and
coat the spring set bolt threaded portion with
liquid gasket (LOCTITE 242 or equivalent), then
Spring tighten the spring set bolt.
Set Bolt Torque N·m ( kg·m / lb·ft)

Ball
19 (1.9 / 14)
281LX00078
12. Output Gear

Output gear
13. Thrust Collar
• Assemble the groove (the orientation is the rear
Thrust collar side) of the output gear in the shift arm and
assemble the taper portion of the thrust collar
facing the rear side.
Shift arm
281LX00079
14. Output Shaft

Output shaft
• Insert the output gear engaging its spline and align
the output shaft tip to the inner lace of the rear
Shift arm
bearing, then strike and install the output shaft by
applying a splint to its front side head portion.
Thrust collar
Output gear
281LX00080
15. Front Ball Bearing

• Align the inner lace side of the front ball bearing to
the output shaft and strike and install the outer
side of the bearing aligning it to the gear case.
Front ball bearing
281LX00081
16. Case Cover

Case cover
Bolt
17. Bolt
• Assemble the bolt by coating the match line for the
gear case of the case cover with liquid gasket
(LOCTITE 518 or equivalent) and the bolt threaded
portion with liquid gasket (LOCTITE 242 or
equivalent), then tighten the bolt at a specified
torque.
Case Cover Bolt Torque N·m ( kg·m / lb·ft)
281LX00082
24 (2.4 / 17)
NOTE:
Cleanly remove the liquid gasket adhering to the
cover installation side of the case cover and gear case
and clean and fully degrease the case by waste cloth
so that no oil will adhere to.
18. Needle Bearing

Idle gear Idle gear shaft
19. Idle Gear
• Coat the needle bearing with assembly all amount
of lithium grease (BESCO L-2 or equivalent) and
assemble the needle bearing in the idle gear.
20. Idle Gear Shaft
• Assemble the tooth round portion of the idle gear
facing the front side and assemble the pin hole of
the idle gear shaft facing the front side.
281LX00083
50 POWER TAKE-OFF
21. Spring Pin

• Align the spring pin hole of the gear case and the
pin hole of the idle gear shaft and strike the spring
pin.
NOTE:
Slit
When the slit on the rear side of the idle gear shaft is
set in the vertical direction, the pin hole will be
aligned.
Spring pin
281LX00084
22. Oil Seal (Output Shaft Side)

Oil seal installer
• Coat the oil seal lip portion with lithium grease
(BESCO L-2 or equivalent) and coat the seal
Oil seal guide Oil seal periphery portion with liquid gasket (LOCTITE 518
or equivalent).
• To prevent the seal lip portion from being
damaged, install it in the seal guide and press-fit it
in the gear case by the oil seal installer.
Oil seal installer : 5-8840-2433-0

281LX00085 Oil seal guide : 5-8840-2564-0
23. Bolt
• To install the oil pump in the PTO, fully coat the
shaft tip portion of the PTO and the oil pump shaft
groove portion with the lithium grease (BESCO L-2
or equivalent) for rust prevention.
Coated with
grease
281LX00086
• Align and install the shaft width across flats

PTO portion on the PTO side and the shaft groove on
the oil pump side and tighten the bolt at a
specified torque.
53 (5.4 / 39)
Oil pump
281LX00087
24. Inner rod

25. Cable connector
26. Spring pin
27. Stopper adapter
28. Spring pin
• If the cable connector or stopper adapter is
removed, install it in the inner rod.
29. Inner rod assembly

• Coat the threaded portion of the inner rod tip with
liquid gasket (LOCTITE 242 or equivalent) and
insert and screw it from the front side of the PTO,
and tighten the inner rod assembly at a specified
Fixed torque.
Oil pump
NOTE:
Tighten the inner rod assembly by inserting a Phillips
PTO Inner rod assembly
screwdriver in the groove of the control cable
connector and pressing it, then applying a wrench to
281LX00088
the stopper adapter on the oil pump side. (The three-
rotation dump truck is in contrast with this.)
Inner Rod Torque N·m ( kg·m / lb·ft)
19 (1.9 / 14)
52 POWER TAKE-OFF
TROBLESHOOTING
Inspection Based on Defect Symptoms
Defect 1. The Dump Body Rise is Disabled.
Inspection of oil pump rotation NG Inspection of cable

• Inspect that oil pump shaft (driving shaft) • Inspect that cable is removed or
rotates (see Fig. 2 at bottom of Page 20). disconnected.
Inspection of PTO
OK • Inspect operation of shift rod and spool.
• Inspect operation of shift arm.
• Inspect loss of gear.
Measure amount of spool extrusion. NG • Adjustment of control cable

• Dump lever = "Up" position = Rear dump truck: See Page 18.
Rear dump truck: 24 mm (0.945 inch) or (Three-rotation dump truck: See Page 24. )
more (See Page 18.).
Three-rotation dump truck: less than 7 mm
(0.276 inch) (See Page 24.)
OK
NG
Inspect leak of hydraulic operating fluid. • Repair or replace leaked parts.
• Leak or replace leak of connecting portion.
OK
NG
NG
Inspect amount of hydraulic operating fluid. • Supply specified amount of hydraulic
operating fluid (see Page 7).
OK
Inspection of existence of oil pump discharge

Inspection method
• When engine is in idling rotation state, touch high-pressure hose of oil pump by hand and sense and
compare hose pulsation at dump lever "Up" and "Neutral".
Same touch: Does not sense pulsation. Different touch: Senses pulsation at "Up" (Note).
Replace oil pump. (See Page 29.) There is the possibility of the equipment matter
side. (Hoist cylinder operation error)
NOTE:
For examination by touch on hose, be careful not to mix this pulsation with engine vibration.
Defect 2. The Body (Cargo Deck) is Lugged During Rise.
Inspect air mixture in hydraulic operating NG (Mixture) • Execute air bleeding of hydraulic
fluid. circuit (see Page 12).
OK
NG (Insufficient)
Inspect amount of hydraulic operating • Supply specified amount of hydraulic
fluid. operating fluid (see Page 7).
OK
There is the possibility of the equipment

matter side. (Hinge wear, incorrect
lubrication of rotary portion, body
distortion, and cylinder rod deflection)
• Contact a service plant of a body
builder.
Defect 3. While the Body (Cargo Deck) is Being Raised, The Oil Pump Portion Causes a
Large Abnormal Sound (Such As Caterwaul or Grate).
NG
Inspect amount of hydraulic operating • Supply specified amount of hydraulic
fluid. operating fluid (see Page 7).
OK NG
• Replace oil pump (see Page 29).

Inspection of PTO
• Inspect that gear is damaged.
Inspection of transmission
• Inspect that the 2nd gear of counter
shaft is damaged.
54 POWER TAKE-OFF
Defect 4. The Dump Body is Kept Being Raised or Does Not Drop Intermediately.
NG
Measure amount of spool extrusion. • Adjust control cable.
• Dump lever "Down" position = Rear dump truck: See Page 18.)
Rear dump truck: less than 2 mm (0.079
inch) (See Page 19.)
( Three-rotation dump truck: See Page
25.
)
Three-rotation dump truck: 27 mm (1.063
inch) or more (See Page 24.)
OK
NG (Excessive)
Inspect amount of hydraulic operating • Adjust amount of hydraulic operating
fluid. fluid (see Page 7).
OK

(Front control valve operation error
inside oil pump)
NG

matter side. (Hoist cylinder, etc.)
builder.
Defect 5. The Fall Speed of The Dump Body is Slow.

(Basic Value: within 20 seconds for single cab, within 25 seconds for double
cab (only for rear dump truck)
NG
Measure amount of spool extrusion. • Adjust control cable.
• Dump lever "Down" position = Rear dump truck: See Page 18.)
Rear dump truck: less than 2 mm (0.079
inch) (See Page 19.)
( Three-rotation dump truck: See Page
25.
)
Three-rotation dump truck: 27 mm (1.063
inch) or more (See Page 24.)
OK

(Front control valve operation error
inside oil pump)
NG

builder.
Defect 6. When a Load is Applied, The Dump Body Drops.

NG
Inspect leak of hydraulic operating fluid. • Repair or replace leaked parts.
• Repair or replace leak of connecting
portion.
NG
OK • Supply specified amount of hydraulic

operating fluid (see Page 7).

(Check valve operation error inside oil
pump)
NG

builder.
56 POWER TAKE-OFF
MAIN DATA AND SPECIFICATIONS

PTO with Oil Pump Assembly
Item Specification
Allowable maximum output torque N·m/rpm (kg·m/rpm) 98/1000 (10/1000)
Deceleration ratio (speed ratio for engine) 0.678
Direction of rotation (viewed from the rear of the PTO) Clockwise rotation
FIXING TORQUE
N·m (kg·m / lb·ft)
53 (5.4/39)
Oil pump
Shift cap
24 (2.4/17)
24 (2.4/17)
PTO
19 (1.9/14)
60 (6.1/44)
Cable holder
24 (2.4/17)
19 (1.9/14)
281LX00091
SPECIAL TOOLS
Illustration Tool No. Tool Name
9-8529-2201-0 Spring pin bar
901LX084
5-8840-2432-0 Bearing installer
901LX085
5-8840-2433-0 Oil seal installer
901LX086
5-8840-2564-0 Oil seal guide
901LX087
Joint (low-pressure side)

5-8840-2439-0
PF3/4 male screw/PF1/2 nut
901LX088
Test hose (2 m long)

5-8840-2435-0 (Between oil pump and oil container)
Metal cap PF1/2 male screw x 2)
901LX089
MEMO
LGPTO-WE-0091
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all countries

except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Nov., 1999 0911-01K-1

No.LGPTO-WE-0091 PRINTED IN JAPAN
WORKSHOP MANUAL
NHR · NKR · NPR · NQR · NPS
GENERAL INFORMATION
SECTION 0

Tokyo, Japan
NOTICE

MANUAL”.
All material contained in this Manual is based on latest product

information available at the time of publication.
prior notice.
Applicable Model
N-Series
NHR55 NPR55 NQR66

NHR69 NPR69 NQR70
NKR55 NPR65 NQR71
NKR69 NPR66 NPS66
NKR58 NPR70 NPS71
NKR66 NPR71
This manual is applicable to 1999 year model.

0A General Information
0B Maintenance and Lubrication

HOME
GENERAL INFORMATION 0A–1
SECTION 0A
GENERAL INFORMATION
CONTENTS
PAGE
General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 2
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 6
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 7
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 9
Recommended Liquid Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–10
Recommended Thread Locking Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–12
0A–2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS

1. Park the vehicle on level ground and chock 11. Keep fixing nuts and bolts separate.
the front or rear wheels before lifting the Fixing nuts and bolts vary in hardness and
vehicle. design according to installation positions.
2. Use1covers1on1the1vehicle1body, seats, and 12. Clean1all1parts1before1inspection1or

floor1to1prevent1damage1and/or1 reassembly.
contaminations.
13. Clean the oil ports and other openings with
3. Disconnect the grounding cable from the compressed air to make certain that they are
battery before performing service operations. free of dirt and obstructions.
This will prevent cable damage or burning
due to shortcircuiting. 14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before
4. Raise the vehicle with a jack set against the installation.
axle or the frame.
15. Use1the1recommended1liquid1gasket1to
5. Support the vehicle on chassis stands. prevent1leakage.
6. Handle brake fluid and antifreeze solution 16. Be sure to tighten bolts and nuts to the
with great care. specified torque, using a properly maintained
Spilling these liquids on painted surfaces will torque wrench.
damage the paint.
17. When service operation is completed, make a
7. The use of the proper tool(s) and special final check to be sure service has been done
tool(s) where specified is essential to efficient, properly and problem has been corrected.
reliable, and safe service operations.
18. When1removing1or1replacing1parts1that
8. Always use genuine ISUZU replacement1 require refrigerant to the discharged from the
parts. Air conditioning system, be sure to use the
ACR4 or equivalent to recover and recycle
9. Discard used cotter pins, gasket, O-rings, oil Refrigerant-134a, to promote the movement
seals, lock washers, and self-locking nuts at for the protection of the ozone layer covering
disassembly. the earth.
Normal function of these parts cannot be
guaranteed if they are reused. 19. To1assure1safety, always1slowly1release1air
pressure1from1the1air1tanks1before
10. Keep the disassembled parts neatly in groups. disconnecting1pipes,1hoses1or1other1parts
This1will1facilitate1smooth1and1correct from1any1unit1under1pressure.
reassembly.
HOW TO USE THIS MANUAL

1. The “GENERAL INFORMATION” includes items should be read and understood fully
collectively the following items 1 to A which before starting each service operations.
have relations with all the sections. These
1 General Repair Instruction 7 Liquid Gasket Application Procedure

2 How To Use This Manual 8 Maintenance Schedule
3 Model Change Information 9 Recommended Fluids, Lubricants and
4 Lifting Instruction Fuels
5 Torque Specification 0 Oil Viscosity Chart
6 Recommended Liquid Gasket A Lubrication Chart
2. The “SERVICE INFORMATION” at the describes the following information and data
beginning of each service operation section, 1 to 6 necessary for the service operation.
1 Troubleshooting 4 Servicing
2 Main Data and Specifications 5 Fixing Torque
3 Service Standard 6 Special Tools
3. The description of each service operation Disassembly,1Inspection1and1Repair1and

section consists of Removal and Installation, Reassembly.
4. Each service operation section begins with a This illustration is useful for finding components,
disassembly view of the unit of equipment service procedure, etc.
(with exception of Inspection and Repair).
Note indicating what model the

illustration is based on.
The1number1represents1the
service1operation1sequence.
Parts within a square frame are to

be removed and installed as a
single unit.
Removal of the parts without

numbers (excluding bolts, nuts,
washers, gaskets, cotteer pins,
etc. ) is unnecessary except when
replacement is needed.
Where1parts1replacement
requires1specific1note,
instructions1are1given1in
“Inspection and Repair”.
Listed here are parts names

arranged in the order of the
service operation procedure, and
used as the title of each service
operation1in1the1detailed
explanation1followed.1
(Parts names are printed in
singular form.)
5. Service operation procedure.
Service operation procedure :

When a detailed explanation is
required or when special tools
have to be used in the removal
(and installation) operation,
drawings and symbols are also
given.
This symbol indicates the type of

service operation to be
performed.
A more detailed explanation of
the various symbols follows.

When the removal (and
installation) operation is
uncomplicated, only a removal
number and a parts name are
given.
Special tools are identified with

the tool names and tool numbers.
The drawing illustration shows
how the tool is used.
6. In this manual, the following symbols are

used to give a full understanding of the
service operation to be performed.
... Remove ... Clean
... Install ... Pay close attention
... Disassemble ... Tighten to specified torque
... Reassemble ... Use special tool(s) (Isuzu’s tool(s))
... Align the marks ... Use special tool(s) (parts manufacturer’s tool(s))
... Correct direction ... Lubricate with oil
... Inspect ... Lubricate with grease
... Take measurement ... Apply liquid gasket
... Adjustment
7. The service standard is indicated in terms of considered serviceable. “Limit” indicates the
“Standard” and “Limit”. limit1value1(Correction1or1replacement1is
The “Standard” means the assembly standard necessary when measurement is beyond this
and standard range within which the parts are limit).
IDENTIFICATION
Chassis Number:
It is stamped on the front right-hand side face of the
chassis side member.
1: NHR and NKR models with independent front
suspension.
2: NPR, NQR and NPS models with rigid axle front
suspension.
Engine Number:
4J Series Engine
It is stamped on the left side rear of the cylinder body.
4H Series Engine
The engine number is stamped on the right side of
the cylinder body.
Vehicle Identification plate

The vehicle identification plate is attached to the
interior side of the cab side panel on the right side.
LIFTING INSTRUCTION
If it is necessary to use a lifting device other than Lifting should only be done at the positions
the original equipment jack, see illustration for indicated to prevent possible damage to the
acceptable lifting points. vehicle.
CAUTION:
Failure to observe the acceptable lift points may result in
unsatisfactory vehicle performance or a durability failure
which may result in loss of control of the vehicle.
Garage Jack and Safety Stand

NHR,NKR,NPR,NQR
Lifting point and supportable point location
NHR,NKR,NPR,NQR
1 3 1 Front axle
2 Side frame front side
3 Rear axle center
4 Side frame rear side
5 Suspension cross member
4
6 Jack up bracket
2
NPS
NPS
1 3
4
2
NHR,NKR
NHR,NKR
(Front
(Front independent
independent suspention)
suspention)
5 3
6
4
Front Side; Lifting Point

Note:
Do not lift or support on engine oil pan.
NHR,NKR
(Front independent suspention)
Front Side Supportable Point
NHR,NKR
Rear Side Lifting Point

Note:
Do not lift or support on rear axle tube.
Rear Side Supportable Point

TORQUE SPECIFICATIONS
STANDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified.

N·m kg·cm / lb·in
Strength 4.8 8.8 9.8

Class
Refined Non-Refined
Bolt
Identifi-
cation 4 8 8 9
Bolt
Diameter x No mark
Pitch (mm)
M 6x1.0 6 (60 / 52 7 (75 / 65 –

M 8x1.25 13 (130 / 113 17 (175 / 152 24 (240 / 208
M10x1.25 27 (2.8 / 20) 37 (3.8 / 27) 50 (5.1 / 37)
M12x1.25 61 (6.3 / 45) 76 (7.8 / 56) 95 (9.7 / 70)
M14x1.5 96 (9.8 / 71) 116 (11.9 / 86) 142 (14.5 / 105)
M16x1.5 130 (13.3 / 96) 170 (17.3 / 125) 200 (20.4 / 148)
M18x1.5 188 (19.2 / 139) 244 (24.9 / 180) 287 (29.3 / 212)
M20x1.5 258 (26.3 / 190) 337 (34.4 / 249) 396 (40.4 / 292)
M22x1.5 332 (33.9 / 245) 453 (46.3 / 335) 530 (54.1 / 391)
M24x2.0 449 (45.8 / 331) 570 (58.2 / 421) 692 (70.6 / 511)
*M10x1.5 26 (2.7 / 20) 36 (3.7 / 27) 48 (4.9 / 35)
*M12x1.5 57 (5.8 / 42) 71 (7.2 / 52) 89 (9.1 / 66)
*M14x2.0 89 (9.1 / 66) 110 (11.2 / 81) 133 (13.6 / 98)
*M16x2.0 124 (12.7 / 92) 162 (16.5 / 119) 191 (19.5 / 141)
The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials
such as casting, etc.
FLARE NUTS
Pipe diameter mm (in) Torque Pipe diameter mm (in) Torque
4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)

6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)
8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)
RECOMMENDED LIQUID GASKET

TYPE BRAND NAME MANUFACTURER APPLICATION PARTS (EXAMPLE)
RTV* ThreeBond 1207B ThreeBond Engine Oil Seal Retainer

Silicon Base ThreeBond 1207C ThreeBond Engine Oil Pan
ThreeBond 1215 ThreeBond Timing Gear Case
ThreeBond 1216 ThreeBond Cylinder Head Cover
ThreeBond 1281 ThreeBond Fuel Pump
Water Pump
Water Base ThreeBond 1141E ThreeBond Rear Axle
etc.
Solvent ThreeBond 1104 ThreeBond
BelcoBond 4 Isuzu
BelcoBond 401 Isuzu
BelcoBond 402 Isuzu
Anaerobic LOCTITE 515 LOCTITE Engine Oil Seal Retainer

LOCTITE 518 LOCTITE Water Pump
Transaxle
etc.
*RTV: Room Temperature Vulcanizer
NOTE:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.001 in). Poor adhesion will result.
3. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer’s instructions at all times.
Application Procedure
1. Completely remove lubricant and moisture from the connecting surfaces.

The surfaces must be perfectly dry.
2. Apply specified bead width of liquid gasket to one of the connecting surfaces.
mm (in.)
SCREW JUDGE-
DEPRESSION
HOLE MENT
1~3
(0.04~0.12)
OK
1~3 More than

(0.04~0.12) 2(0.08)
OK
Apply liquid gasket to
Depression the bolt hole interior
Specified
bead width
NG
Example
Anaerobic Type : 2-3mm (0.08-0.12 inch)
Others : 2-6mm (0.08-0.24 inch)
NOTE:
When the application procedures are specified in this Workshop manual, follow them.
RECOMMENDED THREAD LOCKING AGENT

TYPE COLOR APPLICATION STEPS
1. Completely remove all lubricant and moisture from the
bolts and the female threaded surfaces of the parts to be
LOCTITE 242 Blue joined.
2. Apply LOCTITE to the bolts.

Apply LOCTITE to at least 1/3 of the
bolt’s threaded area
LOCTITE 262 Red
3. Tighten the bolts to the specified torque.

NOTE:
LOCTITE 271 Red
After tightening, be sure to keep the bolts free from vibration
and torque for at least an hour until LOCTITE hardens.
NOTE:
HOME
MAINTENANCE AND LUBRICATION 0B–1
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
PAGE
Maintenance Schedule (for Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–12
Maintenance Schedule (Except Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–18
Recommended Fluids, Lubricants and Diesel Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–14
Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–16
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–18
0B–2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
(For Europe only)
When performing the checks on the following items,
regular inspection items should also be checked.
ABBREVIATIONS USED IN THIS MANUAL
I : Inspect, clean and correct or replace as necessary

A : Adjust
R : Replace or change
T : Tighten to specified torque
L : Lubricate
V ...............................Variation (optional on some models).
OPT ...............................Optional equipment.
4J ...............................For 4JB1-TC engine model.
4H ...............................For 4HE1-TC engine model.
Maintenance schedule
Use odometer reading or months whichever comes first
SERVICE INTERVAL: x 1,000 km. 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

x 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
4J ENGINE
*Engine oil – R – R – R – R – R – R – R – R – R – R
*Oil filter – R – R – R – R – R – R – R – R – R – R
Fuel filter – – – R – – – R – – – R – – – R – – – R
*Air cleaner element – I – I – I – I – I – I – I – I – I – I
Idling speed and acceleration – – – I – – – I – – – I – – – I – – – I
Valve clearances – – – – – – – A – – – – – – – A – – – –
Fuel tank cap & fuel pipes for loose
connections or damage – – – – – – – I – – – – – – – I – – – –
Drive belt tension and damage – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – R – – – – – – – R – – – –
*Exhaust pipes and mounting
damage or looseness – – – I – – – I – – – I – – – I – – – I
Cooling system – – – I – – – I – – – I – – – I – – – I
Engine operation condition – I – I – I – I – I – I – I – I – I – I
4H ENGINE
*Engine oil – – R – – R – – R – – R – – R – – R – –
*Oil filter – – R – – R – – R – – R – – R – – R – –
Fuel filter: Main Fuel filter – – – R – – – R – – – R – – – R – – – R
OPT Main Fuel filter and Sub Fuel
filter: With Sub fuel filter – – – – – – – R – – – – – – – R – – – –
*Air cleaner element – I – I – I – R – I – I – I – R – I – I
Idling speed and acceleration – – – I – – – I – – – I – – – I – – – I
Valve clearances – – – – – – – A – – – – – – – A – – – –
Feed pump strainer – – – I – – – I – – – I – – – I – – – I
connections or damage – – – – – – – I – – – – – – – I – – – –
Drive belt tension and damage – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – R – – – – – – – R – – – –
damage or looseness – – – I – – – I – – – I – – – I – – – I
Cooling system – – – I – – – I – – – I – – – I – – – I
Engine operation condition – I – I – I – I – I – I – I – I – I – I
CLUTCH
Clutch fluid – – I – – I – – R – – I – – R – – I – –
Clutch pedal travel and free play – I I I I I I I I I I I I I I I I I I I

x 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
TRANSMISSION
*Manual Transmission oil – – I – – I – – R – – I – – R – – I – –

Gear control mechanism for
looseness – – – – – – – I – – – – – – – I – – – –
Gear control cable – – A – – – – – A – – – – – A – – – – –
PROPELLER SHAFT
*Universal joints and sliding sleeve – – L – – – – – L – – – – – L – – – – –

Loose connections – – I – – I – – I – – I – – I – – I – –
Splines for excessive wear – – – – – – – – I – – – – – I – – – – –
Bearings and related parts for
looseness – – – – – – – – I – – – – – I – – – – –
Center bearing – – L – – – – – L – – – – – L – – – – –
REAR AXLE
*Differencial gear oil – – I – – I – – R – – I – – I – – R – –
FRONT AXLE
*Kingpin – L – L – L – L – L – L – L – L – L – L
STEERING
Power steering system oil leakage – I – I – I – I – I – I – I – I – I – I

Power steering fluid – – – – – – – R – – – – – – – R – – – –
*Power steering system for
looseness or damage – I – I – I – I – I – I – I – I – I – I
Fitting of knuckles and front axle
for looseness – I – I – I – I – I – I – I – I – I – I
Steering mechanism for looseness
or damage – – – – – – – I – – – – – – – I – – – –
Ball joint boots for damage
(Independent suspension model
only) – I – I – I – I – I – I – I – I – I – I
Ball joint for excessive play
only) – I – I – I – I – I – I – I – I – I – I
Relay lever shaft for excessive play
ony) – I – I – I – I – I – I – I – I – I – I
Steering wheel play I I I I I I I I I I I I I I I I I I I I
Steering function I I I I I I I I I I I I I I I I I I I I
Wheel alignment – – – – – – – – – – – – – – – I – – – –
Power steering hose – – – – – – – – – – – – – – – R – – – –

x 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
SERVICE BRAKES
Brake fluid – – I – – I – – R – – I – – I – – R – –
V Hydro booster fluid (ATF) – – I – – I – – R – – I – – I – – R – –
Brake system for fluid leakage – – I – – I – – I – – I – – I – – I – –
*Brake lining and drum for wear – – I – – I – – I – – I – – I – – I – –
*Disc brake pads and discs for wear – – I – – I – – I – – I – – I – – I – –
Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I
Pipes and hoses for loose
connections or damage – I – I – I – I – I – I – I – I – I – I
PARKING BRAKE
Parking brake cables – – I – – I – – I – – I – – I – – I – –

Parking brake function – – I – – I – – I – – I – – I – – I – –
Parking brake lever travel – – I – – I – – I – – I – – I – – I – –
Lining for wear – – – – – – – – I – – – – – – – – I – –
Drum for wear or damage – – – – – – – – I – – – – – – – – I – –
Ratchet for wear or damage – – – – – – – – I – – – – – – – – I – –
SUSPENSION
Spring leaves for damage – I – I – I – I – I – I – I – I – I – I

Torsion bar Spring (Independent
suspension model only) – I – I – I – I – I – I – I – I – I – I
only) – I – I – I – I – I – I – I – I – I – I
Mount for looseness or damage – I – I – I – I – I – I – I – I – I – I
Shock absorvers for oil leakage – I – I – I – I – I – I – I – I – I – I
Shock absorbers mount for
looseness – I – I – I – I – I – I – I – I – I – I
(independent suspension model
only) – – – – – – – I – – – – – – – I – – – –
Upper links (Independent
suspension model only) L L L L L L L L L L L L L L L L L L L L
WHEELS
Wheel pins and nuts – – – T – – – T – – – T – – – T – – – T

Wheel disc for damage – – – I – – – I – – – I – – – I – – – I
Hub bearing grease – – – – – – – R – – – – – – – R – – – –
Tire pressure and damage – I – I – I – I – I – I – I – I – I – I

x 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
ELECTRICAL EQUIPMENT
Specific gravity of battery – I – I – I – I – I – I – I – I – I – I

electrolyte
OTHERS
Lights, horn, windshield, wiper and

washer – I – I – I – I – I – I – I – I – I – I
Bolts and nuts on chassis and body – – – – – – – I – – – – – – – I – – – –
Maintenance schedule under severe driving conditions
Severe driving conditions

A : Repeated short trips
B : Driving on rough roads
C : Driving on dusty roads
D : Driving extremely cold weather and/or on salted roads
Condition
Item Interval
A B C D A+D
4J Engine oil and oil filter Change every 5,000 km (3,000 miles) ● ●
4H Engine oil and oil filter Change every 7,500 km (4,500 miles) ● ●
Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles) ● ● ●
Air cleaner element Replace every 20,000 km (12,000 miles) ●
Steering system for looseness

Inspect every 5,000 km (3,000 miles) ●
or damage
Universal joints and sliding

Lubricate every 10,000 km (6,000 miles) ●
sleeve grease
Manual transmission and

Change every 20,000 km (12,000 miles) ●
differential gear oil
Brake lining and drum for

Inspect every 10,000 km (6,000 miles) ● ● ●
wear
Disc brake pads and discs

for wear
(EXCEPT EUROPE)

A : Adjust
L : Lubricate
4JG ...............................For 4JG2 engine model.
4J ...............................For 4J engine models.
4HF1-2 ...............................For 4HF1-2 engine model.
4H ...............................For 4H engine model.
MT ...............................For manual transmission model only.
AT ...............................For automatic transmission model only.
SERVICE INTERVAL: x 1,000 km. 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

x 1,000 miles 0.6 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
4J ENGINE
*Engine oil – R R R R R R R R R R R R R R R R R R R R
*Oil filter – – R – R – R – R – R – R – R – R – R – R
Fuel filter – – – – R – – – R – – – R – – – R – – – R
*Air cleaner element – – I – I – I – I – I – I – I – I – I – I
Idling speed and acceleration – – – – I – – – I – – – I – – – I – – – I
Valve clearances I – – – – – – – A – – – – – – – A – – – –
connections or damage – – – – – – – – I – – – – – – – I – – – –
OPT 4JG Timing belt – – – – – – – – – – – – – – – – – – – – R
Drive belt tension and damage I – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – – R – – – – – – – R – – – –
damage or looseness – – – – I – – – I – – – I – – – I – – – I
Cooling system – – – – I – – – I – – – I – – – I – – – I
Engine operation condition – – I – I – I – I – I – I – I – I – I – I
4H ENGINE
*Engine oil – – R – R – R – R – R – R – R – R – R – R
*Oil filter – – R – R – R – R – R – R – R – R – R – R
Fuel filter: Main Fuel filter – – – – R – – – R – – – R – – – R – – – R
OPT Main Fuel filter and Sub Fuel
filter: With Sub fuel filter – – – – – – – – R – – – – – – – R – – – –
*Air cleaner element – – I – I – I – R – I – I – I – R – I – I
Idling speed and acceleration – – – – I – – – I – – – I – – – I – – – I
Valve clearances I – – – – – – – A – – – – – – – A – – – –
Feed pump strainer (Except 4HF1-2 ) – – – – I – – – I – – – I – – – I – – – I
connections or damage – – – – – – – – I – – – – – – – I – – – –
Drive belt tension and damage I – I – I – I – I – I – I – I – I – I – I
Radiator coolant
(Ethylene glycol antifreeze) – – – – – – – – R – – – – – – – R – – – –
damage or looseness – – – – I – – – I – – – I – – – I – – – I
Cooling system – – – – I – – – I – – – I – – – I – – – I
Engine operation condition – – I – I – I – I – I – I – I – I – I – I
MT CLUTCH
Clutch fluid – – I – I – I – R – I – I – I – R – I – I
Clutch pedal travel and free play – I I I I I I I I I I I I I I I I I I I I

x 1,000 miles 0.6 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
TRANSMISSION
* MT Manual Transmission oil – – I – I – I – R – I – I – I – R – I – I

* AT Automatic Transmission fluid – – – – – – – – R – – – – – – – R – – – –
looseness – – – – – – – – I – – – – – – – I – – – –
Gear control cable – – – – A – – – A – – – A – – – A – – – A
TRANSMISSION WITH TRANSFER

CASE (NPS model only)
*Transmission with transfer case oil – – I – I – I – R – I – I – I – R – I – I

looseness – – – – – – – – I – – – – – – – I – – – –
Gear control cable – – – – A – – – A – – – A – – – A – – – A
PROPELLER SHAFT
*Universal joints and sliding sleeve – – – – L – – – L – – – L – – – L – – – L

Loose connections – – I – I – I – I – I – I – I – I – I – I
Splines for excessive wear – – – – – – – – I – – – – – – – I – – – –
Bearings and related parts for
looseness – – – – – – – – I – – – – – – – I – – – –
Center bearing – – – – L – – – L – – – L – – – L – – – L
REAR AXLE
*Differencial gear oil – – I – I – I – R – I – I – I – R – I – I
FRONT AXLE
*Kingpin – – L – L – L – L – L – L – L – L – L – L
Differential gear oil
(NPS model only) – – I – I – I – R – I – I – I – R – I – I

x 1,000 miles 0.6 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
STEERING
Manual steering gear oil – – – – – – I – – – – – I – – – – – I – –

OPT Power steering system oil
leakage – – I – I – I – I – I – I – I – I – I – I
OPT Power steering fluid – – – – – – – – R – – – – – – – R – – – –
* OPT Power steering system for
looseness or damage – – I – I – I – I – I – I – I – I – I – I
Fitting of knuckles and front axle
for looseness – – I – I – I – I – I – I – I – I – I – I
Steering mechanism for looseness
or damage – – – – – – – – I – – – – – – – I – – – –
only) – – I – I – I – I – I – I – I – I – I – I
only) – – I – I – I – I – I – I – I – I – I – I
Relay lever shaft for excessive play
ony) – – I – I – I – I – I – I – I – I – I – I
Steering wheel play – I I I I I I I I I I I I I I I I I I I I
Steering function – I I I I I I I I I I I I I I I I I I I I
Wheel alignment – – – – – – – – – – – – – – – – I – – – –
OPT Power steering hose – – – – – – – – – – – – – – – – R – – – –
SERVICE BRAKES
Brake fluid – – I – I – I – R – I – I – I – R – I – I
V Hydro booster fluid (ATF) – – I – I – I – R – I – I – I – R – I – I
Brake system for fluid leakage – – I – I – I – I – I – I – I – I – I – I
*Brake lining and drum for wear – – – – I – – – I – – – I – – – I – – – I
*Disc brake pads and discs for wear – – I – I – I – I – I – I – I – I – I – I
Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I I
Pipes and hoses for loose
connections or damage – – I – I – I – I – I – I – I – I – I – I
PARKING BRAKE
Parking brake cables – – I – I – I – I – I – I – I – I – I – I

Parking brake function – – I – I – I – I – I – I – I – I – I – I
Parking brake lever travel – – I – I – I – I – I – I – I – I – I – I
Lining for wear – – – – – – – – I – – – – – – – I – – – –
Drum for wear or damage – – – – – – – – I – – – – – – – I – – – –
Ratchet for wear or damage – – – – – – – – I – – – – – – – I – – – –

x 1,000 miles 0.6 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
or months 1 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
SUSPENSION
Spring leaves for damage – – I – I – I – I – I – I – I – I – I – I

Torsion bar Spring (Independent
suspension model only) – – I – I – I – I – I – I – I – I – I – I
only) – – I – I – I – I – I – I – I – I – I – I
Mount for looseness or damage – – I – I – I – I – I – I – I – I – I – I
Spring pin (NPS model only) – – L – L – L – L – L – L – L – L – L – L
Shock absorvers for oil leakage – – I – I – I – I – I – I – I – I – I – I
Shock absorbers mount for
looseness – – I – I – I – I – I – I – I – I – I – I
(independent suspension model
only) – – – – – – – – I – – – – – – – I – – – –
Upper links (Independent
suspension model only) – L L L L L L L L L L L L L L L L L L L L
WHEELS
Wheel pins and nuts T – – – T – – – T – – – T – – – T – – – T

Wheel disc for damage – – – – I – – – I – – – I – – – I – – – I
Hub bearing grease – – – – – – – – R – – – – – – – R – – – –
Tire pressure and damage – – I – I – I – I – I – I – I – I – I – I
Specific gravity of battery – – I – I – I – I – I – I – I – I – I – I

electrolyte
OTHERS
Lights, horn, windshield, wiper and

washer – – I – I – I – I – I – I – I – I – I – I
Drive shaft dust boots for damage
(NPS model only) – – – – I – – – I – – – I – – – I – – – I
Bolts and nuts on chassis and body I – – – – – – – I – – – – – – – I – – – –

A : Repeated short trips
B : Driving on rough roads
C : Driving on dusty roads
D : Driving extremely cold weather and/or on salted roads
Condition
Item Interval
A B C D A+D
4J Engine oil:
Change every 2,500 km (1,500 miles) ● ●
with Partial-flow oil filter
4H Engine oil:
Change every 5,000 km (3,000 miles) ● ●
with Partial-flow oil filter
Engine oil filter Replace every 5,000 km (3,000 miles) ● ●
Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles) ● ● ●
Air cleaner element Replace every 20,000 km (12,000 miles) ●
Steering system for looseness

Inspect every 5,000 km (3,000 miles) ●
or damage
Universal joints and sliding

Lubricate every 10,000 km (6,000 miles) ●
sleeve grease
Manual transmission and

differential gear oil
Automatic transmission gear

fluid
Transmission with transfer

case gear oil (NPS model)
Brake lining and drum for

wear
Disc brake pads and discs

for wear
OIL VISCOSITY CHART

ENGINE OIL
ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE
[Single grade]
;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;
SAE 40, 50
;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 20, 20W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
–30°C –25°C –15°C 0°C 15°C 25°C 30°C

–22°F –13°F 5°F 32°F 59°F 77°F 86°F
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W–30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 15W–40, 20W–40, 20W–50
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
DO NOT USE SYNTHETIC OILS.
* At ambient temperatures below –25°C (–13°F), starting aids (oil pan
heater, block heater, etc.) are recommended to prevent hard starting
[Multi grade] and other engine problems.
MANUAL TRANSMISSION AND TRANSFER CASE OIL (ENGINE OIL)

VISCOSITY GRADE – AMBIENT TEMPERATURE
[Single grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 40, 50
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
–25°C –10°C 5°C 10°C 20°C 35°C

–13°F 14°F 41°F 50°F 68°F 95°F
[Multi grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 5W–30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W–30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 15W–40, 20W–40, 20W–50
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
ET-12 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
FRONT AXLE AND REAR AXLE OIL

GEAR OIL VISCOSITY GRADE – AMBIENT TEMPERATURE
[Single grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 140
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 90
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 80W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 75W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
–25°C –10°C 0°C 15°C 30°C 35°C

–13°F 14°F 32°F 59°F 86°F 95°F
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 75W–90
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 80W–90
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 80W–140
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
[Multi grade]
LUBRICATION CHART
NHR, NKR (Front Independent Suspension) models
◎ Change W : Wheel bearing grease
○ Check and Replenish or Lubricate C : Multipurpose type grease
E : Engine oil M : MoS2 contained type grease
G : Gear Oil B : Brake fluid
A : Automatic transmission fluid
Steering
gear box
G
Brake and
clutch fluid B C Upper link
Front hub
bearing W W Front hub bearing
Upper link C A OPT Power steering

fluid
E OPT Oil bath type

air cleaner oil
4J Engine E E Transmission
4B Engine E Prop. shaft

M universal joint
Prop. shaft
M universal joint
Prop. shaft
M sliding sleeve
Prop.shaft
center bearing M
Rear hub Prop. shaft

bearing W M universal joint
Differential
gear
G W Rear hub bearing
Every month or 3,000km (2,000 miles)
Every 3 months or 5,000km (3,000 miles)

Every 2 years or 40,000km (24,000 miles)

NHR, NKR55, NKR69, NPR55 and NPR69 models

Steering
gear box G
Brake and
clutch fluid
B C King pin
King pin C W Front hub bearing
Front hub
bearing
W
A OPT Power steering

fluid
E OPT Oil bath type

air cleaner oil
4J Engine E E Transmission
Prop. shaft
M universal joint
Prop. shaft
Prop. shaft
M universal joint
center bearing M
Prop. shaft
M sliding sleeve

Differential
G W Rear hub bearing
gear

NKR66, NPR66, NPR70, NPR71, NQR66,NQR70 and NQR71 models

Brake and
clutch fluid B C King pin
King pin C W Front hub bearing
Front hub
bearing
W
Power steering
A fluid
Automatic
A transmission
E Transmission
4H Engine E Prop. shaft

M universal joint
Prop. shaft
V Hydro booster
M universal joint
A
fluid
Prop. shaft
M sliding sleeve
Prop. shaft
center bearing M

Differential
gear
G Rear hub bearing

NPS66 and NPS71 model

Brake and
B clutch fluid
Differential
gear G
C King pin
Front hub
W W Front hub bearing
bearing
King pin
A Power steering
C
Prop. shaft
M universal joint
Prop. shaft
M sliding sleeve
4H Engine Transmission with

E transfer case
with partial-flow E
oil filter
Prop. shaft
M universal joint
Prop. shaft
M universal joint
Prop. shaft
center bearing M
Prop. shaft
M sliding sleeve
Rear spring
spring pin
C
Rear spring
C spring pin

W M universal joint
bearing
Rear hub
Differential
G W bearing
gear
Rear spring Rear spring

shackle pin C C shackle pin

MEMO
LGGEN-WE-9991


All rights reserved. This manual may not be reproduced

in whole or in part, without the permission in writing
of ISUZU MOTORS LIMITED.
Issued by
Tokyo, Japan
First edition Sept., 1999 9909-01K-1

No.LGGEN-WE-9991 PRINTED IN JAPAN
WORKSHOP MANUAL
NKR · NPR · NQR
GENERAL INFORMATION
SECTION 0

Tokyo, Japan
NOTICE

MANUAL”.

prior notice.
Applicable Model
N-Series
NKR55 NPR55 NQR70

NPR70
This manual is applicable to 2000 year model.

0A General Information
0B Maintenance and Lubrication

HOME
SECTION 0A
GENERAL INFORMATION
CONTENTS
PAGE
General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 2
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 6
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 7
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A– 9
Recommended Liquid Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–10
Recommended Thread Locking Agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–12
GENERAL REPAIR INSTRUCTIONS

1. Park the vehicle on level ground and chock 11. Keep fixing nuts and bolts separate.
the front or rear wheels before lifting the Fixing nuts and bolts vary in hardness and
vehicle. design according to installation positions.
2. Use1covers1on1the1vehicle1body, seats, and 12. Clean1all1parts1before1inspection1or

floor1to1prevent1damage1and/or1 reassembly.
contaminations.
13. Clean the oil ports and other openings with
3. Disconnect the grounding cable from the compressed air to make certain that they are
battery before performing service operations. free of dirt and obstructions.
This will prevent cable damage or burning
due to shortcircuiting. 14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before
4. Raise the vehicle with a jack set against the installation.
axle or the frame.
15. Use1the1recommended1liquid1gasket1to
5. Support the vehicle on chassis stands. prevent1leakage.
6. Handle brake fluid and antifreeze solution 16. Be sure to tighten bolts and nuts to the
with great care. specified torque, using a properly maintained
Spilling these liquids on painted surfaces will torque wrench.
damage the paint.
17. When service operation is completed, make a
7. The use of the proper tool(s) and special final check to be sure service has been done
tool(s) where specified is essential to efficient, properly and problem has been corrected.
reliable, and safe service operations.
18. When1removing1or1replacing1parts1that
8. Always use genuine ISUZU replacement1 require refrigerant to the discharged from the
parts. Air conditioning system, be sure to use the
ACR4 or equivalent to recover and recycle
9. Discard used cotter pins, gasket, O-rings, oil Refrigerant-134a, to promote the movement
seals, lock washers, and self-locking nuts at for the protection of the ozone layer covering
disassembly. the earth.
Normal function of these parts cannot be
guaranteed if they are reused. 19. To1assure1safety, always1slowly1release1air
pressure1from1the1air1tanks1before
10. Keep the disassembled parts neatly in groups. disconnecting1pipes,1hoses1or1other1parts
This1will1facilitate1smooth1and1correct from1any1unit1under1pressure.
reassembly.
HOW TO USE THIS MANUAL

1. The “GENERAL INFORMATION” includes 2. The “SERVICE INFORMATION” at the
collectively the following items 1 to A which beginning of each service operation section,
have relations with all the sections. These describes the following information and data
items should be read and understood fully 1 to 6 necessary for the service operation.
before starting each service operations. 1 Troubleshooting
1 General Repair Instruction 2 Main Data and Specifications
2 How To Use This Manual 3 Service Standard
3 Model Change Information 4 Servicing
4 Lifting Instruction 5 Fixing Torque
5 Torque Specification 6 Special Tools
6 Recommended Liquid Gasket
7 Liquid Gasket Application Procedure 3. The description of each service operation
8 Maintenance Schedule section consists of Removal and Installation,
9 Recommended Fluids, Lubricants and Disassembly,1Inspection1and1Repair1and
Fuels Reassembly.
0 Oil Viscosity Chart
A Lubrication Chart
1
2
3
4
5
6
4. Each service operation section begins with a

disassembly view of the unit of equipment
(with exception of Inspection and Repair).
This illustration is useful for finding
components, service procedure, etc.
Note indicating what model the

illustration is based on.
The1number1represents1the
service1operation1sequence.
Parts within a square frame are to

be removed and installed as a
single unit.
Removal of the parts without

numbers (excluding bolts, nuts,
washers, gaskets, cotteer pins,
etc. ) is unnecessary except when
replacement is needed.
Where1parts1replacement
requires1specific1note,
instructions1are1given1in
“Inspection and Repair”.
Listed here are parts names

arranged in the order of the
service operation procedure, and
used as the title of each service
operation1in1the1detailed
explanation1followed.1
(Parts names are printed in
singular form.)
5. Service operation procedure.

When a detailed explanation is
required or when special tools
have to be used in the removal
(and installation) operation,
drawings and symbols are also
given.
This symbol indicates the type of

service operation to be
performed.
A more detailed explanation of
the various symbols follows.

When the removal (and
installation) operation is
uncomplicated, only a removal
number and a parts name are
given.
Special tools are identified with

the tool names and tool numbers.
The drawing illustration shows
how the tool is used.
6. In this manual, the following symbols are

used to give a full understanding of the
service operation to be performed.
... Remove ... Clean
... Install ... Pay close attention
... Disassemble ... Tighten to specified torque
... Reassemble ... Use special tool(s) (Isuzu’s tool(s))
... Align the marks ... Use special tool(s) (parts manufacturer’s tool(s))
... Correct direction ... Lubricate with oil
... Inspect ... Lubricate with grease
... Take measurement ... Apply liquid gasket
... Adjustment
7. The service standard is indicated in terms of considered serviceable. “Limit” indicates the
“Standard” and “Limit”. limit1value1(Correction1or1replacement1is
The “Standard” means the assembly standard necessary when measurement is beyond this
and standard range within which the parts are limit).
IDENTIFICATION
Chassis Number:
It is stamped on the front right-hand side face of the
chassis side member.
1: NKR model with independent front suspension.
2: NKR, NPR and NQR models with rigid axle front
suspension.
Engine Number:
4J Series Engine
It is stamped on the left side rear of the cylinder body.
4H Series Engine
The engine number is stamped on the right side of
the cylinder body.
Vehicle Identification plate

The vehicle identification plate is attached to the
interior side of the cab side panel on the right side.
LIFTING INSTRUCTION
If it is necessary to use a lifting device other than Lifting should only be done at the positions
the original equipment jack, see illustration for indicated to prevent possible damage to the
acceptable lifting points. vehicle.
CAUTION:
Failure to observe the acceptable lift points may result in
unsatisfactory vehicle performance or a durability failure
which may result in loss of control of the vehicle.
Garage Jack and Safety Stand

Lifting point and supportable point location
NKR,NPR,NQR
NHR,NKR,NPR,NQR
1 3 1 Front axle
2 Side frame front side
3 Rear axle center
4 Side frame rear side
5 Suspension cross member
4
6 Jack up bracket
2
NHR,NKR
NKR
(Front independent
suspention)
5 3
6
4
Front Side; Lifting Point

Note:
Do not lift or support on engine oil pan.
NHR,NKR
NKR
(Frontindependent
(Front independentsuspention)
suspention)
Front Side Supportable Point
NHR,NKR
NKR
(Frontindependent
(Front independentsuspention)
suspention)
Rear Side Lifting Point

Note:
Do not lift or support on rear axle tube.
Rear Side Supportable Point

TORQUE SPECIFICATIONS
STANDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified.

N·m kg·cm / lb·in
Strength 4.8 8.8 9.8

Class
Refined Non-Refined
Bolt
Identifi-
cation 4 8 8 9
Bolt
Diameter x No mark
Pitch (mm)
M 6x1.0 6 (60 / 52 7 (75 / 65 –

M 8x1.25 13 (130 / 113 17 (175 / 152 24 (240 / 208
M10x1.25 27 (2.8 / 20) 37 (3.8 / 27) 50 (5.1 / 37)
M12x1.25 61 (6.3 / 45) 76 (7.8 / 56) 95 (9.7 / 70)
M14x1.5 96 (9.8 / 71) 116 (11.9 / 86) 142 (14.5 / 105)
M16x1.5 130 (13.3 / 96) 170 (17.3 / 125) 200 (20.4 / 148)
M18x1.5 188 (19.2 / 139) 244 (24.9 / 180) 287 (29.3 / 212)
M20x1.5 258 (26.3 / 190) 337 (34.4 / 249) 396 (40.4 / 292)
M22x1.5 332 (33.9 / 245) 453 (46.3 / 335) 530 (54.1 / 391)
M24x2.0 449 (45.8 / 331) 570 (58.2 / 421) 692 (70.6 / 511)
*M10x1.5 26 (2.7 / 20) 36 (3.7 / 27) 48 (4.9 / 35)
*M12x1.5 57 (5.8 / 42) 71 (7.2 / 52) 89 (9.1 / 66)
*M14x2.0 89 (9.1 / 66) 110 (11.2 / 81) 133 (13.6 / 98)
*M16x2.0 124 (12.7 / 92) 162 (16.5 / 119) 191 (19.5 / 141)
The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials
such as casting, etc.
FLARE NUTS
Pipe diameter mm (in) Torque Pipe diameter mm (in) Torque
4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)

6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)
8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)
RECOMMENDED LIQUID GASKET

TYPE BRAND NAME MANUFACTURER APPLICATION PARTS (EXAMPLE)
RTV* ThreeBond 1207B ThreeBond Engine Oil Seal Retainer

Silicon Base ThreeBond 1207C ThreeBond Engine Oil Pan
ThreeBond 1215 ThreeBond Timing Gear Case
ThreeBond 1216 ThreeBond Cylinder Head Cover
ThreeBond 1281 ThreeBond Fuel Pump
Water Pump
Water Base ThreeBond 1141E ThreeBond Rear Axle
etc.
Solvent ThreeBond 1104 ThreeBond
BelcoBond 4 Isuzu
BelcoBond 401 Isuzu
BelcoBond 402 Isuzu
Anaerobic LOCTITE 515 LOCTITE Engine Oil Seal Retainer

LOCTITE 518 LOCTITE Water Pump
LOCTITE 5127 LOCTITE Transaxle
etc.
*RTV: Room Temperature Vulcanizer
NOTE:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.001 in). Poor adhesion will result.
3. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer’s instructions at all times.
Application Procedure
1. Completely remove lubricant and moisture from the connecting surfaces.

2. Apply specified bead width of liquid gasket to one of the connecting surfaces.
mm (in.)
SCREW JUDGE-
DEPRESSION
HOLE MENT
1~3
(0.04~0.12)
OK
1~3 More than

(0.04~0.12) 2(0.08)
OK
Apply liquid gasket to
Depression the bolt hole interior
Specified
bead width
NG
Example
Anaerobic Type : 2-3mm (0.08-0.12 inch)
Others : 2-6mm (0.08-0.24 inch)
NOTE:
RECOMMENDED THREAD LOCKING AGENT

TYPE COLOR APPLICATION STEPS
1. Completely remove all lubricant and moisture from the
bolts and the female threaded surfaces of the parts to be
LOCTITE 242 Blue joined.
2. Apply LOCTITE to the bolts.

Apply LOCTITE to at least 1/3 of the
bolt’s threaded area
LOCTITE 262 Red
3. Tighten the bolts to the specified torque.

NOTE:
LOCTITE 271 Red
After tightening, be sure to keep the bolts free from vibration
and torque for at least an hour until LOCTITE hardens.
NOTE:
HOME
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
PAGE
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B– 2
4JB1-TC engine model (ACEA B2 specification engine oil) . . . . . . . . . . . . . . . . . . . . 0B– 3
4JB1-TC engine model (Engine oil that meets or exceeds ACEA B3 specification) . . 0B– 9
4HE1-TC engine model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–15
Maintenance schedule under severe driving conditions . . . . . . . . . . . . . . . . . . . . . . 0B–21
Recommended Fluids, Lubricants and Diesel Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–21
Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–22

A : Adjust
L : Lubricate
4J ...............................For 4JB1-TC engine model.
4H ...............................For 4HE1-TC engine model.
Maintenance schedule: 4JB1-TC engine model (ACEA B2 specification engine oil)
SERVICE INTERVAL:
(Use odometer reading or months x 1000 km 10 20 30 40 50 60 70 80 90 100
Whichever comes first) x 1000 mile 6 12 18 24 30 36 42 48 54 60
4J ENGINE
* Engine oil R R R R R R R R R R or every 6 months
* Engine oil filter R R R R R R R R R R or every 6 months
Fuel filter - R - R - R - R - R or every 12 months
* Air cleaner element I I I R I I I R I I or every 24 months
Idling speed and acceleration - I - I - I - I - I or every 12 months
Valve clearances - - - A - - - A - - or every 24 months
Fuel tank cap and fuel pipes for loose connections - - - I - - - I - - or every 24 months
or damage
Drive belt tension and damage I I I I I I I I I I or every 6 months
Radiator coolant (Ethylene glycol anti-freeze) - - - R - - - R - - or every 24 months
* Exhaust pipes and mountings for looseness or damage - I - I - I - I - I or every 12 months
Cooling system for water leakage - I - I - I - I - I or every 12 months
Engine operation condition I I I I I I I I I I or every 6 months
(I): Inspect and correct or replace as necessary (A): Adjust (R): Replace or change (T): Tighten to specified torque (L): Lubricate
SERVICE INTERVAL:
CLUTCH
Clutch fluid I I I R I I I R I I or every 24 months
Clutch pedal travel and free play I I I I I I I I I I or every 6 months
TRANSMISSION
* Manual transmission oil I I I R I I I R I I or every 24 months
Gear control mechanism for looseness - - - I - - - I - - or every 24 months
Gear control cables - A - A - A - A - A or every 12 months
PROPELLER SHAFT
* Universal joints and sliding sleeve grease - L - L - L - L - L or every 12 months
Loose connections I I I I I I I I I I or every 6 months
Splines for excessive wear - - - I - - - I - - or every 24 months
Bearings and related parts for looseness - - - I - - - I - - or every 24 months
Center bearing - L - L - L - L - L or every 12 months
REAR AXLE
* Differential gear oil I I I R I I I R I I or every 24 months
SERVICE INTERVAL:
FRONT AXLE
* Kingpins L L L L L L L L L L or every 6 months
STEERING
Power steering system oil leakage I I I I I I I I I I or every 6 months
* Power steering system for looseness or damage I I I I I I I I I I or every 6 months
Power steering fluid - - - R - - - R - - or every 24 months
Power steering hoses - - - - - - - R - - or every 48 months
Fitting of knuckles and front axle for looseness I I I I I I I I I I or every 6 months
Steering mechanism for looseness or damage - - - I - - - I - - or every 24 months
Ball joints for damage I I I I I I I I I I or every 6 months
(Independent suspension model only)
Ball joints for excessive play I I I I I I I I I I or every 6 months
Relay lever shaft for excessive play I I I I I I I I I I or every 6 months
Steering wheel play I I I I I I I I I I or every 6 months
SERVICE INTERVAL:
Steering function I I I I I I I I I I or every 6 months
Wheel alignment - - - I - - - I - - or every 24 months
SERVICE BRAKES
Brake fluid I I I R I I I R I I or every 24 months
Brake system for fluid leakage I I I I I I I I I I or every 6 months
* Brake linings and drums for wear I I I I I I I I I I or every 6 months
* Disc brake pads and discs for wear I I I I I I I I I I or every 6 months
Brake pedal travel and free play I I I I I I I I I I or every 6 months

Pipes and hoses for loose connections or damage I I I I I I I I I I or every 6 months
PARKING BRAKE
Parking brake cables I I I I I I I I I I or every 6 months
Parking brake function I I I I I I I I I I or every 6 months
Parking brake lever travel I I I I I I I I I I or every 6 months
Linings for wear - - - I - - - I - - or every 24 months
Drum for wear or damage - - - I - - - I - - or every 24 months
Ratchet for wear or damage - - - I - - - I - - or every 24 months
SERVICE INTERVAL:
SUSPENSION
Spring leaves for damage I I I I I I I I I I or every 6 months
Torsion bar spring I I I I I I I I I I or every 6 months
Ball joint boots for damage I I I I I I I I I I or every 6 months
Ball joints for excessive play - - - I - - - I - - or every 24 months
Mounts for looseness or damage I I I I I I I I I I or every 6 months
Shock absorbers for oil leakage I I I I I I I I I I or every 6 months
Shock absorbers mount for looseness I I I I I I I I I I or every 6 months
Upper links (Independent suspension model only) L L L L L L L L L L or every 6 months
WHEELS
Wheel pins and nuts - T - T - T - T - T or every 12 months
Wheel discs for damage - I - I - I - I - I or every 12 months
Hub bearings grease - - - R - - - R - - or every 24 months
Tire pressures and damage I I I I I I I I I I or every 6 months
SERVICE INTERVAL:
Specific gravity of battery electrolyte I I I I I I I I I I or every 6 months
OTHERS
Lights, horn, windshield, wiper and washers I I I I I I I I I I or every 6 months
Bolts and nuts on chassis and body - - - I - - - I - - or every 24 months
Maintenance schedule: 4JB1-TC engine model (Engine oil that meets or exceeds ACEA B3 specification)
SERVICE INTERVAL:
4J ENGINE
* Engine oil R R R R R R R R R R or every 9 months
* Engine oil filter R R R R R R R R R R or every 9 months
Fuel filter - R - R - R - R - R or every 18 months
* Air cleaner element I I I R I I I R I I or every 36 months
Idling speed and acceleration - I - I - I - I - I or every 18 months
Valve clearances - - - A - - - A - - or every 36 months
Fuel tank cap and fuel pipes for loose connections - - - I - - - I - - or every 36 months
or damage
Drive belt tension and damage I I I I I I I I I I or every 9 months
Radiator coolant (Ethylene glycol anti-freeze) - - - R - - - R - - or every 36 months
* Exhaust pipes and mountings for looseness or damage - I - I - I - I - I or every 18 months
Cooling system for water leakage - I - I - I - I - I or every 18 months
Engine operation condition I I I I I I I I I I or every 9 months
SERVICE INTERVAL:
CLUTCH
Clutch fluid I I I R I I I R I I or every 24 months
Clutch pedal travel and free play I I I I I I I I I I or every 6 months
TRANSMISSION
* Manual transmission oil I I I R I I I R I I or every 24 months
Gear control mechanism for looseness - - - I - - - I - - or every 24 months
Gear control cables - A - A - A - A - A or every 12 months
PROPELLER SHAFT
* Universal joints and sliding sleeve grease - L - L - L - L - L or every 12 months
Loose connections I I I I I I I I I I or every 6 months
Splines for excessive wear - - - I - - - I - - or every 24 months
Bearings and related parts for looseness - - - I - - - I - - or every 24 months
Center bearing - L - L - L - L - L or every 12 months
REAR AXLE
* Differential gear oil I I I R I I I R I I or every 24 months
SERVICE INTERVAL:
FRONT AXLE
* Kingpins L L L L L L L L L L or every 9 months
STEERING
Power steering system oil leakage I I I I I I I I I I or every 9 months
* Power steering system for looseness or damage I I I I I I I I I I or every 9 months
Power steering fluid - - - R - - - R - - or every 36 months
Power steering hoses - - - - - - - R - - or every 72 months
Fitting of knuckles and front axle for looseness I I I I I I I I I I or every 9 months
Steering mechanism for looseness or damage - - - I - - - I - - or every 36 months
Ball joints for damage I I I I I I I I I I or every 9 months
Ball joints for excessive play I I I I I I I I I I or every 9 months
Relay lever shaft for excessive play I I I I I I I I I I or every 9 months
Steering wheel play I I I I I I I I I I or every 9 months
SERVICE INTERVAL:
Steering function I I I I I I I I I I or every 9 months
Wheel alignment - - - I - - - I - - or every 36 months
SERVICE BRAKES
Brake fluid I I I R I I I R I I or every 36 months
Brake system for fluid leakage I I I I I I I I I I or every 9 months
* Brake linings and drums for wear I I I I I I I I I I or every 9 months
* Disc brake pads and discs for wear I I I I I I I I I I or every 9 months
Brake pedal travel and free play I I I I I I I I I I or every 9 months

Pipes and hoses for loose connections or damage I I I I I I I I I I or every 9 months
PARKING BRAKE
Parking brake cables I I I I I I I I I I or every 9 months
Parking brake function I I I I I I I I I I or every 9 months
Parking brake lever travel I I I I I I I I I I or every 9 months
Linings for wear - - - I - - - I - - or every 36 months
Drum for wear or damage - - - I - - - I - - or every 36 months
Ratchet for wear or damage - - - I - - - I - - or every 36 months
SERVICE INTERVAL:
SUSPENSION
Spring leaves for damage I I I I I I I I I I or every 9 months
Torsion bar spring I I I I I I I I I I or every 9 months
Ball joint boots for damage I I I I I I I I I I or every 9 months
Ball joints for excessive play - - - I - - - I - - or every 36 months
Mounts for looseness or damage I I I I I I I I I I or every 9 months
Shock absorbers for oil leakage I I I I I I I I I I or every 9 months
Shock absorbers mount for looseness I I I I I I I I I I or every 9 months
Upper links (Independent suspension model only) L L L L L L L L L L or every 9 months
WHEELS
Wheel pins and nuts - T - T - T - T - T or every 18 months
Wheel discs for damage - I - I - I - I - I or every 18 months
Hub bearings grease - - - R - - - R - - or every 36 months
Tire pressures and damage I I I I I I I I I I or every 9 months
SERVICE INTERVAL:
Specific gravity of battery electrolyte I I I I I I I I I I or every 9 months
OTHERS
Lights, horn, windshield, wiper and washers I I I I I I I I I I or every 9 months
Bolts and nuts on chassis and body - - - I - - - I - - or every 36 months
Maintenance schedule: 4HE1-TC engine model
SERVICE INTERVAL:
(Use odometer reading or months km 11250 22500 33750 45000 56250 67500 78750 90000
Whichever comes first) mile 7000 14000 21000 28000 35000 42000 49000 56000
4H ENGINE
* Engine oil - R - R - R - R or every 14 months
* Engine oil filter - R - R - R - R or every 14 months
Fuel filter: Main fuel filter - R - R - R - R or every 14 months
OPT Main fuel filter and Sub fuel filter: with Sub - - - R - - - R or every 28 months
fuel filter
* Air cleaner element I I I R I I I R or every 28 months
Idling speed and acceleration - I - I - I - I or every 14 months
Valve clearances - - - A - - - A or every 28 months
Feed pump strainer - I - I - I - I or every 14 months
Fuel tank cap and fuel pipes for loose connections - - - I - - - I or every 28 months
or damage
Drive belt tension and damage I I I I I I I I or every 7 months
Radiator coolant (Ethylene glycol anti-freeze) - - - R - - - R or every 28 months
* Exhaust pipes and mountings for looseness - I - I - I - I or every 14 months
or damage
Cooling system for water leakage - I - I - I - I or every 14 months
Engine operation condition I I I I I I I I or every 7 months
SERVICE INTERVAL:
CLUTCH
Clutch fluid I I I R I I I R or every 28 months
Clutch pedal travel and free play I I I I I I I I or every 7 months
TRANSMISSION
* Manual transmission oil I I I R I I I R or every 28 months
Gear control mechanism for looseness - - - I - - - I or every 21 months
Gear control cables - A - A - A - A or every 14 months
PROPELLER SHAFT
* Universal joints and sliding sleeve grease - L - L - L - L or every 14 months
Loose connections I I I I I I I I or every 7 months
Splines for excessive wear - - - I - - - I or every 28 months
Bearings and related parts for looseness - - - I - - - I or every 28 months
Center bearing - L - L - L - L or every 14 months
REAR AXLE
* Differential gear oil I I I R I I I R or every 28 months
SERVICE INTERVAL:
FRONT AXLE
* Kingpins L L L L L L L L or every 7 months
STEERING
Power steering system oil leakage I I I I I I I I or every 7 months
* Power steering system for looseness or damage I I I I I I I I or every 7 months
Power steering fluid - - - R - - - R or every 28 months
Power steering hoses - - - - - - - R or every 56 months
Fitting of knuckles and front axle for looseness I I I I I I I I or every 7 months
Steering mechanism for looseness or damage - - - I - - - I or every 28 months
Steering wheel play I I I I I I I I or every 7 months
Steering function I I I I I I I I or every 7 months
Wheel alignment - - - I - - - I or every 28 months
SERVICE INTERVAL:
SERVICE BRAKES
Brake fluid I I I R I I I R or every 28 months
V Hydro booster fluid (ATF) I I I R I I I R or every 28 months
Brake system for fluid leakage I I I I I I I I or every 7 months
* Brake linings and drums for wear I I I I I I I I or every 7 months
* Disc brake pads and discs for wear I I I I I I I I or every 7 months
Brake pedal travel and free play I I I I I I I I or every 7 months
Pipes and hoses for loose connections or damage I I I I I I I I or every 7 months

PARKING BRAKE
Parking brake cables I I I I I I I I or every 7 months
Parking brake function I I I I I I I I or every 7 months
Parking brake lever travel I I I I I I I I or every 7 months
Linings for wear - - - I - - - I or every 28 months
Drum for wear or damage - - - I - - - I or every 28 months
Ratchet for wear or damage - - - I - - - I or every 28 months
SERVICE INTERVAL:
SUSPENSION
Spring leaves for damage I I I I I I I I or every 7 months
Mounts for looseness or damage I I I I I I I I or every 7 months
Shock absorbers for oil leakage I I I I I I I I or every 7 months
Shock absorbers mount for looseness I I I I I I I I or every 7 months
WHEELS
Wheel pins and nuts T T T T T T T T or every 7 months
Wheel discs for damage I I I I I I I I or every 7 months
Hub bearings grease - - - R - - - R or every 28 months
Tire pressures and damage I I I I I I I I or every 7 months
Specific gravity of battery electrolyte I I I I I I I I or every 7 months
OTHERS
Lights, horn, windshield, wiper and washers I I I I I I I I or every 7 months
Bolts and nuts on chassis and body - - - I - - - I or every 28 months
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on salted roads
Item Interval Condition
A B C D A+B
Engine oil Change every 5,000 km (3,000 miles)
Engine oil filter Replace every 5,000 km (3,000 miles)
Air cleaner element Replace every 20,000 km (12,000 miles)
Exhaust pipes and mountings for looseness or damage Inspect every 10,000 km (6,000 miles)
Manual transmission oil and differential gear oil Change every 20,000 km (12,000 miles)
Universal joints and sliding sleeve grease Lubricate every 10,000 km (6,000 miles)
Kingpins Lubricate every 5,000 km (3,000 miles)
Steering system for looseness or damage Inspect every 5,000 km (3,000 miles)
Brake linings and drums for wear Inspect every 5,000 km (3,000 miles)
Disc brake pads and discs for wear Inspect every 5,000 km (3,000 miles)
RECOMMENDED FLUIDS, LUBRICANTS

AND DIESEL FUELS
In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very
important to select and use correctly best lubricants and diesel fuels.
When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below,
according to the maintenance schedule for each vehicle model.
GRADE
LUBRICATION/FLUID
ACEA API Other
Diesel engine crankcase B2/B3

E2/E3
Manual transmission B2/B3

Transfer case E2/E3
Differential GL-5
Automatic transmission
Power steering DEXRON II, III
Hydro brake booster
Clutch and brake fluid reservoir Hydraulic brake fluid SAE J1703
FMVSS 116 DOT. 3 or 4 grade
Center bearing NLGI #2 or #3

King pin multi purpose type grease
Upper links or wheel bearing grease
Propeller shaft sliding yoke NLGI #2 or #3

Universal joint multi purpose type grease
(General purpose grease containing molybdenum disulfide
in Molybdenum)
Engine cooling system Good quality ethylene glycol antifreeze

or GM spec. 6038-M or equivalent
OIL VISCOSITY CHART

ENGINE OIL
ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE
[Single grade]
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
SAE 40, 50
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 30
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 20, 20W
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 10W
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
–30°C –25°C –15°C 0°C 15°C 25°C 30°C

–22°F –13°F 5°F 32°F 59°F 77°F 86°F
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 10W–30
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 15W–40, 20W–40, 20W–50
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
DO NOT USE SYNTHETIC OILS.
* At ambient temperatures below –25°C (–13°F), starting aids (oil pan
heater, block heater, etc.) are recommended to prevent hard starting
[Multi grade] and other engine problems.
MANUAL TRANSMISSION AND TRANSFER CASE OIL (ENGINE OIL)

VISCOSITY GRADE – AMBIENT TEMPERATURE
[Single grade]
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 40, 50
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 30
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
–25°C –10°C 5°C 10°C 20°C 35°C

–13°F 14°F 41°F 50°F 68°F 95°F
[Multi grade]
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 5W–30
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 10W–30
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 15W–40, 20W–40, 20W–50
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
ET-12 ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
FRONT AXLE AND REAR AXLE OIL

GEAR OIL VISCOSITY GRADE – AMBIENT TEMPERATURE
[Single grade]
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 140
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 90
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
SAE 80W
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
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SAE 75W
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
–25°C –10°C 0°C 15°C 30°C 35°C

–13°F 14°F 32°F 59°F 86°F 95°F
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
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SAE 75W–90
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,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
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SAE 80W–90
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
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SAE 80W–140
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
[Multi grade]
LGGEN-WE-0001EU

This manual is applicable for vehicles in Europe.
All rights reserved. This manual may not be reproduced

in whole or in part, without the permission in writing
of ISUZU MOTORS LIMITED.
Issued by
Tokyo, Japan
First edition April, 2000 0004-01K-1

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WORKSHOP MANUAL
NKR . NPR . NQR
ANTI-LOCK BRAKE SYSTEM

(ABS)
SECTION 5A4
HOME
ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-1
SECTION 5A4
ANTI-LOCK BRAKE SYSTEM (ABS)
Service Precaution
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU will call out those fasteners that require a replacement
after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following these instructions can help you avoid damage to
parts and systems.
CONTENTS
PAGE
Service Precaution .......................................................................................................... 5A4 -1
General Description ........................................................................................................ 5A4 -5
System Components .................................................................................................. 5A4 -6
Electronic Hydraulic Control Unit (EHCU) ................................................................ 5A4 -6
Hydraulic Unit (HU) ..................................................................................................... 5A4 -6
ABS Warning Light ..................................................................................................... 5A4 -6
Wheel Speed Sensor .................................................................................................. 5A4 -6
Normal and Anti-lock Braking.................................................................................... 5A4 -6
Brake Pedal Travel...................................................................................................... 5A4 -7
Acronyms and Abbreviations .................................................................................... 5A4 -7
General Diagnosis ........................................................................................................... 5A4 -7
General Information.................................................................................................... 5A4 -7
ABS Service Precautions ........................................................................................... 5A4 -7
Computer System Service Precautions .................................................................... 5A4 -7
General Service Precautions ..................................................................................... 5A4 -8
Note on Intermittents.................................................................................................. 5A4 -8
Test Driving ABS Complaint Vehicles....................................................................... 5A4 -8
“ABS” Warning Light.................................................................................................. 5A4 -8
Normal Operation ....................................................................................................... 5A4 -8
Basic Diagnostic Flow Chart ..................................................................................... 5A4 -9
Basic Inspection Procedure....................................................................................... 5A4 -9
5A4-2 ANTI-LOCK BRAKE SYSTEM (ABS)
Tech 2 Scan Tool ........................................................................................................ 5A4 -10

Tech 2 Features .......................................................................................................... 5A4 -11
Getting Started ............................................................................................................ 5A4 -11
Operating Procedure (For Example) ......................................................................... 5A4 -12
DTC Modes .................................................................................................................. 5A4 -13
DTC Information Mode ............................................................................................... 5A4 -13
Plotting Snapshot Graph............................................................................................ 5A4 -14
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) .. 5A4 -15
Flow Chart for Snapshot Replay (Plotting Graph) ................................................... 5A4 -16
Tech 2 Data Display .................................................................................................... 5A4 -17
Special Function ......................................................................................................... 5A4 -17
EHCU Connector Pin-out Checks.............................................................................. 5A4 -21
Circuit Diagram ........................................................................................................... 5A4 -22
Connector List ............................................................................................................ 5A4 -26
Part Location............................................................................................................... 5A4 -29
Symptom Diagnosis ........................................................................................................ 5A4 -30
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................... 5A4 -30
Chart TA-1 ABS Works Frequently But Vehicle
Does Not Decelerate (Use TECH 2) ........................................................................... 5A4 -30
Chart A-2 Uneven Braking Occurs While ABS Works ............................................. 5A4 -31
Chart A-3, TA-3 The Wheels Are Locked................................................................... 5A4 -31
Chart A-4 Brake Pedal Feed Is Abnormal ................................................................. 5A4 -32
Chart A-5, TA-5 Braking Sound (From Hydraulic Unit)
Is Heard While Not Braking........................................................................................ 5A4 -33
Diagnostic Trouble Codes .............................................................................................. 5A4 -34
Diagnosis By “ABS” Warning Light Illumination Pattern ............................................ 5A4 -35
Diagnostic Trouble Codes (DTCs)............................................................................. 5A4 -35
Chart B-1-1 With the key in the ON position (Before starting the engine).
Warning light (W/L) is not activated. ......................................................................... 5A4 -39
Chart 1 (DTC 13/C0213) Vehicle Type Error.............................................................. 5A4 -40
Chart 2 (DTC 14/C0214) Low Power Voltage of
Rear Sensor or EHCU Abnormality ........................................................................... 5A4 -40
Chart 3 (DTC 15/C0215) Low Power Voltage OUT of Range ................................... 5A4 -41
Chart 4 (DTC 25/C0225) Exhaust Brake Cut Circuit Abnormality ........................... 5A4 -42
Chart 5 (DTC 33/C0233) Motor Drive Circuit Abnormality ....................................... 5A4 -42
Chart 6 (DTC 34/C0234) Abnormal Motor Rotation .................................................. 5A4 -42

Chart 7 (DTC 41/C0241) Solenoid Valve Power Supply Abnormality ..................... 5A4 -43
Chart 8 (DTC 43, 45/C0243, C0245) Solenoid Valve Circuit Abnormality ............... 5A4 -43
Chart 9 (DTC 51/C0251) FL Speed Sensor Circuit Abnormality .............................. 5A4 -43
Chart 10 (DTC 52/C0252) FR Speed Sensor Circuit Abnormality............................ 5A4 -43
Chart 11 (DTC 53/C0253) RL Speed Sensor Circuit Abnormality............................ 5A4 -44
Chart 12 (DTC 54/C0254) RR Speed Sensor Circuit Abnormality ........................... 5A4 -45
Chart 13 (DTC 61/C0261) Abnormal FL Speed Sensor Signal................................. 5A4 -46
Chart 14 (DTC 62/C0262) Abnormal FR Speed Sensor Signal ................................ 5A4 -48
Chart 15 (DTC 63/C0263) Abnormal RL Speed Sensor Signal ................................ 5A4- 50
Chart 16 (DTC 64/C0264) Abnormal RR Speed Sensor Signal................................ 5A4- 51
Chart 17 (DTC 65/C0265) Tire Size Error................................................................... 5A4- 52
Unit Inspection Procedure.............................................................................................. 5A4- 53
Chart C-1-1 FL Speed Sensor Output Inspection Procedure .................................. 5A4- 53
Chart C-1-2 FR Speed Sensor Output Inspection Procedure.................................. 5A4- 54
Chart C-1-3 RL Speed Sensor Output Inspection Procedure.................................. 5A4- 55
Chart C-1-4 RR Speed Sensor Output Inspection Procedure ................................. 5A4- 57
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2) ............................ 5A4- 58
Electronic Hydraulic Control Unit (EHCU)..................................................................... 5A4- 59
Removal....................................................................................................................... 5A4- 59
Installation................................................................................................................... 5A4- 59
Front Speed Sensor ........................................................................................................ 5A4- 60
Front Speed Sensor and Associated Parts .............................................................. 5A4- 60
Removal....................................................................................................................... 5A4- 60
Inspection and Repair ................................................................................................ 5A4- 60
Installation................................................................................................................... 5A4- 60
Front Speed Sensor Rotor.............................................................................................. 5A4- 61
Front Speed Sensor Rotor and Associated Parts.................................................... 5A4- 61
Removal....................................................................................................................... 5A4- 61
Installation................................................................................................................... 5A4- 62
Rear Speed Sensor ......................................................................................................... 5A4- 63
Rear Speed Sensor and Associated Parts................................................................ 5A4- 63
Removal....................................................................................................................... 5A4- 64
Installation................................................................................................................... 5A4- 64
Rear Speed Sensor Rotor ............................................................................................... 5A4- 65
Rear Speed Sensor Rotor and Associated Parts ..................................................... 5A4- 65
Removal....................................................................................................................... 5A4- 65
Installation................................................................................................................... 5A4- 65
Special Tools ................................................................................................................... 5A4- 67
General Description determine when a wheel is about to stop turning and

The Anti-lock Brake System (ABS) works on all four adjust brake pressure to maintain best braking.
wheels. A combination of wheel speed sensor and This system helps the drive maintain greater control of
Electronic Hydraulic Control Unit (EHCU) can the vehicle under heavy braking conditions.
9 ABS
TO EHCU
6 DIAG
ENGINE CONTROLLER
OR TO EHCU 5
CAB EXH BRAKE CUT RELAY
4
10
TO EHCU
3 ELECTRONIC HYDRAULIC
EHCU CONTROL UNIT(EHCU)
1 HYDRAULIC UNIT(HU)
2
4
5
8
Legend
(1) Hydraulic Line (7) Load Sensing Proportioning Valve (LSPV)
(2) Electronic Line (8) Battery
(3) Electronic Hydraulic Control Unit (EHCU) (9) ABS Warning Light
(4) Front Wheel Speed Sensor (10) Brake Switch
(5) Rear Wheel Speed Sensor
(6) Diagnosis Connector
System Components ABS Warning Light

The Anti-lock Brake System consists of a Electronic
Hydraulic Control Unit (EHCU), four Wheel Speed
Sensors and Warning Light.
Electronic Hydraulic Control Unit (EHCU)

The EHCU consists of Electronic Brake Control
Module (EBCM) and Hydraulic Unit (HU).
The EHCU is located at the frame side, in front of rear
spring bracket.
The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the hydraulic unit
according to the signal from each sensor, cancelling
ABS to return to normal braking when a malfunction
has occurred in the ABS.
The EHCU is self-diagnosing function which can
indicate faulty circuits during diagnosis.
Vehicles equipped with the Anti-lock Brake System

CONNECTOR has an amber “ABS” warning light in the instrument
panel. The “ABS” warning light will illuminate if a
EHCU malfunction in the Anti-lock Brake System is detected
by the Electronic Hydraulic Control Unit (EHCU). In
case of an electronic malfunction, the EHCU will turn
“ON” the “ABS” warning light and disable the Anti-lock
Tang lock braking function.
The “ABS” light will turn “ON” for 2 seconds after the
ignition switch is to the “ON” position, and then will go
Push
out.
If the “ABS” light comes “ON” and stays “ON” while
Lever driving, the Anti-lock Brake System should be
inspected for a malfunction according to the diagnosis
Move lever outside procedure.
Wheel Speed Sensor

NOTE: It consists of a sensor and a rotor. The sensor is
When disconnecting harness connector from EHCU, attached to the knuckle on the front wheels and to the
push the tang lock of the connector ( portion) and bracket on the brake back plate on the rear wheels.
release the tang lock. Then move the lever. The front speed sensor is coil type and rear is Hall IC
type.
Hydraulic Unit (HU) The sensor rotors press-fitted to front and rear wheel
It consists of a Motor, Plunger Pump, Solenoid Valves hubs output pulse frequency depending on wheel
and Check Valve. rotation.
Solenoid Valves: Reduces or holds the caliper fluid The speed sensors find vehicle speed from its
pressure for each front disc brake or both rear drum frequency.
brakes according to the signal sent from the EHCU.
Reservoir: Temporarily holds the brake fluid that Normal and Anti-lock Braking
returns from the front and rear wheel brake so that Under normal driving conditions, the Anti-lock Brake
pressure of front wheel brake can be reduced System functions the same as a standard power
smoothly. assisted brake system. However, with the detection of
Plunger Pump: Feeds the brake fluid held in the wheel lock-up, a slight bump or kick-back will be felt in
reservoir to the master cylinder. the brake pedal. This pedal “bump” will be followed by
Motor: Drives the pump according to the signal from a series of short pedal pulsations which occurs in rapid
EHCU. Check Valve: Controls the brake fluid flow. succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function VDC

or until the vehicle is stopped. A slight ticking or Volts DC
popping noise may be heard during brake applications VAC
when the Anti-lock features is being used.
Volts AC
When the Anti-lock feature is being used, the brake
W/L
pedal may rise even as the brakes are being applied.
Warning Light
This is also normal. Maintaining a consist force on the
pedal will provide the shortest stopping distance. WSS
Wheel Speed Sensor
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System General Diagnosis
may be stopped by applying normal force to the brake General Information
pedal. Although there is no need to push the pedal ABS malfunction can be classified into two types,
beyond the point where it stops or holds the vehicle, by those which can be detected by the ABS warning light
applying more force the pedal will continue to travel and those which can be detected as a vehicle
toward the floor. abnormality by the driver.
This extra brake pedal travel is normal. In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOWCHART” and repair.
Acronyms and Abbreviations Please refer to Section 5A for the diagnosis of
Several acronyms and abbreviations are commonly mechanical troubles such as brake noise, brake judder
used throughout this section: (brake pedal or vehicle vibration felt when braking),
ABS uneven braking, and parking brake trouble.
Anti-lock Brake System
CKT
ABS Service Precautions
Circuit Required Tools and Items:
DLC • Box Wrench
Data Link Connector • Brake Fluid
DTC • Special Tool
Diagnostic Trouble Code Some diagnosis procedures in this section require the
installation of a special tool.
DVM
5-8840-0285-0 (J-39200) High Impedance
Digital Volt Meter (High Impedance Multimeter)
Multimeter
EHCU
When circuit measurements are requested, use a
Electronic Hydraulic Control Unit circuit tester with high impedance.
FL
Front Left Computer System Service Precautions
FR The Anti-lock Brake System interfaces directly with the
Front Right Electronic Hydraulic Control Unit (EHCU) which is a
GEN control computer that is similar in some regards to the
Generator Engine Control Module. These modules are designed
to withstand normal current draws associated with
HU
vehicle operation. However, care must be taken to
Hydraulic Unit avoid overloading any of the EHCU circuits. In testing
MV for opens or shorts, do not ground or apply voltage to
Millivolts any of the circuits unless instructed to do so by the
RL appropriate diagnostic procedure. These circuits
Rear Left should only be tested with a high impedance
multimeter 5-8840-0285-0 (J-39200) or special tools
RR
as described in this section. Power should never be
Rear Right removed or applied to any control module with the
RPS ignition in the “ON” position. Before removing or
Revolution per Second connecting battery cables, fuses or connectors, always
SW turn the ignition switch to the “OFF” position.
Switch
General Service Precautions case of such trouble as can be detected by the driver
The following are general precautions which should be as a vehicle symptom, however, it is necessary to give
observed when servicing and diagnosing the Anti-lock a test drive following the test procedure mentioned
Brake System and/or other vehicle systems. Failure to below, thereby reproducing the symptom for trouble
observe these precautions may result in Anti-lock diagnosis on a symptom basis:
Brake System damage. 1. Start the engine and make sure that the “ABS” W/L
• If welding work is to be performed on the vehicle goes OFF. If the W/L remains ON, it means that
using an electric arc welder, the EHCU connector the Diagnostic Trouble Code (DTC) is stored.
should be disconnected before the welding Therefore, read the code and locate the fault.
operation begins. 2. Start the vehicle and accelerate to about 30km/h
• The EHCU connector should never be connected (19 mph) or more.
or disconnected with the ignition “ON”. 3. Slowly brake and stop the vehicle completely.
• The EHCU is not separately serviceable and must 4. Then restart the vehicle and accelerate to about 40
be replaced as assemblies. Do not disassemble km/h (25 mph) or more.
any component which is designated as non- 5. Brake at a time so as to actuate the ABS and stop
serviceable in this Section. the vehicle.
• If only rear wheels are rotated using jacks or drum 6. Be cautious of abnormality during the test. If the
tester, the system will diagnose a speed sensor W/L is actuated while driving, read the DTC and
malfunction and the “ABS” warning light will locate the fault.
illuminate. But actually no trouble exists. After 7. If the abnormality is not reproduced by the test,
inspection stop the engine once and re-start it, then make best efforts to reproduce the situation
make sure that the “ABS” warning light does not reported by the customer.
illuminate. 8. If the abnormality has been detected, repair in
If the battery has been discharged accordance with the “SYMPTOM DIAGNOSIS”.
The engine may stall if the battery has been NOTE:
completely discharged and the engine is started via • Be sure to give a test drive on a wide, even road
jumper cables. This is because the Anti-lock Brake with little traffic.
System (ABS) requires a large quantity of electricity. In
• If an abnormality is detected, be sure to suspend
this case, wait until the battery is recharged, or set the
the test and start trouble diagnosis at once.
ABS to a non-operative state by removing the fuse for
the ABS. After the battery has been recharged, stop
the engine and install the ABS fuse. Start the engine
“ABS” Warning Light
again, and confirm that the ABS warning light does not When ABS trouble occurs and actuates when possible
light. the “ABS” warning light, the trouble code
corresponding to the trouble is stored in the EHCU.
Note on Intermittents Only the ordinary brake system is available when the
ABS is turned OFF. When the “ABS” warning light is
As with virtually any electronic system, it is difficult to
actuated, if the starter switch is set ON after setting it
identify an intermittent failure. In such a case
OFF once, the EHCU checks up on the entire system
duplicating the system malfunction during a test drive
and, if there is no abnormality, judges ABS to work
or a good description of vehicle behavior from the
currently and the warning light works normally even
customer may be helpful in locating a “most likely”
though the trouble code is stored.
failed component or circuit. The symptom diagnosis
chart may also be useful in isolating the failure. Most NOTE: Illumination of the “ABS” warning light indicates
intermittent problems are caused by faulty electrical that anti-lock braking is no longer available. Power
connections or wiring. When an intermittent failure is assisted braking without anti-lock control is still
encountered, check suspect circuits for: available.
• Suspected harness damage.
Normal Operation
• Poor mating of connector halves or terminals not
fully seated in the connector body (backed out). “ABS” Warning Light
• Improperly formed or damaged terminals. When the ignition is first moved from “OFF” to “ON”,
the amber “ABS” warning light will turn “ON” for 2
Test Driving ABS Complaint Vehicles seconds and will turn “OFF”.
In case that there has been an malfunction in the
lighting pattern of “ABS” warning light, the fault can be
located in accordance with the “DIAGNOSIS BY “ABS”
WARNING LIGHT ILLUMINATION PATTERN”. In
Basic Diagnostic Flow Chart

Step Action Yes No
1 1. Customer complaint. Go to Step 2 Go to Step 3
2. Questioning to customer.
3. Basic inspection (Refer to “Basic inspection procedure”)
Using TECH 2?
2 Make sure of DTC by TROUBLE CODE. Go to Step 5 Go to Step 4
Is EHCU including DTC?
3 Check if the DTC is stored. Go to Step 5 Go to Step 4
Is EHCU including DTC?
4 Test drive. Go to Step 5 Trouble diagnosis
Is W/L lit? based on symptom
(Refer to
“SYMPTOM
DIAGNOSIS”) Go
to Step 5
5 1. Repair of faulty part. Repeat the Go to Step 6
2. Elimination of DTC. diagnosis of the
3. Inspection of “ABS” W/L illumination pattern with ignition symptom or DTC
SW “ON”. appears again Go
to Step 1
4. Test drive.
Does repeat trouble?
6 1. Reconnect all components and ensure all components Finished Go to Step 6
are properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Basic Inspection Procedure

1. Basic Inspection of Service Brake
Step Action Yes No
1 Is the fluid level normal? Go to Step 2 Replenish with
fluid.
Go to Step 2
2 Does fluid leak? Repair. Go to Step 3
Go to Step 3
3 Is the booster functioning normal? Go to Step 4 Repair.
Go to Step 4
4 Is the pad and rotor normal? Go to Step 5 Repair.
Go to Step 5
5 Reconnect all components and ensure all components are Finished Go to Step 5
properly mounted.
2. Ground Inspection
Step Action Yes No
1 Are ABS-related ground points ok? Go to Step 2 Repair.
Go to Step 2
2 Reconnect all components and ensure all components are Finished Go to Step 2
properly mounted.
Tech 2 Scan Tool

From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2
scan tool user guide.
Legend
(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech-2
(3) SAE 16/19 Adapter
Tech 2 Features 6. Turn on the vehicle ignition.

1. Tech 2 is a 12 volt system. Do not apply 24 volt. 7. Power the Tech 2 ON and verify the Tech 2 power
2. After connecting and/or installing the Vehicle up display.
Communications Interface (VCI) module, PCMCIA
card and DLC connector to the Tech 2, connect
the tool to the vehicle DLC.
2
3. Make sure the Tech 2 is powered OFF when
removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the
Tech 1 Mass Storage Cartridge.
Tech
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and
Press [ENTER] to continue.
static electricity, so care should be taken in the Software Version: X.XXX
handling of the card.
7. The Tech 2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu by pressing the NOTE: The RS232 Loop back connector is only to use
EXIT key several times before shutting down. for diagnosis of Tech 2. Refer to user guide of the
9. To clear Diagnostic Trouble Codes (DTCs), open Tech 2.
Application Menu and press “F1: Clear DTC Info”.
Getting Started
• Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The Isuzu 2000 Model Year System PCMCIA card
(1) inserts into the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech 2 (5).
4. Make sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC.
Operating Procedure (For Example)

Vehicle Identification
The power up screen is displayed when you power up Select one of the following
the tester with the Isuzu systems PCMCIA card. Follow Vehicle Type (s)
(UE) Rodeo/Amigo, Wizard/MU
the operating procedure below. (TF ) LUV
(N∗) ELF, NPR, NQR
(Off-Road) Industrial Engine
Tech
Press [ENTER] to continue.
Software Version: X.XXX
2 (N∗) ELF, NPR, NQR
(N∗ENTER)
System Selection Menu

( 1 ) 2 0 0 1 ( N∗ ) E L F , N P R , N Q R
3/4
F0: Engine
F1: Chassis
(ENTER) F2: Body
Main Menu
F0: Diagnostics
F1: Code Index
F2: View Capture Data
(F2 ENTER)
F3: Tool Options Vehicle Identification
F4: Download / Upload Help Select one of the following
Chassis
ABS
(F0)
Vehicle Identification
Select one of the following
Model Year(s) 1/2
ABS
(1) 2001
(Y) 2000
(X) 1999 (ABS/ASR ENTER)
(W) 1998
1/4
(1) 2001
(2000, ENTER)
Menu
• The following table shows which functions are used Diagnostic Trouble Codes
for the available equipment versions.
F0: Read DTC Info Ordered By Priority
Chassis F1: Clear DTC Information

(Y) 2000 (N∗) ELF, NPR, NQR F2: DTC Information
Electronic System: ABS
F3: Clear & Reset Vehicle Type
Partnumber 8972521653
Identifier 00(2WD)
20(4WD)
40(ABS/ASR)
60(12V vehicle)
Partnumer
Confirm The following is a brief description of each of the sub

menus in DTC Info and DTC. The order in which they
appear here is alphabetical and not necessarily the
way they will appear on the Tech 2.
DTC Modes
DTC Information Mode
Use the DTC info mode to search for a specific type of
Chassis stored DTC information. There are two choices. The
service manual may instruct the techinician to test for
DTCs in a certain manner. Always follow published
F0: Diagnostic Trouble Codes service procedures.
F1: Data Display
F2: Snapshot
F3: Actuator Test
There are two options available in Tech 2 DTC mode

to display the enhanced information available. After
selecting DTC, the following menu appears.
• DTC Info
• Clear Info
When CODE “13” is displayed (Vehicle Type Error)

Step Action Value(s) Yes No
1 Check harness. - Erase vehicle Replace the
Is it okay? type with TECH harness.
2 and reread
harness
information.
Diagnostic Trouble Codes

Clear & Reset Vehicle Type
F0: Read DTC Info
F1: Clear DTC Info
F2: DTC Info Do you want clear &

Reset Vehicle Type?
(F3: ENTER)
YES NO
YES: Clear vehicle type and reread vehicle harness

information.
NO: Return
DTC Status
Current Diagnostic Trouble Codes

This selection will display all DTCs that have failed
during the present ignition cycle.
History Diagnostic Trouble Codes

This selection will display only DTCs that are stored in
the EHCU’s history memory.
Plotting Snapshot Graph

This test selects several necessary items from the
data list to plot graphs and makes data comparison on
a long term basis. This test can check ABS
performance and defect by graphing wheel speed
differences between right and left sides, and front and
rear sides obtained from the ABS data list menu.
For trouble diagnosis, you can collect graphic data
(snap shot) directly from the vehicle.
You can replay the snapshot data as needed.
Therefore, accurate diagnosis is possible, even though
the vehicle is not available.
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
Flow Chart for Snapshot Replay (Plotting Graph)

Tech 2 Data Display Special Function

Use the Tech 2 data Values only after the ABS There are 12 different menus available for this test.
Diagnostic System Check has been completed, no The state of each circuit can be tested by using these
DTC(s) were noted, and you have determined that the menus. Especially when DTC cannot be detected, a
on-board diagnostics are functioning properly. Tech 2 faulty circuit can be diagnosed by testing each circuit
values from a properly-running engine may be used for by means of these menus.
comparison with the engine you are diagnosing. Even when DTC has been detected, the circuit tests
using these menus could help discriminate between a
ABS Data mechanical trouble and an electrical trouble.
Ignition SW is “ON” position. In all cases test condition; Engine stops with the key
turned to the “ON” position. To be more specific, the
(For example) test is conducted with the brake pedal stepped on after
stepping once and releasing.
• Engine: Stop
• Ignition SW: ON
• Brake Pedal: ON-OFF-ON
If the Ignition SW was turned OFF or communication
was lost, make sure to apply the brake pedal ON-OFF-
ON once again and then continue the test.
Actuator Test
F0: ABS Relay Test

F1: Return Pump Relay Test
F2: Front Left Solenoid Valve Test
F3: Front Right Solenoid Valve Test
F4: Rear Left Solenoid Valve Test
F5: Rear Right Solenoid Valve Test
F6: ABS Check Light Test
F7: Exhaust Brake Cut Test
ABS Warning Lamp ABS Motor

Test condition: Engine stops with the key turned to the Test condition: Engine stops with the key turned to the
“ON” position. To be more specific, the test is “ON” position. To be more specific, the test is
conducted with the brake pedal stepped on after conducted with the brake pedal stepped on after
stepping once and releasing. stepping once and releasing.
• The circuit is normal if the warning light in the meter Make sure of the working sound of the ABS motor.
panel comes on and goes out in accordance with The circuit is normal if the working sound of the ABS
Tech 2’s instruction. motor is made in accordance with Tech 2’s instruction.
Actuator Test Actuator Test
F0: ABS Relay Test F0: ABS Relay Test

F2: Front Left Solenoid Valve Test F2: Front Left Solenoid Valve Test
F3: Front Right Solenoid Valve Test F3: Front Right Solenoid Valve Test
F4: Rear Left Solenoid Valve Test F4: Rear Left Solenoid Valve Test
F5: Rear Right Solenoid Valve Test F5: Rear Right Solenoid Valve Test
F7: Exhaust Brake Cut Test F7: Exhaust Brake Cut Test
ABS Relay Exhaust Brake Cut Relay

Test condition: Engine stops with the key turned to the Test condition: Engine stops with the key turned to the
“ON” position. To be more specific, the test is “ON” position. To be more specific, the test is
conducted with the brake pedal stepped on after conducted with the brake pedal stepped on after
stepping once and releasing. stepping once and releasing.
Make sure of the working sound of the ABS relay. Make sure of the working sound of the exhaust brake
The circuit is normal if the working sound of the ABS cut relay.
relay is made in accordance with Tech 2’s instruction. The circuit is normal if the working sound of the
exhaust brake cut relay is made in accordance with
Tech 2’s instruction.
Actuator Test
Actuator Test
F2: Front Left Solenoid Valve Test
F3: Front Right Solenoid Valve Test F0: ABS Relay Test
F4: Rear Left Solenoid Valve Test F1: Return Pump Relay Test
F5: Rear Right Solenoid Valve Test F2: Front Left Solenoid Valve Test
F6: ABS Check Light Test F3: Front Right Solenoid Valve Test
F7: Exhaust Brake Cut Test F4: Rear Left Solenoid Valve Test
Hold Valve Test Select a Iso Solenoid

Purpose: The purpose of this test is to detect brake from the Front Left Solenoid Valve Test
pipe and valve line harness wire wrong connections Function Menus.
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake Front Left Solenoid Valve Test
pipe, valve line harness and valve.
Actuator Test
Dump Solenoid
F0: ABS Relay Test

3. Press the Hold Valve “ON” Soft Key with the brake
pedal stepped on.
4. Release the brake pedal.
5. Make sure that the Hold Valve “ON” aimed at by
Test conditions: The ignition key is the “ON” position Tech 2 and the wheel locked position are the
with the four wheels lifted up. The brake pedal is same. If different, check brake pipe, valve line
stepped on, released and stepped on again with the harness wiring and H/UNIT. Repair is needed if
parking brake released. abnormality is found.
6. Conduct Step 2 through Step 5 above on all the
Test procedure: four wheels.
1. Connect Tech 2 with the vehicle, and select
Special Function from the menus. CAUTION: When conducting this test, please
observe the following cautions.
2. Select a Hold Valve Menu from the Special
Function Menus. 1. Do not start the engine without fail.
2. Lift up the vehicle at the level floor.
• Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
Actuator Test
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
F0: ABS Relay Test
F1: Return Pump Relay Test so that the surface may become unslippery.
5. Do not load the vehicle.
F3: Front Right Solenoid Valve Test • When lifting up the vehicle, be sure to
F5: Rear Right Solenoid Valve Test observe the lifting up points. Refer to
F6: ABS Check Light Test vehicle lifting points in 0A section.
Release Valve Test Select a Dump Solenoid

Purpose: The purpose of this test is to detect brake from the Front Left Solenoid Valve Test
pipe and valve line harness wire wrong connections Function Menus.
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake Front Left Solenoid Valve Test
pipe, valve line harness and valve.
Actuator Test
Iso Solenoid
F0: ABS Relay Test

3. Press the Release Valve “ON” Soft Key with the

brake pedal stepped on.
4. Make sure that the Release Valve “ON” aimed at
by Tech 2 and the wheel released position are the
same. If different, check brake pipe, valve line
Test conditions: The ignition key is in the “ON” position
harness wiring and H/UNIT. Repair is needed if
with the four wheels lifted up. The brake pedal is
abnormality is found.
stepped on, released and stepped on again with the
parking brake released. 5. Conduct Step 2 through Step 5 above on all the
four wheels.
Test procedure:
CAUTION: When conducting this test, please
1. Connect Tech 2 with the vehicle, and select observe the following cautions.
Special Function from the menus.
1. Do not start the engine without fail.
2. Select a Release Valve Menu from the Special 2. Lift up the vehicle at the level floor.
Function Menus. • Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
Actuator Test 4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
F0: ABS Relay Test 5. Do not load the vehicle.
F1: Return Pump Relay Test • When lifting up the vehicle, be sure to
F3: Front Right Solenoid Valve Test observe the lifting up points. Refer to
F4: Rear Left Solenoid Valve Test vehicle lifting points in 0A section.
EHCU Connector Pin-out Checks • Perform checks with high impedance digital
• Disconnect EHCU. multimeter 5-8840-0285-0 (J-39200) or equivalent.
Key Nominal Value

Multimeter Measure
No. Circuit to be Tested Switch (24V Battery Note
Scale/Range between Pin
Position Vehicle)
1 EHCU Power Circuit OFF VDC 3(+)-1(-) 0-0.3V
ON VDC 3(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 2(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 24(+)-1(-) 9.5-16.5V
(16.5-34V)
2 EHCU Ground Circuit OFF Ω 1(+)-GND Less than 0.01 Ω
OFF Ω 23(+)-GND Less than 0.01 Ω
3 EXHIN Circuit ON VDC 7(+)-1(-) 9.5-16.5V Engine Run
(16.5-34V)
4 EXHOUT Circuit ON VDC 8(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 8(+)-1(-) 0-0.3V
5 Brake Switch Signal OFF VDC 16(+)-1(-) 0-0.3V
Circuit
OFF VDC 16(+)-1(-) 9.5-16.5V Apply Brake
(16.5-34V) Pedal
6 ABS W/L Circuit ON VDC 6(+)-1(-) 9.5-16.5V
(16.5-34V)
OFF VDC 6(+)-1(-) 0-0.3V
7 FL Speed Sensor OFF kΩ 10(+)-11(-) 1-2kΩ
OFF kΩ 10(+)-1(-) More than
1000kΩ
OFF VDC 10(+)-11(-) More than 200mV Turn Wheel at
0.5RPS
8 FR Speed Sensor OFF kΩ 32(+)-33(-) 1-2kΩ
OFF kΩ 32(+)-1(-) More than
1000kΩ
OFF VDC 32(+)-33(-) More than 200mV Turn Wheel at
0.5RPS
Circuit Diagram-FOR 12VOLT

F-17
STOP LAMP SW ; STOP LAMP
3W 10A 0.5G/Y 1 2 0.5G
B-66 B-66
FL-4
ABS
60A 3R 3R
RELAY ;
EXH.BRAKE F-14
FL-1 5W EXH.BRAKE
MAIN 5 2B/R 15A
80A B-38 0.5LG
8B 8W 2 5W 3W 1
H-6 B-38
H-5
RELAY; 0.5W/L 2 4 40
B-38 B-38
0.5LG/W
CHARGE
FL-2 3 1 2
P-1
KEY SW
BATTERY J-16 J-16 J-16
50A RELAY ;
P-2
RELAY ; TAIL
0.3B
EXH.B/CUT
(ABS) SW ;
ENG.WARMING
0.3B
3W/B
P-5 J-16 J-16 0.5LG/R 2 5 0.3B

B-31 B-31
5 4
0.5LG/B 3 6 0.5BR/R
B-31 B-31
1
0.5LG/B
0.3B 1 4 0.5BR/R
0.5B
H-7 KEY SW B-31 B-31
OFF
0.3B 0.3B
ACC
3W/B 2 B 0.5B/Y
B-67 F-12
ON 3 3B/Y
B-67 GAUGE
ST 0.5LG/B
BACK
10A METER
H-5
ABS
0.5B/Y 36 8 7
B-51 B-51
0.5B/Y
0.5B/Y
0.5LG/B
0.3W/V
0.5W
0.5B/Y
0.5B/Y
5 3 4
B-69 B-35 B-35
2
J-50 RELAY ;
SW ; EXH.BRAKE
ABS IND.
SW ; NEUTRAL
(Neutral=ON) B-35 B-35
B-69
5 2
3
0.5LG/L
J-50
0.3B
IND.LAMP ; 0.5B
1 EXH.BRAKE
0.5LG/L 0.5LG/L 1 10
B-51 B-52
0.5B/G
H-8
0.5LG/R
17
4 5
J-18 J-18 0.5BR/B
RELAY ;
EXH.BRAKE
CONTROL
0.85B
J-18 J-18
0.5LG/W
2 3
0.5LG/B
3
B-18
2B
H-5 DIODE
12 SW ; CLUTCH
0.5LG/B 1 2 0.5LG/R 1 2
B-89 B-89 B-18 B-18
0.3B 0.5B
2B
0.5B
0.85B
FRAME-LH (FRONT) B-1
8 JOINT
3B 2 7 B-29 CONNECTOR 3B 3B
HEADLIGHT BRACKET (LH) B-7
3B 3B 3B
2B 2B 2B
FRAME-LH (CENTER) J-9
0.5G 11 0.5G 2 0.5G

H-5 H-16
0.5G
0.5G
3R
STOP STOP
LAMP LAMP
0.5LG (LH) (RH)
0.5G
EHCU ; ABS
16
J-500 STOP LAMP 22 0.5L 2
RL 12V J-500 J-78
SPEED SENSOR
3R 24 (RR,LH)
J-500 MOTOR +B 34 0.5Y 1
RL SIG J-500 J-78
3R 2
J-500 VALVE +B
32 0.5V 1
FL SIG J-500 J-75
0.5BR/R
3B 23
J-500 MOTOR GND SPEED SENSOR
(FRT,LH)
33 0.5R/B 2
3B 1 FL GRD J-500 J-75
J-500 VALVE GND
15
H-8 8
J-500 EXH.B/CUT
OUT 10 0.5P 1
FR SIG J-500 J-74
0.5LG/B 7 SPEED SENSOR
J-500 EXH.B/CUT
(FRT,RH)
0.5BR/R
IN 11 0.5L 2
FR GRD J-500 J-74
0.3W/V 35 6
H-5 J-500 IND.
0.5B/Y 3 21 0.5R 4
J-500 IG RR 12V J-500 J-78
SPEED SENSOR
12 0.5W (RR,RH)
3
H-14 MODE1 RR SIG J-500 J-78
10
0.5BR/R
29 0.3W/B 33
MODE2 J1850 J-500 H-5
2 4 0.3W/G 34 0.3W/G
MODE3 FRASH J-500 H-5
E-9
3B
ALDL
B-79
SW ; THERMO CONNECTOR
(ENG.WARM)
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
E-9
0.5B
0.5B
1
0.3W/B
0.5BR/B 9 0.5BR/B 16
H-14 H-8
0.5BR/B 0.5BR/B
SW ; ACCEL 3
0.5LG/W 2 1 32 0.5LG 0.5LG
B-75 B-75 H-5
0.5LG J-23
DIODE ;
FICD
1 0.5G/O A/C
J-23 COMPRESSOR
J-23
2
0.5LG
0.5L
1 1 1
J-31 J-40 J-41
MAG.VALVE ; VSV ; VSV ;

EXH.BRAKE INT.THROTTLE FICD
J-31 J-40 J-41

2 2 2
0.5B
0.5B
0.5B
3B 3B
3B
2B 2B 0.5B
Circuit Diagram-FOR 24VOLT
F-10
STOP LAMP SW ; STOP LAMP
5W 10A 0.5G/Y 1 2 0.5G
B-66 B-66
FL-4
ABS
40A 3R 3R
RELAY ;
EXH.BRAKE F-14
FL-1 EXH.BRAKE
MAIN 5 2B/R 10A 0.5LG/W
60A B-38 0.5LG
8B 8W 2 5W 3W 1
H-6 B-38
H-8
RELAY; 0.5W/R 2 4 8
B-38 B-38
0.5LG/W
CHARGE
FL-2 3 1 2
P-1
KEY SW
BATTERY J-16 J-16 J-16
60A RELAY ;
P-2
TAIL
RELAY ;
0.3B
EXH.B/CUT
SW ;
(ABS)
ENG.WARMING
0.3B
3W/B
J-16 J-16 0.5LG/R 2 5 0.3B

P-3 B-31 B-31
5 4
BATTERY 0.5LG/B 3 6 0.5BR/B
P-4 B-31 B-31
1
0.5LG/B
H-7 0.3B 1 4 0.5BR/B
0.5B
KEY SW B-31 B-31
OFF
0.3B
P-5
ACC
3W/B 2 B 0.5B/Y
B-67 F-12
ON 3 3B/Y
B-67 GAUGE
ST 0.5LG/B
BACK
10A METER
ABS
0.5B/Y 0.5B/Y
0.5B/Y 8 7
B-51 B-51
0.5B/Y
0.3W/V
0.5W
6 0.5B/Y
H-14 H-8 3 4
0.5B
5
0.5P
B-35 B-35
5
2
B-69
E-11 RELAY ;
ABS IND.
SW ; NEUTRAL
SW ; EXH.BRAKE
(Neutral=ON) B-35 B-35
5 2
0.3B
E-11
B-69 IND.LAMP ; 0.5B
1 EXH.BRAKE
0.5B
3
0.5LG/R 0.5LG/R 8 10
B-51 B-52
H-14 H-5
0.5BR/R
0.5LG/R
10 38
0.5B/G
4 5
A/C 0.5G/O
J-18 J-18 COMPRESSOR
RELAY ; 39
0.85B
EXH.BRAKE
CONTROL H-5
J-18 J-18
0.5BR/R
2 3
0.5LG/B
0.5LG/W
1
0.5B
17 B-18
H-8 DIODE
SW ; CLUTCH
0.5LG/B 1 2 0.5LG/R 3 2
B-89 B-89 B-18 B-18
0.3B 0.5B
2B
0.5B
0.85B
FRAME-LH (FRONT) B-1
8 JOINT
3B 2 7 B-29 CONNECTOR 3B 3B
HEADLIGHT BRACKET (LH) B-7
3B 3B 3B
2B 2B 2B
FRAME-LH (CENTER) J-9
0.5G 11 0.5G 2 0.5G

H-5 H-16
0.5G
0.5G
3R
STOP STOP
LAMP LAMP
0.5LG (LH) (RH)
0.5G
THERMO SW ;
ENG.WARMING
RELAY ;
0.5BR 1 2
CERAMIC E-86 E-86
HEATER EHCU ; ABS
0.5BR/B
16
J-500 STOP LAMP 22 0.5L 2
RL 12V J-500 J-149
SPEED SENSOR
24 (RR,LH)
J-500 MOTOR +B 34 0.5Y 1
H-200 RL SIG J-500 J-149
2 3R 2
J-500 VALVE +B
32 0.5V 1
0.5BR/B
3B 23 FL SIG J-500 J-75

J-500 MOTOR GND SPEED SENSOR
(FRT,LH)
33 0.5R/B 2
3B 1 FL GRD J-500 J-75
J-500 VALVE GND
0.5BR/B
8
J-500 EXH.B/CUT
OUT 10 0.5P 1
FR SIG J-500 J-74
0.5LG/B 7 SPEED SENSOR
J-500 EXH.B/CUT
(FRT,RH)
11 IN 11 0.5L 2
FR GRD J-500 J-74
3B
H-8
0.3W/V 5 6
H-8 J-500 IND.
0.5B/Y 3 21 0.5R 2
J-500 IG RR 12V J-500 J-148
0.5BR/B SPEED SENSOR
0.5B/Y(NQR) 12 0.5W (RR,RH)
5 4 15 1
J-500 MODE1 RR SIG J-500 J-148
J-15 J-15
0.5B/Y(NQR) 14 29 0.3W/B 33
J-500 MODE2 J1850 J-500 H-5
0.5B/Y(NQR) 17 4 0.3W/G 34 0.3W/G

RELAY ; J-500 MODE3 FRASH J-500 H-5
ENG.WARMING CUT
J-15 J-15 ALDL
C/U ; ENGINE B-79
CONNECTOR
1 2
0.5BR/R
0.5BR/W 18 0.5BR/W 21
H-5 B-233 QWS 16 15 14 13 12 11 10 9
SW ; ACCEL 8 7 6 5 4 3 2 1
0.5LG/W 1 2 32 0.5LG 0.5LG 14 14 0.3Y
B-75 B-75 H-5 B-233 EXH.BRAKE CHECKER B-234
0.5B
0.5B
0.5BR/R
0.5L/W 15 29 0.3L 0.3W/B
4 B-234 FICD DIAG B-234
J-23
DIODE ;
FICD
1 3 0.5L/W 37 0.5LG
J-23 J-23 H-5
J-23
2
0.5L/G
2 6
0.5LG
H-13 H-13
0.5L/G
4 1 1
EX-1 J-31 EX-3
VSV ; MAG.VALVE ; VSV ;

FICD EXH.BRAKE INT.THROTTLE
EX-1 J-31 EX-3

2 2 2
12
0.5B
0.5B
H-13
0.5B
0.5B
3B 3B
3B
0.5B
Connector List
Connector List
Connector List
Part Location
FUSE BOX ASM STARTER SW J-148 R/RH

F-12,F-14,F-17 (12V) SENSOR (24V)
F-10,F-12,F-14 (24V) B-35,B-38 RELAY BOX RELAY BOX ASM
J-15 (24V),J-16,J-18 RELAY J-149 R/LH
B-17,B-18,J-23 DIODE SENSOR (24V)
FL-1,FL-2,FL-4 FUSIBLE LINK J-78 R/RH,R/LH
B-233,B-234 ECU (24V) SENSOR (12V)
B-29 JOINT CONNECTOR (24V)

(12V)
H-5~H-8 H-16
J-500 ABS EHCU

J-74 F/RH SENSOR
BATTERY
B-66 STOPLIGHT SW J-9 EARTH ; FRAME

(BRAKE SW)
B-79 ALDL CONNECTOR
B-1 EARTH ; FRAME (FR)
B-7 EARTH ; HEADLIGHT B/T J-75 F/LH SENSOR
B-67 IGNITION SW "A" B-51 ABS WARNING LIGHT (METER)
Symptom Diagnosis 5. Braking sound (from Hydraulic Unit) is heard while

The symptoms that cannot be indicated by the warning not braking.
light can be divided in the following five categories: These are all attributable to problems which cannot be
1. ABS works frequently but vehicle does not detected by EHCU self-diagnosis. Use the customer
decelerate. complaint and a test to determine which symptom is
present. Then follow the appropriate flow chart listed
2. Uneven braking occurs while ABS works.
below.
3. The wheels lock during braking.
4. Brake pedal feel is abnormal
Diagnostic Flow Charts

No. Symptom
Without TECH 2 With TECH 2
1 ABS works frequently but vehicle does not decelerate. Chart A-1 Chart TA-1
2 Uneven braking occurs while ABS works. Chart A-2 Chart TA-2
3 The wheels are locked. Chart A-3 Chart TA-3
4 Brake pedal feel is abnormal. Chart A-4 -
5 Braking sound (from Hydraulic Unit) is heard while not Chart A-5 Chart TA-5
braking.
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate
Step Action Yes No
1 Is braking force distribution normal between the front and Go to Step 2 Repair brake parts.
rear of the vehicle? Go to Step 6
2 Are axle parts installed normally? Go to Step 3 Repair axle parts.
Go to Step 6
3 Is there play in each wheel speed sensor? Go to Step 4 Repair wheel
speed sensor.
Go to Step 6
4 Is there damage, or powdered iron sticking to each wheel Go to Step 5 Replace sensor or
speed sensor/sensor rotor? sensor rotor.
Go to Step 6
5 Is the output of each wheel speed sensor normal? (Refer to Replace EHCU. Replace wheel
chart C-1 or TC-1) Go to Step 6 speed sensor or
repair harness.
Go to Step 6
6 Reconnect all components and ensure all components are Repeat the “Basic Go to Step 6
properly mounted. diagnostic flow
Was this step finished? chart.”
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step Action Yes No
1 1. Connect TECH 2. Go to Step 2 Replace wheel
2. WHEEL SENSORS make sure of the output conditions speed sensor.
of each sensor. Go to Step 3
Is the output of each sensor normal?
2 Return to Chart A-1. Go to Step 3 Go to Step 2
Was the Chart A-1 finished?
3 Reconnect all components, ensure all components are Repeat the “Basic Go to Step 3
Chart A-2 Uneven Braking Occurs While ABS Works

Step Action Yes No
1 Is there play in each sensor? Go to Step 2 Repair.
Go to Step 5
2 Damage or powdered iron sticking to each sensor/sensor Go to Step 3 Repair.
rotor? Go to Step 5
3 Is the output of each sensor normal? (Refer to chart C-1 or Go to Step 4 Replace sensor or
TC-1) repair harness.
Go to Step 5
4 Is brake pipe connecting order correct? Replace EHCU. Reconnect brake
Go to Step 5 pipe correctly.
Go to Step 5
Chart A-3, TA-3 The Wheels Are Locked

Step Action Yes No
1 Is ABS working? Go to Step 2 Go to Step 4
2 Is vehicle speed under 10 km/h (6mph)? Go to Step 3 Normal.
3 Is sensor output normal? (Chart C-1 or TC-1) Go to Step 4 Replace sensor or
repair harness.
Go to Step 5
4 Is hydraulic unit grounded properly? Replace hydraulic Correct.
unit. Go to Step 5
Go to Step 5
Chart A-4 Brake Pedal Feed Is Abnormal

Step Action Yes No
1 Is the stop light actuated when the brake pedal is depressed? Go to Step 2 Go to Step 3
2 1. Turn the key off. Go to Step 4 Harness NG
2. Disconnect EHCU connector. between brake SW
3. Measure the voltage between J-500 EHCU connector and EHCU.
terminals 16 and 1, when brake pedal is depressed. Go to Step 7
Is the voltage between 9 - 16 V?
3 Is stop light fuse 12V: F-17, 24V: F-10 normal? Go to Step 5 Replace fuse
12V: F-17,
24V: F-10.
Go to Step 7
4 Is there continuity between J-500 EHCU connector terminal 1 Go to Step 6 Repair body
to body ground? grounded harness.
Go to Step 7
5 Is the brake SW normal? Repair stop light Replace brake
harness. SW.
Go to Step 7 Go to Step 7
6 Is the check harness/connector for suspended Hydraulic system Repair harness.
disconnection? leakage or air entry Go to Step 7
Go to Step 7
properly mounted. and diagnostic flow
Chart A-5, TA-5 Braking Sound (From Hydraulic Unit) Is Heard While Not Braking
Step Action Yes No
1 Is this the first time the vehicle is being driven after starting It is self checking Go to Step 2
the engine? sound.
Normal.
2 Is vehicle speed under 10 km/h (6 mph)? It is self checking Go to Step 3
sound.
Normal.
3 Check for the following condition: ABS may Go to Step 4
• At the time of shift down or clutch operation. sometime be
• At the time of low µ drive (ice or snow road) or rough road actuated even
drive. when brake pedal
is not applied.
• At the time of high-speed turn.
• At the time of passing curb.
• At the time of operating electrical equipment switches.
• At the time of racing the engine.
Did it occur under any one condition above?
4 Is there play in each sensor/wheel speed sensor rotor? Go to Step 5 Repair.
Go to Step 7
5 Damage or powdered iron sticking to each sensor/wheel Repair. Go to Step 6
speed sensor rotor? Go to Step 7
6 Is each sensor output normal? (Refer to chart C-1 or TC-1). Check Repair.
harness/connector Go to Step 7
for suspected
disconnection.
If no disconnection
is found, replace
EHCU.
Go to Step 7
Diagnostic Trouble Codes

Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
Item (except
Flash Serial Diagnosis Wiring) Chart No.
out Communications
12 - Normal - -
13 C0213 Vehicle Type Error EHCU 1
14 C0214 Low Power Voltage of Rear Sensor or ECU
EHCU 2
Abnormality
15 C0215 Low Power Voltage EHCU 3
25 C0225 Exhaust Brake Cut Circuit Abnormality Relay or EHCU 4
33 C0233 Motor Drive Circuit Abnormality EHCU 5
34 C0234 Abnormal Motor Rotation EHCU 6
41 C0241 Solenoid Valve Power Supply Abnormality EHCU 7
43 C0243 Solenoid Valve Circuit Abnormality
EHCU 8
45 C0245 Solenoid Valve Circuit Abnormality
51 C0251 FL Speed Sensor Circuit Abnormality 9
52 C0252 FR Speed Sensor Circuit Abnormality 10
53 C0253 RL Speed Sensor Circuit Abnormality 11
54 C0254 RR Speed Sensor Circuit Abnormality 12
Sensor, EHCU
61 C0261 Abnormal FL Speed Sensor Signal 13
62 C0262 Abnormal FR Speed Sensor Signal 14
63 C0263 Abnormal RL Speed Sensor Signal 15
64 C0264 Abnormal RR Speed Sensor Signal 16
65 C0265 Tire Size Error Tire, Sensor, EHCU 17
* Important: DTC 20 (Reference Voltage High) cannot be indicated by Tech 2. DTC 20 can be indicated and
confirmed by flashing using Diagnosis Switch.
Diagnosis BY “ABS” Warning Light ON position or if the warning light is actuated during
Illumination Pattern driving, trouble should be diagnosed on a illumination
In the event that there is abnormality in the “ABS” pattern basis as follows:
warning light illumination pattern while the key is in the
No. Condition “ABS” Warning Light Illumination Pattern Diagnostic

1 Warning light is Normal
actuated normally
2 Warning light is not lit Warning light lighting circuit

trouble→Go to Chart B-1
3 Warning light is Diagnostic trouble codes

actuated while driving are stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.
Diagnostic Trouble Codes (DTCs)

When the warning light in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.
1. How to start DTC display:
• Confirm that the vehicle has come to a
complete stop (with the wheels standing still)
and that the brake pedal is not depressed.
(Unless these two conditions are satisfied, DTC
display cannot be started.)
• With the key switch OFF and short B-79
diagnosis connector terminal 12 to ground.
Then turn the key switch ON.
• DTCs can be displayed also by TECH 2.
The DLC (for Tech 2) is located behind the driver side lower cluster panel
2. DTC display: 3. How to erase code:

• DTC is displayed by blinking warning light. • Conduct brake switch ON/OFF operation 6 or
• Double-digit display. more times within 3 seconds of self-diagnosis
• First, normal DTC 12 is displayed three times startup.
and then any other DTCs are displayed three • The code cannot be erased if more than 3
times. (If no other DTCs have been stored, the seconds have passed since self-diagnosis
display of DTC 12 will be repeated.) startup, or if self-diagnosis has started with
brake switched on (brake pedal depressed).
• DTCs can be erased also by Tech 2.
4. An example of DTC display

Display of DTC 23
After displaying DTC 12 three times, one DTC after The DTC 12 is displayed repeatedly. (display is
another is displayed, starting with the most recent one. discontinued after about 5 minutes)
(However, display is discontinued after about 5
minutes.)
5. How to display vehicle model: 6) Illuminating number of times indicates the

1) Turn the key switch OFF. vehicle model.
2) Short the diagnosis connector terminal 12 to
ground. Vehicle model Illuminating number of times
3) Slightly push the brake pedal. NKR, NPR 1
4) Turn the key switch ON. NQR 8
5) ABS warning light illuminates.
Chart B-1-1 With the key in the ON position (Before starting the engine). Warning light
(W/L) is not activated.
1 Is W/L fuse F-12 disconnected? - Go to Step 5 Go to Step 2
2 Is W/L burnt out? - Go to Step 6 Go to Step 3
3 1. Turn the key off. 12V: 9.5-16.5V Go to Step 4 Go to Step 7
2. Disconnect EHCU connectors. 24V: 16.5-34V
3. Turn the key on.
4. Using DVM, measure the voltage between
J-500 EHCU connector terminals 6 and 1.
Does the DVM display a voltage within the
specified value?
4 Check the continuity between J-500 EHCU - Go to Step 9 Go to Step 8
connector terminal 1 and body ground.
Is there continuity?
5 Replace the fuse. - Go to Step 10 -
Is action complete?
6 Replace the W/L bulb. - Go to Step 10 -
Is action complete?
7 Locate and repair open circuit, poor connection - Go to Step 10 -
or short circuit in the ignition feed circuit.
Is action complete?
8 Locate and repair open circuit, poor connection - Go to Step 10 -
or short circuit in the ground circuit.
Is action complete?
9 1. Check the harness for suspected - Go to Step 10 -
disconnection.
2. If no fault found, replace the EHCU.
Is action complete?
10 1. Reconnect all components, ensure all - Go to “Basic -
components are properly mounted. diagnostic flow
2. Clear diagnostic trouble code. chart.”
Chart 1 (DTC13/C0213) Vehicle Type Error

1 1. Disconnect EHCU connector. NQR: Go to Step 2 Go to Step 5
2. Turn the key on. All terminal
3. Measure the voltage at terminal 14, 15, battery voltage
and 17. NKR, NPR:
All terminal 0V
2 1. Turn the key off and connect EHCU. - Go to Step 3 Replace the
2. Connect the TECH 2. EHCU.
3. Clear the vehicle type. Go to Step 3
4. Does the warning light turn off?
3 Confirm the vehicle type. - Go to Step 4 Replace the
Is the vehicle type okay? EHCU.
Repeat Step 3
4 Clear the DTC. - Troubleshooting -
completed.
5 Repair harness. - Go to Step 3 Replace the
Does the warning light turn off? EHCU.
Go to Step 3
Chart 2 (DTC14/C0214) Low Power Voltage of Rear Sensor or EHCU Abnormality

1 Perform chart 11 and 12. - Go to Step 2 Go to Step 1
2 1. Turn the key off. - Go to Step 3 Go to Step 4
2. Disconnect the EHCU connector.
3. Measure continuity between the body
ground and J-500 connector terminal 1, 23.
3 1. Connect the EHCU connector. - Go to Step 5 Go to Step 6
2. Clear DTC.
3. Turn the key from off to on and perform
diagnosis procedure.
Does the DTC repeat?
4 Repair the open/short circuit or malfunction at - Go to Step 6 -
connection of connector.
Is this step completed?
5 Replace the EHCU. - Go to Step 6 -
6 1. Install all parts. Verify each part is properly - Go to “Basic Go to Step 6
installed. diagnostic flow
2. Clear DTC. chart”.
Chart 3 (DTC15/C0215) EHCU Voltage OUT of Range

1 Is the battery voltage okay? - Go to Step 2 Go to Step 5
2 1. Turn the key off. 12 V vehicle: Go to Step 3 Go to Step 6
2. Disconnect the EHCU connector. 10-16 V
3. Start the engine. 24 V vehicle:
4. Measure voltage between J-500 connector 17-33.5 V
terminal 2 and J-500 connector terminal 1,
23.
Is the voltage within the specified value?
3 Locate the malfunction of connection in the - Go to Step 4 Go to Step 8
circuit.
Is the circuit malfunction specified?
4 Repair the malfunction and perform diagnosis - Go to Step 7 Go to Step 8
procedure.
Does the DTC repeat?
5 Charge or replace the battery. - Go to Step 8 -
6 Repair open/short circuit or malfunction at - Go to Step 8 -
connection of connector between J-500
connector terminal 2 and fusible link FL-4.
7 Replace the EHCU. - Go to Step 8 -
8 1. Install all parts. Verify each part is properly - Go to “Basic Go to Step 8
installed. diagnostec flow
2. Clear DTC. chart”.
Chart 4 (DTC25/C0225) Exhaust Brake Cut Circuit Abnormality

1 1. Disconnect EHCU connector. 12 V vehicle: Go to Step 2 Go to Step 4
2. Start the engine. More than 5 V
3. Measure voltage between EHCU terminals 24 V vehicle:
8 and 1. More than 10 V
2 Measure voltage between EHCU terminals 7 12 V vehicle: Go to Step 3 Go to Step 6
and 1. More than 5 V
Is the voltage within the specified value? 24 V vehicle:
More than 10 V
3 Short EHCU terminal 8 to 1. - Replace the Replace the
Is the voltage at EHCU terminal 7 less than 1.5 EHCU. exhaust brake
V? cut relay.
4 Measure resistance of the exhaust brake cut 12 V vehicle: Go to Step 5 Replace the
relay coil. 60-120 ohms exhaust brake
24 V vehicle: cut relay.
210-310 ohms
5 Measure voltage at coil power side of relay box 12 V vehicle: Check harness Repair harness
connector. (key at on position) 10-16 V between EHCU and/or power
Is the voltage within the specified value? 24 V vehicle: terminal 8 and line.
20-32 V exhaust brake
cut relay.
Repair as
necessary.
6 Turn the exhaust brake switch on. - Repair harness Go to exhaust
Does the exhaust brake indicator light turn on? of EHCU brake diagnosis
terminal 7. procedure.
Chart 5 (DTC33/C0233) Motor Drive Circuit Abnormality

1 1. Disconnect EHCU connector. 12 V vehicle: Go to Step 2 Go to Step 3
2. Measure voltage between EHCU terminals 10-16 V
24 and 1. 24 V vehicle:
Is the voltage within the specified value? 20-32 V
2 Measure continuity between EHCU terminals - Replace the Repair the
23 and 1. EHCU. harness.
3 Check the ABS fusible link (12V: 60A, 24V: - Repair the Replace the
40A). harness. ABS fusible link
Is it okay? (12V: 60A,
24V: 40A).
Chart 6 (DTC 34/C0234) Abnormal Motor Rotation

• Replace EHCU.
Chart 7 (DTC41/C0241) Solenoid Valve Power Supply Abnormality

1 1. Disconnect EHCU connector. 12 V vehicle: Replace the Go to Step 2
2. Measure voltage between EHCU terminals 10-16 V EHCU.
2 and 1. 24 V vehicle:
Is the voltage within the specified value? 20-32 V
2 Check the ABS fusible link (12V: 60A, 24V: - Repair the Replace the
40A). harness. ABS fusible link
Is it okay? (12V: 60A,
24V: 40A).
Chart 8 (DTC 43, 45/C0243, C0245) Solenoid Valve Circuit Abnormality

• Replace EHCU.
Chart 9 (DTC51/C0251) FL Speed Sensor Circuit Abnormality

1 1. Disconnect EHCU connector. 1-2 k ohms Replace the Go to Step 2
2. Measure resistance between EHCU EHCU.
terminals 32 and 33.
Is the resistance within the specified value?
2 1. Disconnect the FL speed sensor - Repair the Replace the FL
connector. harness. speed sensor.
2. Measure the FL speed sensor resistance.
Is the resistance okay?
Chart 10 (DTC52/C0252) FR Speed Sensor Circuit Abnormality

1 1. Disconnect EHCU connector. 1-2 k ohms Replace the Go to Step 2
2. Measure resistance between EHCU EHCU.
terminals 10 and 11.
Is the resistance within the specified value?
2 1. Disconnect the FR speed sensor - Repair the Replace the FR
connector. harness. speed sensor.
2. Measure the FR speed sensor resistance.
Is the resistance okay?
Chart 11 (DTC53/C0253) RL Speed Sensor Circuit Abnormality

1 1. Disconnect EHCU connector. - Go to Step 2 Repair the
2. Disconnect RL speed sensor connector. harness.
3. Measure continuity between EHCU
terminal 22 and positive side of chassis
harness connector connected to RL speed
sensor.
2 Measure continuity between EHCU terminals - Go to Step 3 Repair the
22 and 1. harness.
3 1. Start the engine. Less than 2 V Go to Step 4 Repair the
2. Measure voltage between EHCU terminals harness.
22 and 1.
4 Measure continuity between EHCU terminal 34 - Go to Step 5 Repair the
and positive side of chassis harness connector harness.
connected to RL speed sensor.
34 and 1. harness.
34 and 1.
7 Check the RL speed sensor (Refer to chart C- 0.2-4.5 V Replace the Replace the RL
1-3 or TC-1). EHCU. speed sensor.
specified value?
Chart 12 (DTC54/C0254) RR Speed Sensor Circuit Abnormality

1 1. Disconnect EHCU connector. - Go to Step 2 Repair the
2. Disconnect RR speed sensor connector. harness.
3. Measure continuity between EHCU
terminal 21 and positive side of chassis
harness connector connected to RR speed
sensor.
21 and 1. harness.
21 and 1.
4 Measure continuity between EHCU terminal 12 - Go to Step 5 Repair the
and positive side of chassis harness connector harness.
connected to RR speed sensor.
12 and 1. harness.
12 and 1.
7 Check the RR speed sensor (Refer to chart c- 0.2-4.5 V Replace the Replace the RR
1-4 or TC-1). EHCU. speed sensor.
specified value?
Chart 13 (DTC 61/C0261) Abnormal FL Speed Sensor Signal

1 Is there play in the FL wheel bearing? - Go to Step 10 Go to Step 2
2 Is there play in the FL speed sensor/sensor - Go to Step 11 Go to Step 3
rotor?
3 Is there powdered iron sticking to FL speed - Go to Step 12 Go to Step 4
sensor/sensor rotor?
4 Check the FL speed sensor. (Refer to Chart C- - Go to Step 5 Go to Step 8
1-1 or TC-1)
Is the FL sensor output normal?
5 Is there a broken tooth or indentation in the - Go to Step 13 Go to Step 6
sensor rotor?
6 Using DVM, measure the resistance between 1000 k ohms or Go to Step 7 Go to Step 9
J-500 EHCU connector terminal 33 and more
ground.
Does the DVM display a resistance within the
specified value?
7 1. Clear diagnostic trouble code. - Go to Step 18 Go to Step 16
2. Test drive and perform system self-check.
8 Is there damage or indentation in the speed - Go to Step 14 Go to Step 15
sensor?
9 1. Disconnect FL sensor connector. 1000 k ohms or Go to Step 17 Go to Step 14
2. Using DVM, measure the resistance more
between J-75 sensor connector terminal 2
and ground.
specified value?
10 Adjust wheel bearing preload. - Go to Step 19 -
Is action complete?
11 Repair or replace speed sensor/sensor rotor. - Go to Step 19 -
Is action complete?
12 Repair speed sensor/sensor rotor. - Go to Step 19 -
Is action complete?
13 Replace sensor rotor. - Go to Step 19 -
Is action complete?
14 Replace FL speed sensor. - Go to Step 19 -
Is action complete?
15 Check the FL speed sensor circuit. Refer to - Verify repair
Chart 9.
Is action complete?
16 Check for a poor connection and an open - Go to Step 19 -
circuit on the harness between EHCU and
sensor connectors.
Refer to “Note on Intermittents” described in
earlier this section.
Is action complete?

17 1. Locate open circuit, poor connection or - Go to Step 19 Go to Step 19
short circuit on the harness between EHCU
and sensor connectors.
2. Repair the harness.
Is action complete?
18 Replace EHCU. - Go to Step 19 -
Is action complete?
19 1. Reconnect all components, ensure all - Go to “Basic Go to Step 19
Chart 14 (DTC 62/C0262) Abnormal FR Speed Sensor Signal

1 Is there play in the FR wheel bearing? - Go to Step 10 Go to Step 2
2 Is there play in the FR speed sensor/sensor - Go to Step 11 Go to Step 3
rotor?
3 Is there powdered iron sticking to FR speed - Go to Step 12 Go to Step 4
4 Check the FR speed sensor. (Refer to Chart - Go to Step 5 Go to Step 8
C-1-2 or TC-1)
Is the FR sensor output normal?
sensor rotor?
6 Using DVM, measure the resistance between 1000 k ohms or Go to Step 7 Go to Step 9
J-500 EHCU connector terminal 11 and more
ground.
specified value?
sensor?
9 1. Disconnect FR sensor connector. 1000 k ohms or Go to Step 17 Go to Step 14
2. Using DVM, measure the resistance more
between J-74 sensor connector terminal 2
and ground.
specified value?
Is action complete?
Is action complete?
Is action complete?
Is action complete?
14 Replace FR speed sensor. - Go to Step 19 -
Is action complete?
15 Check the FR speed sensor circuit. Refer to - Verify repair -
Chart 10.
Is action complete?
sensor connectors.
Is action complete?

17 1. Locate open circuit, poor connection or - Go to Step 19 Go to Step 19
Is action complete?
Is action complete?
Chart 15 (DTC 63/C0263) Abnormal RL Speed Sensor Signal

1 Is there play in the RL wheel bearing? - Go to Step 8 Go to Step 2
2 Is there play in the RL speed sensor/sensor - Go to Step 9 Go to Step 3
rotor?
3 Is there powdered iron sticking to RL speed - Go to Step 10 Go to Step 4
4 Check the RL speed sensor. (Refer to Chart C- - Go to Step 5 Go to Step 7
1-3 or TC-1)
Is the RL sensor output normal?
sensor rotor?
sensor?
Is action complete?
Is action complete?
Is action complete?
Is action complete?
12 Replace RL speed sensor. - Go to Step 16 -
Is action complete?
13 Check the RL speed sensor circuit. Refer to - Verify repair -
Chart 11.
Is action complete?
sensor connectors.
Is action complete?
Is action complete?
Chart 16 (DTC 64/C0264) Abnormal RR Speed Sensor Signal

1 Is there play in the RR wheel bearing? - Go to Step 8 Go to Step 2
2 Is there play in the RR speed sensor/sensor - Go to Step 9 Go to Step 3
rotor?
3 Is there powdered iron sticking to RR speed - Go to Step 10 Go to Step 4
4 Check the RR speed sensor. (Refer to Chart - Go to Step 5 Go to Step 7
C-1-4 or TC-1)
Is the RR sensor output normal?
sensor rotor?
sensor?
Is action complete?
Is action complete?
Is action complete?
Is action complete?
12 Replace RR speed sensor. - Go to Step 16 -
Is action complete?
13 Check the RR speed sensor circuit. Refer to - Verify repair -
Chart 12.
Is action complete?
sensor connectors.
Is action complete?
Is action complete?
Chart 17 (DTC65/C0265) Tire Size Error

1 Does the tire size match the vehicle - Go to Step 2 Replace the
specification? abnormal tire.
2 Check wear and inflation of the tire. - Go to Step 3 Repair or
Are they okay? replace the
abnormal tire.
3 Are the sensor rotors normal? - Go to Step 4 Replace the
abnormal
sensor rotor.
4 Test run the vehicle. - Replace the Recheck the
Does the malfunction repeat. EHCU. DTC.
Unit Inspection Procedure DIAGNOSIS” and “DIAGNOSIS BY ‘ABS’ WARNING

This section describes the following inspection LIGHT ILLUMINATION PATTERN”:
procedures referred to during “SYMPTOM
without TECH 2 with TECH 2

Speed Sensor Output Inspection Chart C-1-1 to C-1-4 Chart TC-1
Chart C-1-1 FL Speed Sensor Output Inspection Procedure

1 1. Turn the key off. 200 mV or more Go to Step 5 Go to Step 2
2. Disconnect EHCU connector.
3. Jack up the vehicle, with all wheels off the
ground.
4. Measure the AC voltage between J-500
EHCU connector terminals 32 and 33 while
turning FL wheel at a speed of 0.5 RPS.
specified value?
2 1. Disconnect FL sensor connector. 1.0-2.0 k ohms Go to Step 4 Go to Step 3
2. Using DVM, measure the resistance
between J-75 sensor connector terminals 1
and 2.
specified value?
3 1. Locate open circuit, poor connection or - Go to Step 5 -
Is action complete?
4 Replace FL sensor. - Go to Step 5 -
Is action complete?
Chart C-1-2 FR Speed Sensor Output Inspection Procedure

1 1. Turn the key off. 200 mV or more Go to Step 5 Go to Step 2
ground.
4. Measure the AC voltage between J-500
EHCU connector terminals 10 and 11 while
turning FR wheel at a speed of 0.5 RPS.
specified value?
2 1. Disconnect FR sensor connector. 1.0-2.0 k ohms Go to Step 4 Go to Step 3
2. Using DVM, measure the resistance
between J-74 sensor connector terminals 1
and 2.
specified value?
3 1. Locate open circuit, poor connection or - Go to Step 5 -
Is action complete?
4 Replace FR sensor. - Go to Step 5 -
Is action complete?
Chart C-1-3 RL Speed Sensor Output Inspection Procedure

1 1. Turn the key off. 0.2-4.5V Go to Step 5 Go to Step 2
ground.
4. Connect a 120 ohms resistor between
J-500 EHCU connector terminal 22 and
ground. Apply voltage of 12V to EHCU
connector terminal 22.
5. Using DVM, measure the DC voltage
between J-500 connector terminal 22 and
ground while turning RL wheel at a speed
of 0.5 RPS.
specified value?
2. Disconnect RL sensor connector.
sensor connector terminal 2 (sensor side)
and ground.
4. Apply 12V voltage at sensor connector
terminal 1 (sensor side).
between sensor connector terminal 2
(sensor side) and ground while turning RL
wheel at a speed of 0.5 RPS.
specified value?
3 1. Locate open circuit, poor connection short - Go to Step 5 -
sensor connectors.
Is action complete?
4 Replace RL sensor. - Go to Step 5 -
Is action complete?
Legend
(1) Battery (4) Speed Sensor
(2) DVM
(3) Resistor
Chart C-1-4 RR Speed Sensor Output Inspection Procedure

ground.
J-500 EHCU connector terminal 21 and
ground.
between J-500 connector terminal 21 and
ground while turning RR wheel at a speed
of 0.5 RPS.
specified value?
2. Disconnect RR sensor connector.
sensor connector terminal 2 (sensor side)
and ground.
4. Apply 12V voltage at sensor connector
terminal 1 (sensor side).
between sensor connector terminal 2
(sensor side) and ground while turning RR
wheel at a speed of 0.5 RPS.
specified value?
3 1. Locate open circuit, poor connection short - Go to Step 5 -
sensor connectors.
Is action complete?
4 Replace RR sensor. - Go to Step 5 -
Is action complete?
Legend
(1) Battery (4) Speed Sensor
(2) DVM
(3) Resistor
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

Step Action Yes No
1 1. Connect TECH 2. Go to Step 2 Go to Step 6
2. Check the minimum speed of each sensor by WHEEL
SENSORS.
Is the sensor speed more than 5km/h (3mph)?
2 Check the sensor harness for suspected disconnection Replace speed Repair.
(check while shaking harness/connector). sensor. Go to Step 3
Is the sensor harness connection normal? Go to Step 3
3 Check the minimum speed of each sensor by WHEEL Go to Step 4 Go to Step 6
SENSORS.
Is the sensor speed more than 5 km/h (3mph)?
4 Check the sensor rotor. Go to Step 5 Replace sensor
Is the sensor rotor normal? rotor.
Go to Step 5
5 Check the minimum speed of each sensor by WHEEL Repair harness or Go to Step 6
SENSORS. connector between
Is sensor speed more than 5 km/h (3 mph)? EHCU and speed
sensor.
Go to Step 6
Electronic Hydraulic Control Unit (EHCU)

Removal Installation
1 To install, follow the removal steps in the reverse
order, noting the following points.
NOTE:
• If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU should be
removed from the vehicle before the welding
4 operation begins.
• Do not put a radio equipment etc, that emits strong
radio wave near the EHCU.
• Do not wet the control unit. If wetted, wipe off water
immediately and dry it fully.
5
3 • Never loosen any screw on the control unit.
• Do not paint the control unit.
• Prevent possible electrostatic discharge damage.
• Do not touch the control unit pin type terminal with
2 a metalic tip of a screwdriver or tester.
• Do not apply voltage to the terminal.
Legend
(1) Brake Pipe
(2) EHCU Bracket Fix Bolt & Nut
(3) EHCU Bracket
(4) Harness Connector
(5) EHCU
1. Disconnect battery ground cable.

2. Disconnect brake pipes.
3. Remove EHCU bracket fix bolts & nut.
4. Remove EHCU bracket.
5. Remove EHCU.
Front Speed Sensor

Front Speed Sensor and Associated Parts
Legend
(1) Speed Sensor Connector (4) Sensor Fixing Bolt
(2) Sensor Cable Fixing Bolt (5) Speed Sensor
(3) Sensor Cable Fixing Bolt (6) Front
Removal Installation
1. Remove speed sensor connector. 1. Install speed sensor and take care not to hit the
2. Remove sensor cable fixing bolts. speed sensor pole piece during installation.
3. Remove the speed sensor fixing bolt. 2. Install speed sensor fixing bolt and tighten the
4. Remove speed sensor. fixing bolt to the specified torque.
Torque: 22 N⋅⋅m (2.2kgf⋅⋅m/16lb⋅⋅ft)
3. Install speed sensor cable fixing bolts and tighten
Inspection and Repair the fixing bolt to the specified torque.
1. Check the speed sensor pole piece for presence of Torque
foreign materials; remove any dirt, etc. Bolts (2): 22 N⋅⋅m (2.2kgf⋅⋅m/16lb⋅⋅ft)
2. Check the pole piece for damage; replace speed Bolts (3): 45 N⋅⋅m (4.6kgf⋅⋅m/33lb⋅⋅ft)
sensor if necessary. NOTE: Confirm that a white or yellow line marked on
3. Check the speed sensor cable for short or open the cable is not twisted when connecting the speed
circuit, and replace with a new one if necessary. sensor cable.
To check for cable short or open, bend or stretch 4. Connect speed sensor connector.
the cable while checking for continuity.
Front Speed Sensor Rotor

Front Speed Sensor Rotor and Associated Parts
Legend
(1) Disk Brake Assembly (6) Hub and Disc Assembly
(2) Hub Cap (7) Speed Sensor Rotor
(3) Cotter Pin (8) Inner Bearing and Outer Bearing
(4) Hub Nut (9) Oil Seal
(5) Washer (10) Spacer
Removal
1. Remove disc brake assembly and support the
caliper assembly so that the brake hose is not
stretched or damaged.
2. Remove hub cap.
3. Remove cotter pin and hub nut.
4. Remove washer.
5. Remove hub and disc assembly.
6. Remove speed sensor rotor.

7. Remove inner bearing, oil seal spacer.
Inspection and Repair 4. Install a cotter pin through the nut and knuckle and
1. Check the speed sensor rotor for damage bend it over.
including tooth chipping, and if damaged, replace • If the notch in the nut does not line up with the
the speed sensor rotor. cotter pin hole in the knuckle, tighten the nut
until it does. Do not loosen the nut to line up a
notch and the knuckle hole.
Installation 5. Apply grease into the hub cap and install it.
1. Using a bench press, install speed sensor rotor. • 0.4N (40g/0.09lbf)
2. Install spacer onto the knuckle spindle. 6. Install the disc brake assembly and tighten two
3. Apply grease into the outer and inner bearings and bolts to the specified torque.
install bearings in the hub. • Torque: 221 N⋅⋅m (22.5kgf⋅⋅m/163lb⋅⋅ft)
4. Install oil seal into hub and disc assembly and
install hub and disc assembly on to the knuckle
spindle.
Preload Adjustment
Adjust the wheel bearing as follows:
1. Tighten the nut until you are unable to manually
rotate the hub and disc assembly.
2. Loosen the nut.
3. Attach a spring balancer to one stud. Gradually
retighten the nut until the hub and disc assembly
bearing is adjusted to the specified preload.
• Hub bearing preload

New Hub Bearing 9.8-24.5N (1-2.5kgf/2.2-5.5lbf)
Reused Hub Bearing 4.9-19.6N (0.5-2kgf/1.1-
4.4lbf)
Rear Speed Sensor

Rear Speed Sensor and Associated Parts
Legend
(1) Brake Drum (3) Speed Sensor
(2) Speed Sensor Fixing Bolt (4) Speed Sensor Bracket
Removal Inspection and Repair

1. Check the speed sensor for presence of foreign
materials; remove any dirt, etc.
2. Check the speed sensor for damage, and replace
the speed sensor if necessary.
3. Check the speed sensor harness for a short or an
open, and replace with a new one if necessary. To
check for harness short or open, bend or stretch
the cable while checking for continuity.
Installation
1. Install speed sensor bracket and tighten the nut to
the specified torque.
Torque:
GVW Range 12,000 lbs. and 14,500 lbs. model
108 N⋅⋅m (11kgf⋅⋅m/80lb⋅⋅ft)
GVW Range 17,950 lbs. model
157 N⋅⋅m (16kgf⋅⋅m/116lb⋅⋅ft)
2. Install the speed sensor and take care not to hit
Legend the speed sensor during installation.
(1) Speed Sensor Connector 3. Install the speed sensor fixing bolt and tighten it to
(2) Front
(3) Speed Sensor
4. Install brake drum and tighten bolts to the specified
(4) Rear Axle torque.
Torque: 13 N⋅⋅m (1.3kgf⋅⋅m/9.5lb⋅⋅ft)
1. Disconnect speed sensor connector. 5. Connect speed sensor connector.
2. Remove brake drum. NOTE: Confirm that the harness is not twisted when
3. Remove speed sensor fixing bolt. connecting the speed sensor connector.
4. Remove speed sensor.
5. Remove speed sensor bracket.
Rear Speed Sensor Rotor

Rear Speed Sensor Rotor and Associated Parts
Legend
(1) Brake Drum (6) Outer Bearing
(2) Axle Shaft (7) Rear Hub
(3) Outer Oil Seal (8) Speed Sensor Rotor
(4) Lock Washer (9) Inner Bearing
(5) Bearing Nut (10) Inner Oil Seal
Removal Inspection and Repair

1. Remove brake drum. 1. Check the speed sensor rotor for damage
2. Remove axle shaft. including tooth chipping. If damaged, replace
3. Remove outer oil seal, using a screwdriver. speed sensor rotor.
4. Remove lock washer.
5. Remove bearing nut with a hub bearing nut
Installation
wrench. 1. Using a bench press, install speed sensor rotor.
6. Remove hub assembly from axle case. NOTE: Do not reuse the sensor rotor.
2. Install spacer on to the axle case.
7. Remove outer bearing from hub assembly.
3. Apply grease into the outer and inner bearings and
8. Remove speed sensor rotor from hub assembly.
install bearings in the hub.
9. Remove inner bearing and inner oil seal from axle
4. Install outer oil seal into hub.
case.
5. Install hub assembly onto the axle case. 6) Rotate the hub several times to the right and
left.
7) Measure the bearing preload a second time.
6. Set the lock nut with the notched line facing out.
Preload Adjustment
1) Turn the hub to the left and right several times 8) Align the axle case groove with the closest
to establish bearing conformity. bearing nut slit.
2) Use the bearing nut wrench to tighten the NOTE: If it is difficult to align the axle case and bearing
bearing nut until the hub can not be manually nut, slightly tighten the bearing nut.
rotated. 7. Install the lock washer with the lock washer tabs
3) Loosen the bearing nut until hub rotates easily. inserted to the axle case grooves.
Install the lock bolts to prevent the bearing nut
from loosening.
Check that the lock washer tabs are inserted to the
axle case grooves.
8. Apply grease to the outer oil seal lip inner and
outer circumferences and install outer oil seal.
9. Clean the axle shaft.
Apply gear oil to the axle shaft spline.
Insert the axle shaft into the axle case.
Take care not to damage the oil seal.
10. Tighten the axle shaft nuts to the specified torque
a little at a time.
11. Install brake drum.
4) Set the spring balancer to the wheel pin in the

position shown in the illustration.
5) Measure the hub bearing preload by carefully
pulling on the spring balancer and noting the
indicator reading.
Hub Bearing Preload (At Wheel Pin)
42-52 N (4.3-5.3kgf/9.4-11.6lbf)
Special Tools
ILLUSTRATION TOOL NO. TOOL NAME
5-8840-0385-0
(J-35616)
Connector test adapter kit
5-8840-0285-0
(J-39200)
High impedance multimeter
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) Tech 2
LGBRK-WE-0101



reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.
Issued by
Tokyo, Japan
First edition Jan., 2001

LGBRK-WE-0101 PRINTED IN JAPAN
WORKSHOP MANUAL
NHR • NKR • NPR
ENGINE
4H SERIES
SECTION 6
MEMO
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NOTICE

MANUAL”.

All rights are reserved to make changes at any time without prior
notice.
Applicable Model :
N Series
NKR66 NPS66 NQR71
NPR66 NPS71
NPR70 NQR66
NPR71 NQR70
This manual is applicable to 1996 year model and later vehicles

except those sold in the United States of America, and Canada.
00 Service Information
6A Engine Mechanical
6A3 Engine (4HF1/4HF1-2/4HE1-T/4HE1-TC/4HG1/4HG1-T)
6B Engine Cooling
6C Fuel System
6D Engine Electrical
6E Emission and Electrical Diagnosis
6F Exhaust
6G Turbocharger
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FUEL SYSTEM 6C – 1
SECTION 6C
FUEL SYSTEM
CONTENTS
PAGE
General Description....................................................................................................... 6C - 2
On-Vehicle Service ........................................................................................................ 6C - 8
Fuel Filter Assembly (Except 4HF1-2 model) .......................................................... 6C - 8
Fuel Filter Assembly (4HF1-2 model only)............................................................... 6C - 12
Injection Nozzle Assembly........................................................................................ 6C - 14
Injection Pump Assembly (Except 4HF1-2 model).................................................. 6C - 33
Injection Pump Assembly (4HF1-2 model only) ...................................................... 6C - 39
Injection Timing Adjustment..................................................................................... 6C - 44
Injection Pump Data .................................................................................................. 6C - 48
Aneroid Compensator Adjustment .......................................................................... 6C - 75
Fuel Tank .................................................................................................................... 6C - 76
Fuel Gauge Unit ......................................................................................................... 6C - 78
Accelerator Control ....................................................................................................... 6C - 79
Accelerator Control Cable ........................................................................................ 6C - 79
Accelerator Pedal ...................................................................................................... 6C - 81
Idling Control Cable .................................................................................................. 6C - 82
Air Cleaner Element .................................................................................................. 6C - 84
6C – 2 FUEL SYSTEM
GENERAL DESCRIPTION
When working on the fuel system, there are several Pre-Fuel Filter
things to keep in mind: When the condensed water in the pre-fuel filter
• Any time the fuel system is being worked on, (water separator) comes to the warning level
disconnect the negative battery cable except for indicated on its plastic body, drain the fluid
those tests where battery voltage is required. immediately from the drain plug located bottom of
• Always keep a dry chemical (Class B) fire water separator.
extinguisher near the work area.
• Replace all pipes with the same pipe and Injection Pump
fittings that were removed. The fuel injection system includes a fuel tank, fuel
Clean and inspect “O” rings. Replace where hoses and lines, a fuel/water separator, fuel filters,
required. a fuel pump, a Bosch-type in-line fuel injection
• Always relieve the line pressure before pump with an internal governor, delivery valves,
servicing any fuel system components. fuel injection lines and for fuel injection nozzles.
• Do not attempt repairs on the fuel system until The fuel pump, injection pump and the nozzle are
you have read the instructions and checked the manufactured by ZEXEL corporation, but serviced
pictures relating to that repair. by Bosch.
Remove the injection pump and governor
assembly as a unit to have it services. Do not open
DESCRIPTION
or break any seals on the pump or the warranty is
Fuel Filters void. The injection pump has an identification plate
attached to the pump body.
The Purpose of the fuel filters is to clean the fuel of
any dirt particles that can cause wear on the fuel
injection nozzle’s sliding surface; and to separate
any water from the fuel, which is ever-present from
the condensation in the fuel tank. The pre-fuel filter
(water separator) is located between the fuel tank
and the injection pump. The secondary fuel filter is
located between the fuel pump and the injection
pump.
FUEL FLOW
6C-3-1.tif
040LX005.tif
Aneroid Compensator Function

The bellows in the aneroid compensator is provided with an
initial set force by the aneroid compensator spring (10) and
is compressed by the push rod C (11). As the atmospheric
pressure drops, the bellows (9) begins to expand against
the force of the aneroid compensator spring (10), which in
turn causes the push rod B (13), through the push rod C
(11) and the boost compensator lever (12)F, to move to the
left.
Then the push rod B (13) comes into contact with the U-
shaped lever (16) and, as the expanding bellows over
come the force of the cancel spring installed on the U-
shaped lever (16), causes the U-shaped lever to turn
clockwise. Because the bottom of the sensor lever (15) is
in touch with the torque cam (51), the torque cam (51) then
works as a pivot on which the top of the sensor lever (15)
moves to the right together with the U-shaped lever (16). At
the same time, the control rack (19), which is hooked on
the sensor lever (15), moves toward the governor to
reduce fuel injection.
6C-4-1.tif
BRIEF EXPLANATION OF EMISSION AND

ELECTRICAL CONTROL SYSTEM
MITICS (Mechanically Integrated Timing and
Injection Control System)
4HE1-TC
The Mechanically Integrated Timing and Injection rate Control
System(MITICS) utilizes mechanical control, in comparison
with TICS systems, which utilize electronic control.
MITICS is equipped with the RLD-M type governor, which
contains a pre-stroke control mechanism. With this, pre-stroke
position (ie., beginning of static injection) can be varied to
control injection timing and injection rate (i.e., the fuel injection
quantity injected from the nozzle per cam angle degree).
This enables high injection rates1 in the low and medium
speed ranges through a short injection interval, thus
contributing to higher engine torque and cleaner exhaust.
MITICS was developed in response to the demands of medium
sized diesel engines for low cost, low fuel consumption, high
output and cleaner emissions.
High injection rates using a short injection interval.

• The speed at which the injection pump plunger rises
slows as engine speed decreases and the pressure
inside the injection pipe decreases. Because of this,
the nozzle spray deteriorates and makes it impossible
to obtain the proper fuel - air mixture.
To obtain the proper mixture at low and medium
speeds, it is necessary to increase the pressure inside
the injection pipes using a short injection interval.
040LW006.tif
• The left hand figure shows plunger speed and cam lift
in relation to cam angle. It can be seen from the graph
that plunger speed increases together with cam lift.
MITICS varies the beginning of injection position at low
and medium speeds so that injection occurs when the
plunger speed increases during the latter half of cam
lift (shown by the bold line). At high speeds, injection is
performed when the plunger speed decreases during
the first half of cam lift to prevent an excessive
increase in injection pipe pressure.
040LW007-1.tif This enables high pressures at low and medium
speeds with a fast plunger speed. Thus, a fine fuel oil
spray is injected into the cylinder from the nozzles
within a short time to provide the proper mixture for
combustion, helping to increase torque and keep
exhaust emissions clean.
GOVERNOR (MODEL RLD-M)

4HE1-TC
The RLD-J type governor can be used with the MI, MITICS
injection pumps, and was designed to have better control
and endurance than the previous RLD type governor.
Although the basic construction is identical to that of the
RLD type governor, the RLD-M type is larger to match the
applicable pumps’ larger size.
FEATURES
1. Variable speed control governor with decreased lever
reaction force
As with the previous RLD type governor, RLD-M governor
control is accomplished using the speed control lever to
change the fulcrum of the internal link mechanism.
Consequently, as the reaction force of the governor spring
does not act directly on the speed control lever, only a very
small lever reaction force is exerted on the accelerator
6C-6-1.tif pedal.
2. Set torque characteristics through internal torque cam

At full load, the tip of the sensor lever traces the face of the
torque cam to determine the full load rack position and
control the full load injection quantity.
Consequently, the torque characteristics demanded by the
engine can be freely set by changing the shape of the
torque cam face.
6C-6-2.tif
3. Improved control through internal guide plate

When the speed control lever is operated, the 2nd
supporting lever’s pin moves along the guide plate. The
floating lever connected to the pin thus moves to change
the ball joint fulcrum positions. In the intermediate to high
speed ranges, the guide plate causes the floating lever to
move to increase the lever ratio continuously from 1.1
(idling) - 6 (full speed). This increase in the lever ratio in the
intermediate to high speed range improves speed droop.
6C-6-3.tif
INJECTION NOZZLE
A Bosch hole type injection nozzle is used. It consists of
the nozzle body and the needle valve assembly.
The injection nozzle assembly sprays pressurized fuel from
the injection pump into the combustion chamber through
the nozzle body injection orifice.
6C-7-1.tif
FUEL FILTER AND WATER SEPARATOR

A cartridge type fuel filter and a water separator are used
along with the in-line type injection pump.
As the inside of the injection pump is lubricated by the fuel
which it is pumping, the fuel must be perfectly clean. The
fuel filter and the water separator remove water particles
and other foreign material from the fuel before it reaches
the injection pump.
The water separator has an internal float. When the float
reaches the specified level, a warning light comes on to
remind you to drain the water from the separator.
6C-7-2.tif
ON-VEHICLE SERVICE
FUEL FILTER ASSEMBLY (Except 4HF1-2 model)
6C-8-1.tif
REMOVAL
Preparation
• Disconnect battery ground cable.
• Tilt the cab
1. Fuel Pipe
2. Fuel Filter Assembly
INSTALLATION
Fuel Filter Bracket Torque N∙m (kg∙m/lb∙ft)
34 (3.5/25)
1. Fuel Pipe
Fuel Pipe Joint Bolt Torque N∙m (kg∙m/lb∙ft)
23 (2.4/17)
Air Bleeding
• Loosen the priming pump cap !.
• Loosen the air bleeding plug; ".
(4HG1-T model only)
• Operate the priming pump.
Pump the primer pump until fuel flow is free of air
bubbles.
(Except 4HG1-T model)
For 4HE1-TC • Tighten the air bleeding plug ".
(4HG1-T model only)
080LW001-1.tif
• Loosen the bleeding plug #.
bubbles.
• Tighten the bleeder plug #.
bubbles.
(Except 4HE1-TC model)
• Loosen the bleeding plug on the injection pump $.
(4HE1-TC model only)
bubbles.
• Tighten the bleeding plug on the injection pump $.
• Lock the priming pump cap !.
NOTE:
Check for fuel leakage from around the injection pump
and the fuel filter.
CARTRIDGE REPLACEMENT
REMOVAL
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
6C-8-3.tif
INSTALLATION
1. Clean the upper cover fitting face.
This will allow the new fuel filter to seat properly.
6c-8-4.tif
2. Apply a light coat of engine oil to the O-ring.

3. Supply fuel to the new fuel filter to facilitate bleeding.
4. Turn in the new fuel filter until the filter O-ring is fitted
against the sealing face.
Be very careful to avoid fuel spillage.
5. Use the filter wrench to turn in the fuel filter an
additional 1/3 to 2/3 of a turn.
6C-10-1.tif
6. Operate the priming pump to bleed the air from the fuel
line.
Refer to “FUEL FILTER ASSEMBLY” for more detailed
information.
7. Start the engine.
Crank the engine for ten seconds or until it starts.
If the engine does not start after ten seconds, repeat
Step 6.
DRAINING THE PRE-FUEL FILTER

1. Loosen the air bleeding plug and drain plug by turning
them counterclockwise.
2. Drain approximately 0.1 liters (3.4 oz) of water.
3. Securely tighten the drain plug.
4. Operate the primer pump on the fuel pump to bleed the
fuel system.
5. Tighten the air bleeding plug.
6. Start the engine and check to be sure no fuel is leaking
from the drain plug.
7. Make sure that the warning light in the instrument
panel is off.
(Except 4HE1-TC)
6C-10-2.tif
041LX001.tif
FUEL FILTER ASSEMBLY (4HF1-2 model only)
6C-11-1.tif
REMOVAL
Preparation
1. Filler cap
2. Lead switch wiring connector
3. Fuel hose
• Draw out inlet and outlet hoses from the fuel filter and
cork the hoses to prevent fuel outflow.
6C-11-2.tif
4. Fuel filter installing bolt
5. Fuel filter assembly
INSTALLATION
5. Fuel filter assembly
4. Fuel filter installing bolt
3. Fuel hose
• Connect the inlet hose and outlet hose.
2. Lead switch wiring connector
1. Filler cap
CARTRIDGE REPLACEMENT
Removal
1) Remove the cartridge using a filter wrench.
Special Tool
Filter wrench: 5-8840-0253-0
2) Remove the sedimenter/center.
6C-12-1.tif
Reassembly
1) Fit the sedimenter/center in a new cartridge.
2) Clean the cartridge mounting surface of the filter body
so that the new cartridge can be seated completely.
3) Apply engine oil thinly to the new cartridge O-ring.
4) Fill the new cartridge with light oil to facilitate air
bleeding.
5) Tighten the cartridge until the O-ring comes into
contact with the sealing surface. Sufficient care should
6C-12-2.tif be taken not to spill the light oil.
Give 1/3 to 2/3 of a turn using a filter wrench.
Special Tool
Air Bleeding
1) Actuate the priming pump 1 to send the air in the fuel
system to the injection pump.
2) Loosen the sedimenter air bleeding plug 2 and operate
the priming pump until no bubbles appear.
3) Tighten the air bleeding plug completely.
4) Try to start the engine. If the engine is not started within
10 seconds, air bleeding should be conducted once
again.
6C-12-3.tif 5) Check that there is no fuel leak, and then tighten the
priming pump completely.
Water Drain
If more than specified has collected, the warning light is lit.
Under this condition, follow the following water drain
procedure:
1) Place a container (Approximately 0.2 liters capacity)
beneath the drain plug on the separator.
2) Loosen the drain plug and air bleeding plug.
3) After draining, tighten the drain plug.
4) Operate the priming pump several times again and
check for fuel leak.
5) Tighten the air bleeding plug.
6) Make sure that the warning light in the instrument panel
is off.
INJECTION NOZZLE ASSEMBLY
6C-13-1.tif
REMOVAL
Preparation
• Tilt the cab.
1. Nozzle Cover
2. Leak-Off Pipe
6C-14-1.tif
3. Fuel Injection
1) Loosen the injection pipe sleeve nuts #.
Do not apply excessive force to the injection pipes %.
2) Loosen the injection pipes clips ".
3) Remove the injection pipe assembly.
Plug the delivery valve holder ! ports and nozzle
holder $ ports with caps to prevent the entry of foreign
material.
6C-15-1.tif
4. Injection Nozzle Assembly

Mark the nozzle holder assemblies fitting positions by
tagging each nozzle holder assembly with the cylinder
number from which it was removed.
6C-15-2.tif
INSPECTION
Before disassembling the injection nozzle assembly, check
nozzle opening pressure, spray pattern, chatter and oil
leakage.
Opening Pressure
Use a nozzle tester to check the injection nozzle opening
pressure.
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or adjusted.
2
Injection Nozzle Opening Pressure Mpa (kg/cm /psi)
4HF1/4HF1-2/4HG1 18.14 (185/2,631)
4HE1-TC 21.57 (220/3,128)
1st 18.1 (185/2,631)
6C-15-3.tif 4HG1-T
2nd 21.1 (215/3,057)
1st 17.65 (180/2,560)
4HE1-T
2nd 21.57 (220/3,128)
Spray Pattern
Check the spray pattern
Refer to the illustration.
Spray Condition
• Correct
• Incorrect (Restrictions in orifice)
• Incorrect (Dripping)
If the spray condition is bad, the injection nozzle must be
replaced or adjusted.
6C-15-4.tif
Leakage
Hold the tester handle to about 2070 kPa (300 psi) below
the opening pressure. If no drops of fuel fall from the
nozzle tip within 10 seconds, the nozzle is not leaking
Chatter
An easily audible chatter at all pump lever speeds should
be heard.
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE WILL
SPRAY OUT UNDER GREAT PRESSURE. IT CAN
EASILY PUNCTURE A PERSON’S SKIN. KEEP YOUR
HANDS AWAY FROM THE INJECTION NOZZLE
TESTER AT ALL TIMES.
DISASSEMBLY
Clamp the injection nozzle holder in a vice.
1. Flange
6C-16-1.tif
2. Retaining Nut
Use a wrench to remove the injection nozzle retainer nut.
6C-16-2.tif
3. Injection Nozzle
Keep the nozzle along with the needle valve separately to
maintain the original nozzle to needle valve combination.
4. Spacer
5. Spring Seat
6. Nozzle Spring
7. Adjusting Shim
Keep the adjusting shims in the original groups to hold the
initial shim to nozzle spring combination.
6C-17-1.tif 8. Nozzle Holder Body
CAUTION
• Wash all the parts removed and arrange them on a
cylinder basis, care should be taken not to miss
any parts.
• Soak the nozzle ASM in a parts receptacle filled
with light oil.
• Care should be taken not to miss shim, if used.
INSPECTION
Injection Nozzle Needle
1) Remove the nozzle from the nozzle body.
2) Carefully wash the nozzle needle and the nozzle body
in clean diesel fuel.
3) Check that the nozzle needle moves smoothly inside
the injection nozzle body.
If the nozzle does not move smoothly, it must be
6C-17-2.tif repaired (See “Nozzle Lapping Procedure” below).
Nozzle Lapping Procedure

1) Lap the nozzle needle # and the nozzle body ! by
applying a compound of oxidized chrome and animal
oil ".
NOTE:
Do not apply an excessive amount of the oxidized
chrome and animal oil compound to the injection
needle valve seat area.
2) Carefully wash the needle valve and the nozzle body in
6C-17-3.tif
clean diesel fuel after lapping.
Nozzle Body and Needle Valve

Check the nozzle body and the needle valve for damage
and deformation.
The nozzle and body assembly must be replaced if either
of these two conditions are discovered during inspection.
NOTE:
New nozzles must be cleaned in a solvent to remove
protective coating.
The nozzle body and needle must always be replace as
6C-18-1.tif
an assembly.
REASSEMBLY
8. Nozzle Holder Body
7. Adjusting Shim
6. Nozzle Spring
5. Spring Seat
4. Spacer
6C-18-2.tif
3. Injection Nozzle
Install the nozzle dowel pin with it set to the dowel hose of
the nozzle holder body.
6C-18-3.tif
2. Retaining Nut
Clamp the injection nozzle holder in a vice.
Tighten the injection nozzle holder retaining nut to the
specified torque.
Injection Nozzle Holder Retaining
Nut Torque N∙m (kg∙m/lb∙ft)
34 (3.5/25)
Remove the injection nozzle holder from the vice.

6C-18-4.tif 1. Flange
ADJUSTMENT OF INJECTION STARTING

PRESSURE
After reassemble of the injection nozzle, recheck the
opening pressure and spray condition.
Opening Pressure
Attach the injection nozzle holder to the injection nozzle
tester.
6C-19-1.tif Apply pressure to the nozzle tester to check that the
injection nozzle opens at the specified pressure.
If the injection nozzle does not open at the specified
pressure, install or remove the appropriate number of
adjusting shims to adjust it.
2
Injection Nozzle Opening Pressure Kpa (kg/cm /psi)
18,142 (185/2,631)
Opening Pressure Adjustment

1) Clamp the injection nozzle holder # in a vise !.
2) Use a wrench to remove the injection nozzle retaining
nut ".
6C-19-2.tif
3) Remove the injection nozzle holder from the vise.

4) Remove the injection nozzle $, the spacer %, the
spring seat & the spring ' and the adjusting shim (.
5) Install the new adjusting shim, the spring, the sprig
seat, the spacer, the injection nozzle, and the retaining
nut.
6) Clamp the injection nozzle holder in the vise.
7) Tighten the injection nozzle holder retaining nut to the
specified torque.
6C-20-1.tif
Injection Nozzle Holder Retaining
Nut Torque N∙m (kg∙m/lb∙ft)
34 (3.5/25)
8) Remove the injection nozzle holder from the vise.

9) Attach the injection nozzle holder to the injection nozzle
tester.
10) Apply pressure to the nozzle tester to check that the
pressure, install or remove the appropriate number or
Removing or installing one shim will increase or
decrease the nozzle opening pressure approximately
2
3.77 kg/cm (53.6 psi/370 kPa).
Adjusting Shim Availability mm(in)
Range 0.5 - 1.5 (0.02 - 0.06)
Increment 0.025 (0.001)
Total Number of Shims 41
Spray Pattern
Check the spray condition.
Refer to the illustration.
Spray Condition
• Correct
• Incorrect (Restrictions in orifice)
• Incorrect (Dripping)
If the spray condition is bad, the injection nozzle must be
replaced or adjusted.
6C-20-2.tif
Refer to “Adjustment”.
Note:
Adjust the nozzle in a well ventilated area. Do not
inhale oil or spray injected from the nozzle.
4-1 Injection Nozzle (Two spring nozzle holder)

(4HG1-T, 4HE1-T only)
The two-spring nozzle holder has been developed to

reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Disassembly
1. Retaining nut
2. Nozzle & pin
3. Spacer & pin
4. Lift piece
5. Spring seat
6. Push rod
7. Shim (Second nozzle opening pressure adjustment)
8. Second spring
9. Collar
10. Spring seat
11. First spring
12. Shim (First nozzle opening pressure adjustment)
13. Nozzle holder body
14. Eye bolt
15. Gasket
080LX002.tif
(1) Before disassembly remove carbon deposit from

nozzle and nozzle holder using a wire brush and wash
the outside nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush
during cleaning it.
(2) Disassemble the nozzle holder assembly to numerical
order.
REASSEMBLY AND OPENING

PRESSURE ADJUSTMENT
2. Shim (First opening pressure adjustment)
3. First spring
4. Spring seat
5. Collar
6. Second spring
7. Push rod
8. Shim (Second opening pressure adjustment)
9. Spring seat
10. Lift piece
11. Spacer & pin
12. Nozzle & pin
13. Retaining nut
14. Gasket
15. Eye bolt
The nozzle holder is adjusted as the components are

reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
080LX003.tif
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.
REASSEMBLY AND ADJUSTMENT PROCEDURE

1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.
2 Full needle valve lift confirmation Confirm the full needle valve lift in accordance with the
closed method.
3 Pre-lift confirmation Confirm pre-lift in accordance with the closed method.

CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
4 Second nozzle opening pressure Confirm the second nozzle opening pressure in accordance
confirmation with the closed method.
5 Second nozzle opening pressure Adjust the second nozzle opening pressure using the shim.
adjustment
6 Confirm the condition of the fuel spray with the nozzle and
Final inspection nozzle holder assembled.
First nozzle opening pressure adjustment

1. Clamp the nozzle holder in a vise.
040MV015.tif
2. Install the shim, first spring and spring seat in the

nozzle holder.
040MV016.tif
3. Install the collar, second spring, shim, spring seat and

pushrod in the nozzle holder.
040MV017.tif
4. Install the pins, lift piece and spacer in the nozzle

holder.
040MV018.tif
5. Install the pins in the spacer.

6. Install the nozzle on the spacer.
040MV019.tif
7. Hand-tighten the adjustment retaining nut together with

the gasket to the nozzle holder.
Retaining nut: 157892-3200 (ZEXEL)
Gasket: 157892-5100 (ZEXEL)
040MV010.tif
8. Tighten the adjustment retaining nut to the specified

torque.
Torque: 29 - 39 N∙m (3.0 - 4.0 kg∙m)
040MV014-1.tif
9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.
CAUTION:
Use a micrometer to measure shim thickness.
040MV030.tif
• First nozzle opening pressure adjusting shims

Part No. (ZEXEL) Thickness (mm)
150538-9800 0.40
150538-9900 0.50
150539-0000 0.52
150539-0100 0.54
150539-0200 0.56
150539-0300 0.58
150539-0400 0.60
040LX010.tif
150539-0500 0.70
Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining
nut.
Gasket: 026508-1140 (ZEXEL)
Plug: 157892-1600 (ZEXEL)
040MV013.tif
2. Position the nozzle holder with the nozzle facing down

and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 157892-5000 (ZEXEL)
040MV012.tif
3. Install the nut on the dial gauge holder.

Nut: 157892-1000 (ZEXEL)
040MV011.tif
4. Install the pin to the dial gauge.

Note:
The lengths of the pins do not include the threaded
portions.
Pin (λ=100 mm): 157892-5200 (ZEXEL)
Dial gauge: 157954-3800 (ZEXEL)
040MV029.tif
5. Secure the dial gauge to the nozzle holder using the

nut so that the pin contacts the tip of the first spring
seat.
CAUTION:
• Secure the dial gauge so that a stroke of 2 mm can
be measured.
• Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)
040MV009.tif
6. Set the nozzle holder to the nozzle tester and put

needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.
040MV030.tif
8. Operate the nozzle tester and increase the in-line

2
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that
the nozzle’s needle valve moves through its full lift.
Record full lift ‘L’. (Read dial gauge)
Note:
The above operation is used to determine whether
the nozzle seat is worn and whether the nozzle
assembly is in good condition.
040MV008.tif
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.
Note:
The in-line pressure will decrease and needle valve
lift (as indicated on the dial gauge) will also
decrease a little.
040MV007.tif
040MV006.tif
2. Read the needle valve lift ‘λ’ from the dial gauge
indication (once the needle valve has descended when
the second spring has stopped operating). Refer to the
pre-lift measuring point for ‘λ’.
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure
2
+approx 1 MPa (10 kg/cm ).
Note:
This point can be found while the pressure is
decreasing.
040MV025-1.tif
3. Confirm that pre-lift ‘λ’ is as specified.

Pre-lift mm
4HG1-T 0.04
4HE1-T 0.10
040MV005.tif
4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit.
Service kit: ZEXEL
4HG1-T 105019-2310
4HE1-T 105019-1070
040MV031.tif
Second nozzle opening pressure confirmation

1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
2
kg/cm ) so that the nozzle’s needle valve moves
through its full lift.
040MV030.tif
2. Release the nozzle tester handle so that in-line

pressure decreases.
Note:
The in-line pressure will decrease and needle valve
lift (as indicated on the dial gauge) will also
decrease a little.
040MV022.tif
3. Then, read the pressure gauge indication (second

nozzle opening pressure) the instant that the dial gauge
indicates the specified needle valve lift (usually pre-lift λ
+ 0.05 mm).
040MV024.tif
040MV026.tif
Second nozzle opening pressure adjustment

If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and replace
the shim until the pressure is as specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
• Use a micrometer to measure shim thickness.
040MV017.tif
• Second nozzle opening pressure adjusting shims

Part No. (ZEXEL) Thickness (mm)
150591-4000 0.40
150591-5000 0.50
150591-5200 0.52
150591-5400 0.54
150591-5600 0.56
150591-5800 0.58
150591-5900 0.59
040LX009.tif
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.tif
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-tighten
the retaining nut. Then, tighten the original retaining nut
to the specified torque.
Torque: 59 - 79 N∙m (6.0 - 8.0 kg∙m)
040MV014-1.tif
4. Set the nozzle holder to the nozzle tester and check

first nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.
040MV030.tif
INSTALLATION
4. Injection Nozzle Assembly
1) Install a new injection nozzle gasket and O-ring to the
nozzle holder, and then install the nozzle holder to the
cylinder head as shown in the illustration.
6C-30-1.tif
2) Tighten the nozzle holder flange nuts to the specified

torque in the numerical order.
Nozzle Holder Flange Nuts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6C-30-2.tif
3. Fuel Injection Pipe

1) Install the injection pipe assembly and temporarily
tighten the injection pipe sleeve nuts.
2) Set the clips in the prescribed position shown in the
illustration.
CAUTION:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
Clip Screw Torque N∙m (kg∙m/lb∙in)
3 (0.3/26)
3) Tighten the injection pipe sleeve nuts to the specified

torque.
Injection Pipe Sleeve Nut Torque N∙m (kg∙m/lb∙ft)
29 (3/22)
6C-30-3.tif
Fuel Injection Pipe (4HF1-2 model only)

1) Connect Injectin Pipe and fix with clips as illustrated.
Injection Pipe Tightening Torque N∙m (kg∙m/lb∙ft)
29 (3.0/22)
Clip Tightening Torque N∙m (kg∙m/lb∙in)

3 (0.3/26)
6C-31-1.tif
2. Leak Off Pipe

Leak-Off Pipe Joint Bolt Torque N∙m (kg∙m/lb∙in)
13 (1.3/113)
1. Nozzle Cover
• Connect battery ground cable.
6C-31-2.tif
INJECTION PUMP ASSEMBLY (Except 4HF1-2 model)
6C-32-1.tif
REMOVAL
Preparation
• Disconnect battery ground cable
• Drain coolant
1. Intake Air Duct
2. Vacuum Hose
3. Oil Level Guide Tube
• Remove the guide tube fixing bolt and pull out the
guide tube.
6C-33-1.tif
4. Engine Stop Cable

• Loosen locking nut at bracket and disconnect.
• Engine stop cable from injection pump stop lever.
6C-33-2.tif
For 4HE1-TC
6C-33-3.tif
5. Accelerator Control Cable

• Loosen locking nut at bracket and disconnect
accelerator control cable from injection pump control
lever.
6C-33-4.tif
6C-34-1.tif
6. Engine Control Wire

7. Engine Control Lever
8. Oil Pipe
9. Fuel Return Hose
10.Fuel Feed Hose
• Disconnect fuel hose from injection pump side and
take care not to spill and enter dust.
11 Nozzle Cover
6C-34-2.tif
12. Leak-Off Pipe

13. Fuel Pipe
15. PCV Hose
6C-34-3.tif
16. Injection Pipe

• Loosen the injection pipe sleeve nuts #.
Do not apply excessive force to the injection pipes %.
• Loosen the injection pipes clips ".
• Remove the injection pipe assembly.
Plug the delivery valve holder ! ports and nozzle
holder $ ports with caps to prevent the entry of foreign
material.
6C-34-4.tif
17. Injection Pump Assembly

1) Remove the injection pump bracket bolts and the
injection pump rear bracket bolts.
2) Then remove the injection pump assembly.
6C-35-1.tif
18. Injection Pump Rubber Spacer

(For 4HF1/4HG1/4HE1-T)
6C-35-2.tif
INSTALLATION
18. Injection Pump Rubber Spacer
Stick the rubber spacer to the location indicated in the
illustration with pressure sensitive adhesive double coated
tape. (4HF1/4HG1/4HE1-T Engine)
6C-35-3.tif

1) Turn the crankshaft until the timing mark on the
crankshaft damper pulley is aligned with “13°” line.
2) Check the No.1 cylinder intake and exhaust valve
rocker arms for any play.
If the No.1 cylinder intake and exhaust valve rocker
arms are depressed the No.4 piston is at on the
compression stroke.
Rotate the crankshaft one full turn (360 degrees) and
realign the crankshaft damper pulley timing mark with
6C-35-4.tif
the “13°” line.
NOTE:
BTDC 13° to be aligned with here is an angle at which
the injection pump is installed, and has nothing to do
with the injection timing.
• Remove the inspection hole plug from the cylinder
body.
• Install the O-ring to the injection pump bracket.
3) Align the injection pump bracket slit with the timer slit.
4) Install the injection pump assembly to the cylinder
body.
NOTE:
When the injection pump has a poor gear engagement
while installing the assembly to the cylinder body,
insert a screwdriver into the slit on the time peripheral
with the pump bracket slit used as a guide, and move
it up and down to get it into forcibly.
6C-36-1.tif
5) After installing the injection pump, the injection timing

can be checked through the timing check hole provided
at the injection pump bracket.
Set the No.1 cylinder to the BTDC (injection timing of
engine mode) on the compression stroke. When the
pointer of the timing check hole comes in line with the
mark on the timer periphery of the injection pump as
shown in the illustration, the injection timing is normal.
After completion of the injection timing check, tighten
the check hole plug to the specified torque.
6C-36-2.tif
Injection Timing deg

4HF1: 4HE1-TC BTDC 8
4HG1 BTDC 9
BTDC 7 (Except Colombia)
4HG1-T
BTDC 9 (For Colombia)
4HE1-T BTDC 7
140RW080.tif

crankshaft damper pulley is aligned with “8°” line
NOTE:
Position in its normal rotating direction. (for 4HE1-TC
only)
6C-36-4.tif
7) Adjust injection pump downward so that the “8°” comes

to position in the timing check hole.
(for 4HE1-TC only)
NOTE:
Whenever the injection pump is replaced, be sure to
adjust the injection timing. For the details of the
adjustment, refer to the “SECTION 00 SERVICING:
INJECTION TIMING INSPECTION AND ADJUSTMENT”.
140RW079.tif
8) Tighten the injection pump bracket nuts and bolts to

Injection Pump Bracket Nut and
Bolt Torque N∙m (kg∙m/lb∙ft)
48 (4.9/35)
9) Install the injection pump rear bracket.

Injection Pump Rear Bracket
Bolt Torque N∙m (kg∙m/lb∙ft)
6C-37-1.tif 48 (4.9/35)
10) Install the inspection hole plug.

Inspection Hole Plug Torque N∙m (kg∙m/lb∙ft)
48 (4.9/35)
Note:
In case the crank pulley has two marks as illustrated,
# BTDC 49° mark on the second crest and ! TDC
mark on the third crest (as viewed from the front side),
be sure to set at the mark !. (If there are two different
marks on one and same crest, set at the mark which
comes second when rotated in the normal direction.)
The mark # is used when installing the injection
pump for 4HF1-2.
012RW133.tif
16. Fuel Injection Pipe

1) Install the injection pipe assembly and temporarily
tighten the injection pipe sleeve nuts.
2) Set the clips in the prescribed position shown in the
illustration.
CAUTION:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3 (0.3/26)
3) Tighten the injection pipe sleeve nuts to the specified

torque.
Injection Pipe Sleeve Nut Torque N∙m (kg∙m/lb∙ft)
29 (3/22)
15. PCV Hose

14. Fuel Filter
Fuel Filter Bracket Bolt Torque N∙m (kg∙m/lb∙ft)
040LX020.tif
34 (3.5/25)
INJECTION PUMP ASSEMBLY (4HF1-2 model only)
6C-38-1.tif
INSTALLATION
1) Turn the crankshaft to set No. 1 cylinder to 49° before
TDC in its compression stroke.
(49° is a pump assembling angle, not related to
injection timing.)
6C-38-2.tif
2) Install O-ring to the injection pump.

3) Apply paint on the ) (Z) marked side of the injection
pump gear.
4) Align the pump bracket mark with the tooth (under side
of the pump) just before the ) (Z) marked tooth.
5) Insert the pump using the block side of stud bolt as a
guide.
6C-38-3.tif
6) After installing the injection pump, remove the

tachometer sensor from the housing, and make sure
that the painted gear is at the center of the sensor
mounting hole.
7) Tighten injectin pump clamping bolt and nut to
specified torque:
Bolt Tightening Torque N∙m (kg∙m/lb∙ft)
48 (4.9/35)
6C-39-1.tif
Nut Tightening Torque N∙m (kg∙m/lb∙ft)
24 (2.4/17)
8) With reference to Injection Timing Check &

Adjustment, set No. 1 Cylinder to 12° before its TDC.
Note:
# BTDC 49° mark on the second crest and TDC mark
on the third crest (as viewed from the front side), be
sure to set at the mark !. (If there are two different
012RW133.tif
Injection Pipe (4HF1-2 model only)

1) Connect Injection Pipe and fix with clips as illustrated.
Injection Pipe Tightening Torque N∙m (kg∙m/lb∙ft)
29 (3.0/22)
Clip Tightening Torque N∙m (kg∙m/lb∙in)

3 (0.3/26)
6C-39-3.tif
13. Fuel Pipe

Do not apply excessive force to the fuel pipe.
Fuel Pipe Joint Bolt # Torque N∙m (kg∙m/lb∙ft)
41 (4.2/30)
Fuel Pipe Joint Bolt ! Torque N∙m (kg∙m/lb∙ft)

23 (2.3/17)

4 (0.4/35)
6C-40-1.tif
12. Leak Off Pipe

Leak-Off Pipe Joint Bolt Torque N∙m (kg∙m/lb∙in)
13 (1.3/113)
11. Nozzle Cover

10. Fuel Feed Hose
9. Fuel Return Hose
6C-40-2.tif
Air Bleeding
1) Loosen the priming pump cap ! at the side of the
injection pump.
2) Loosen the bleeder valve # at the top of the fuel filter.
3) Operate the priming pump to bleed the air from the
injection pump.
4) Retighten the bleeder valve.
5) Operate the priming pump.
6C-40-3.tif
Check for fuel leakage from around the injection pump
and the fuel filter.
6) Lock the priming cap to the injection pump.
For 4HE1-TC
080LW001-1.tif
Air Bleeding (4HF1-2 model only)

1) Actuate the priming pump # to send the air in the fuel
2) Loosen the sedimenter air bleeding plug ! and
operate the priming pump until no bubbles appear.
3) Tighten the air bleeding plug completely.
4) Try to start the engine. If the engine is not started within
10 seconds, air bleeding should be conducted once
again.
6C-41-1.tif
5) Check that there is not fuel leak, and then tighten the
priming pump completely.
8. Oil Pipe
Oil Pipe Joint Bolt Torque N∙m (kg∙m/lb∙ft)
17 (1.7/12)
6C-41-2.tif
7. Engine Control Lever Assembly

Engine Control Lever Bolt Torque N∙m (kg∙m/lb∙ft)
24 (2.4/17)
6. Engine Control Wire
6C-41-3.tif
6C-41-4.tif

1) Check to see if the idling control knob is turned to the
extreme left.
2) Attach the tip end of the cable to the engine control
lever.
3) Pull the outer cable toward the front side of the vehicle,
and provide the engine control wire and the inner cable
with an appropriate play before fastening the clamp
with a nut.
4) Check to see if the injection pump control lever is at the
6C-42-1.tif
idling position (with the lever in touch with the stopper
bolt).
4. Engine Stop Cable

1) Attach the end tip of the cable to the engine stop lever.
2) Pull the cable toward the rear side of the vehicle, and
fasten the clamp with a nut at the position where the
lever stops.
6C-42-2.tif
3. Oil Level Gauge Guide Tube

1) Install the O-rings to the guide tube lower portion and
insert the guide tube completely to the cylinder body.
2) Tighten the guide tube bolt to the specified torque.
Guide Tube Bolt Torque N∙m (kg∙m/lb∙in)
13 (1.3/113)
2. Vacuum Hose
6C-42-3.tif
1. Intake Air Duct
• Pour coolant into radiator.
• Start engine and check for oil and fuel leakage
carefully.
INJECTION TIMING ADJUSTMENT

Injection Pump Notched Line Inspection
1) Check the injection pump bracket nuts # for
looseness.
Tighten as required.
2) Check that the notched lines ! on the injection pump
bracket and the timing gear case are aligned.
If the notched lines are not aligned, the injection timing
6C-43-1.tif
must be checked.
3) Same time, check injection timing on the crank damper
pulley. If the injection timing aligned with incorrect, the
injection timing must be readjusted.
6C-43-2.tif
Injection Timing Adjustment (Except 4HF1-2

model)
crankshaft damper pulley is aligned with the injection
timing of each engine mode mark in the illustration.
Injection Timing deg
4HF1 : 4HE1-TC BTDC 8
4HG1 BTDC 9
4HG1-T : 4HE1-T BTDC 7
6C-43-3.tif
2) Remove the two foam rubbers.

3) Loosen the four injection pump fixing nuts #.
This will allow the pump to pivot.
Do not bend or scratch the fuel pipe.
4) Aligne the notched line between the injection pump
bracket and the timing gear case.
Make sure that the timing mark on the crank damper
pulley is aligned with correct injection timing.
6C-43-4.tif
6C-44-1.tif
5) Tighten the injection pump fixing nuts # to the

specified torque.
Injection Pump Fixing Nut Torque N∙m (kg∙m/lb∙ft)
25 (2.6/19)
Note:
If there are two marks on the crank pulley, the front
side of mark is for setting BTDC 49° and the rear side
of mark is for setting TDC.
6C-44-2.tif
Idling Speed Adjustment (Except 4HF1-2 model)

1. Idling Rotation Check
1) Idle the engine.
2) Measure the number of the idling rotations with a
tachometer.
3) When the number of the idling rotations is outside
the specified value, adjust it with the idling adjust
bolt (arrow-marked).
Number of idling rotations:
6C-44-3.tif
550 to 600 rpm (at M/T standard)
640 to 690 rpm (at A/T standard)
(4HE1-TC)
775 to 825 rpm (at M/T and A/T standard)
Injection Timing Check (4HF1-2 model only)

1) Set No. 1 Cylinder to the TDC in the compression
stroke.
2) Disconnect Injection Pipe.
3) Put down Wax CSD lever, insert a spacer (10 ~ 12
mm/0.39 ~ 0.47 in) thick between the plunger and
adjust bolt, and cancel the Wax CSD.
080LX001.tif
4) Remove the pump rear plug, connect a dial gage and

set the lift at 1 mm (0.039 in).
Special Tool
Measuring device: 5-9940-0145-0
6C-45-2.tif
5) Set the crankshaft damper pulley TDC mark to the

pointer or 45° before TDC.
6) Set the dial gage to the “0” position.
7) Turn the crankshaft leftwise and rightwise a little and
make sure that the needle stays in the “0” position.
6C-45-3.tif
8) Turn the crankshaft in the normal direction and read

the measuring device’s indication at the 12° before
TDC position.
NOTE:
As there is no 12° mark, set midway between the 11°
and 13° marks.
Standard value: 0.5 mm (0.0197 in)
6C-45-4.tif
Note:
# BTDC 49° mark on the second crest and ! TDC
mark on the third crest (as viewed from the front side),
be sure to set at the mark !. (If there are two different
The mark # is used when installing the injection
pump for 4HF1-2.
012RW133.tif
Injection Timing Adjustment

(4HF1-2 model only)
If injection timing is out of the specified range, follow the
following procedure for adjustment:
1) Loosen injection pump fixing nuts and bracket bolt.
2) Adjust the mounting angle of injection pump:
• If injection timing is too fast, bring the injection pump
closer to the engine.
• If injection timing is too slow, put the injection pump
6C-46-1.tif
more distant from the engine.
3) When the dial gage has indicated the specified value,
tighten the fixing nuts and bolt to specified torque.
Nut Tightening Torque N∙m (kg∙m/lb∙ft)
24 (2.4/17)
Bolt Tightening Torque N∙m (kg∙m/lb∙ft)

48 (4.9/35)
4) Disconnect the dial gage, install and tighten the plug to

specified torque. (Make sure of a coper washer being
attached to the plug)
Plug Tightenng Torque N∙m (kg∙m/lb∙ft)

17 (1.7/12)
5) Release the wax CSD and connect the injection pipe.

Pipe Sleeve Nut Tightening
Torque N∙m (kg∙m/lb∙ft)
29 (3.0/22)
IDLING SPEED CHECK & ADJUSTMENT (4HF1-2

model only)
1) Warm up the engine.
2) Measure idling speed by means of tachometer.
3) If idling speed is out of the standard, adjust with an
idling adjust bolt (indicated by and arrow mark).
Idling speed: 575 - 625 rpm
6C-46-2.tif
INJECTION PUMP DATA

INJECTION VOLUME ADJUSTMENT
TEST CONDITIONS
4HF1 Engine
Item Condition
Injection nozzle and holder assembly ZEXEL Part No.: 105118-6050
Injection nozzle ZEXEL Part No.: 105017-1860
Nozzle holder ZEXEL Part No.: 105048-3673
Injection nozzle opening 185 (2,631/18,142)
2
pressure kg/cm (psi/kPa)
Injection line dimensions
Inside diameter mm (in) 2.0 (0.079)
Outside diameter mm (in) 6.0 (0.236)
Length mm (in) 500 (19.7)
2
Fuel delivery pressure kg/cm (psi/kPa) 1.6 (22.75/156.9)
Test fuel SAE Standard Test Diesel Fuel (SAE J967d)
ISO Standard Test Diesel Fuel (ISO 4113)
Test fuel temperature °C (°F) 40 - 45 (104 - 113)
Identification numbers 101401-7070
101401-7060
101401-7090
101401-7311
IDENTIFICATION PLATE AND NUMBER

Use the data following the injection pump identification
number to adjust the injection volume.
6C-47-1.tif
INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Identification Numbers : 101401-7070/101401-7060
[4HF1 Engine]
Pre-stroke : No. 1 plunger 4.1 ± 0.05 mm
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 30') Plungers are numbered from the Governor side
Tappet clearance : Bolt adjustment type : More than 0.3 mm for all cylinders.
: Shim adjustment type : Manually rotate the camshaft 2-3 times and
confirm that it rotates smoothly.
Injection Volume
Adjusting Pump speed Injection volume Variance

Remarks
point (r.p.m.) (cc/1000 strokes) (%)
960 61 ± 1.6 ±4 Basic
H 285 16 ± 1.3 ±10.0
A 960 61 ± 1 - Basic
B 1,600 (62) ± 2 -
C 500 (60.5) ± 2 -
+ 16
I 150 (82) − 0 -
Timing Advance Specification
1,050 1,600
Pump Speed (r.p.m.) 1,000
or less or more
0.5 Finish
Degree for Angle of Lead (deg.) Start
or less 5 ± 0.5
Governor Adjustment
B06LT001-1.tif

Identification Numbers : 101401-7090
[4HF1 Engine]
Injection Volume

Remarks
960 61 ± 1.6 ±4 Basic
H 285 16 ± 1.3 ±10.0
A 960 61 ± 1 - Basic
B 1,600 (62) ± 2 -
C 500 (60.5) ± 2 -
+ 16
I 150 (82) − 0 -
1,050 1,600
or less or more
0.5 Finish
or less 5 ± 0.5
Governor Adjustment
B06LT002-1.tif

[4HF1 Engine]
Injection Volume

Remarks
960 61 ± 1.6 ±4 Basic
H 285 16 ± 1.3 ±10.0
A 960 65 ± 1 - Basic
B 1,600 (62) ± 2 -
C 500 (63.5) ± 2 -
+ 16
I 150 (82) − 0 -
1,600
or more
0.5 Finish
Degree for Angle of Lead (deg.)
or less 5 ± 0.5
Governor Adjustment
027LT003.tif 027LT002.tif
B06LT001-1.tif

TEST CONDITIONS
4HF1-2 (Bosch distributor type)
Item Condition
Injection nozzle and holder assembly ZEXEL Part No.: -
Injection nozzle opening
2 133 (1,891 / 1,304)
2

6C-54-1.tif

[4HF1-2 Engine]
Injection Volume
Pump speed Injection volume Uneven amplitude Oil temperature
3 3 Remarks
(r.p.m.) (mm /strokes) (mm /strokes) (°C)
500 (48.2 ± 4.5) - 48 ± 2
960 60.3 ± 1.0 5.0 50 ± 2 Basic
1280 (63.9 ± 3.5) - 50 ± 2
1600 (61.4 ± 4.5) - 50 ± 2
1925 17.9 ± 3.0 5.5 50 ± 2 Basic
300 10.1 ± 2.0 2.0 48 ± 2 Basic
150 37.0 ± 10 - 48 ± 2
Pump Speed (r.p.m.) 1,100 1,280 1,600 1,800
Degree for Angle of Lead (deg.) 0.7 2.8 6.2 Finish

6.5
Governor Adjustment (4HF1-2)
040LX007.tif
040LX006.tif
040LX008.tif

TEST CONDITIONS
4HG1 Engine
Item Condition
2 185 (2,631/18,142)
2
101401-7440

6C-56-1.tif

[4HG1 Engine] : 101401-7440
Injection Volume

Remarks
1,310 70.5 ± 1.6 ±4 Basic
H 315 10 ± 1.3 ±10.0
A 1,310 70.5 ± 1 - Basic
B 1,600 (75.5) ± 2 -
C 520 (64) ± 2 -
D 960 (70.5) ±2
−0 -
+ 16
I 150 (95) − 0 -
1,050 1,600
or less or more
0.5 Finish
or less 5 ± 0.5
Governor Adjustment
040LW026.tif
040LW016.tif
040LW012.tif
040LW029.tif 040LW030.tif
040LW013.tif

TEST CONDITIONS
4HG1-T
Item Condition
2 184 (2,616/18,044)
2

6C-59-1.tif

[4HG1-T Engine]
Tappet clearance : Shim adjustment type : Manually rotate the camshaft 2-3 times and
: Bolt adjustment type : More than 0.3 mm for all cylinders.
Injection Volume
Rack Pump Injection q’ty Max var

Adjusting 3
Position Speed (cm /1000 bet. cyl. Fixed Remarks
point
(mm) (rpm) strokes) (%)
11.5 1000 73.5 ± 1.6 ±4 Rack Basic
(Measure)
H Approx. 8.9 315 ±10 Rack
± 1.3
Basic Boost press. kPa (mmHg)
A R1 (11.5) 1000 73.5 ± 1 - Lever
Above 62.0 (Above 465)
Boost press. kPa (mmHg)
B R1 +1.0 1500 (78.5) ± 2 - Lever
Above 62.0 (Above 465)
Boost press.
C R2 –0.8 500 (66.5) ± 2 - Lever
0
(Measure) Boost press.
I - 150 - Lever
± 16 0
Confirm that the timing of is
advanced 1°±30’ from A.
Pump speed Below

N1 N3
(rpm) (N1 + 50)
Advance Below Finish
Start
angle (°) 0.5 4.0 ± 0.5
Governor Adjustment (4HG1-T)
040LX014.tif
040LX011.tif
040LX015.tif
040LX012.tif
040LX013.tif
040LX003.tif

TEST CONDITIONS
4HE1-T
Item Condition
2 185 (2,631/18,142)
2
101401-7420
101401-7273

6C-62-1.tif

Identification Numbers : 101401-7410/101401-7420/101401-7273
[4HE1-T Engine]
Injection Volume

Remarks
1,160 96.5 ± 1.6 ±4 Basic
H 375 14.5 ± 1.3 ±10.0
Z 375 - - Basic
A 1,160 96.5 ± 1 -
B 1,450 (97) ± 2 -
C 700 (81) ± 2 -
I 150 (100) + 18
− 0
-
1,185 1,450
or less or more
0.5 Finish
or less 4.8 ± 0.5
Governor Adjustment
040LW024.tif
040LW017.tif
040LW014.tif 040LW027.tif 040LW030.tif
040LW015.tif

TEST CONDITIONS
4HE1-TC Engine
Item Condition
2 185 (2,631/18,142)
2
107492-1062
107492-1032
107492-1100
107492-1110
107492-1120
107492-1130
897212-9350 (ISUZU NO.)

6C-65-1.tif

[4HE1-TC Engine]
Injection Volume

Remarks
1000 82.5 ± 1.6 ± 4 Basic
H 400 19 ± 1.5 ± 14
Z 500 - -
A 1000 82.5 ± 1 - Basic
B 1,450 (92.5) ± 2 -
C 500 (67) -
D 1,450 (89.5) -
I 150 (220) -
Governor Adjustment
040LX018.tif
040LX017.tif
040LX019.tif
040LW021.tif
040LW028.tif

Identification Numbers : 107492-1023 / 107492-1100
[4HE1-TC Engine]
Injection Volume

Remarks
1,000 107.5 ± 1.6 ±4 Basic
H 400 22 ± 1.5 ±10.0
Z 510 - - Basic
A 1,000 107.5 ± 1 -
B 1,200 (112.5) ± 2 -
C 500 (78) -
D 1,200 (103) -
I 150 (235) -
Governor Adjustment
ipf
040LW025.tif
040LW020.tif
040LW010.tif
040LW022.tif

Identification Numbers : 107492-1062 / 107492-1120 / 897212-9350 (ISUZU NO.)
[4HE1-TC Engine]
Injection order : 1 - 3 - 4 - 2 (interval 90° ± 15')-Plungers are numbered from the Governor side
Injection Volume

Remarks
1,000 107.5 ± 1.6 ± 4 Basic
H 400 22 ± 1.5 ± 14
Z 510 - - Basic
A 1,000 107.5 ± 1 -
B 1,400 (121.5) ± 2 -
C 500 (78) ± 2 -
D 1,400 (113) -
I 150 (235) -
Governor Adjustment
040LW010.tif
040LW023.tif
040LW028.tif

Identification Numbers : 10749-1032 / 107492-1130
[4HE1-TC Engine]
Injection Volume

Remarks
900 78 ± 1.6 ± 4 Basic
H 400 19 ± 1.5 ± 14
Z 500 - - Basic
A 900 78 ± 1 -
B 1,450 (98.5) ± 2 -
C 500 (67.5) -
D 1,450 (91.5) -
E 700 (78) -
I 150 (220) -
Governor Adjustment
040LW025.tif
040LW018.tif
040LW011.tif 040LW028.tif 040LW031.tif
040LW021.tif
ANEROID COMPENSATOR ADJUSTMENT
6C-74-1.tif
FUEL TANK
6C-75-1.tif
REMOVAL
Preparation
• Loosen fuel filler cap.
• Drain fuel from drain plug.
• After the drain fuel, tighten the drain plug to the
specified torque.
N∙m (kg∙m/lb∙ft)
29 (3/22)
1. Evapo Fuel Hose

2. Fuel Feed Hose
3. Fuel Return Hose
• Plugging the return hose to prevent fuel from getting
spilt, tie it to the fame with the plugged end up.
4. Fuel Gauge Unit Connector
• Remove the fuel gauge unit connector.
5. Band
• Remove the nut of the fuel tank fixing band, and then
remove the band end on the frame side.
6. Fuel Tank
• Pull out the fuel tank to the outside.
NOTE:
When it is not possible to pull out the fuel tank,
remove the bracket and then draw out the fuel tank
downward.
INSTALLATION
6. Fuel Tank
NOTE:
When the bracket was removed to take off the fuel
tank, install the bracket to the frame and tighten it to
55 (5.6/41)
Also, when mounting the fuel tank to the bracket, place

the packing section attached to the fuel tank securely
on the bracket.
5. Band
• Tighten the band to the specified torque
N∙m (kg∙m/lb∙in)
12 (1.2/104)

• Connect the fuel gauge unit connector.
3. Fuel Return Hose
2. Fuel Feed Hose
• Set the hose to the pipe more than 25mm deep.
1. Evapo Fuel Hose
• Fill the fuel to the fuel tank.
FUEL GAUGE UNIT
6C-77-1.tif
REMOVAL
Preparation: Disconnect Battery ground cable.
• Disconnect fuel gauge unit connector from fuel gauge
unit.
2. Fuel Gauge Unit
• Remove fuel gauge unit fixing screw and fuel gauge
unit.
NOTE:
• After removing fuel gauge unit, cover fuel tank with
waste to prevent any dust entering
INSTALLATION
2. Fuel Gauge Unit
• Connect the wiring connector to the fuel gauge unit.
ACCELERATOR CONTROL
ACCELERATOR CONTROL CABLE
6C-78-1.tif
REMOVAL
1. Adjust Nut
• Loosen the adjust nut on the cable bracket mounted.
2. Accelerator Control Wire (Injection pump side)
• Remove the control wire from injection pump control
lever.
3. Accelerator Control Wire (Accelerator pedal side)
• Remove the Accelerator control wire from accelerator
pedal.
• Pull out the wire to the chassis side through the
grommet hole of the floor board, and remove the
control cable.
INSPECTION
Check the following items, and replace the control cable if
any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should be free of damage and
corrosion.
INSTALLATION
• Take care that the core wire of the cable does not get
damaged or inded.
• Put the cable through the grommet hole from under the
floor.
• Set the groove of the grommet securely into the floor
panel.
4. Accelerator Control Wire (Accelerator Pedal side)
• Connect the accelerator control wire to Accelerator
pedal.
3. Cable Clips
• Install the cable clip to chassis frame.
• Tighten the cable clips to the specified torque
16 (1.6/12)
2. Accelerator Control Wire

1. Adjust Nut
• Attach the end tip of the wire to the engine control
lever.
• Pull the outer cable gently toward the front of the
vehicle, and provide the engine control wire and the
accelerator control wire an appropriate play before
fastening the clamp with a nut.
8 (0.8/69)
• Check to see if the injection pump lever is at the idle

position (with the lever in touch with the stopper bolt).
• Connect the battery ground cable.
• Check to see if the accelerator pedal fully is in the
range of 5 to 10mm above the pedal pad.
• Press down on the accelerator pedal fully, and check to
see if the engine rotates at the maximum speed with
the linkage in the smooth operation.
• In the operating range of the accelerator pedal, check
to see if the accelerator pedal and the injection pump
lever return without fail to the original positions.
ACCELERATOR PEDAL
6C-80-1.tif
REMOVAL
1. Switch Connector
2. Accelerator Control Cable.
• Remove control cable from Accelerator pedal bracket.
3. Idling Control Cable
• Remove control cable from accelerator pedal bracket.
4. Accelerator Pedal Assembly
• Remove accelerator pedal assembly from brake pedal
bracket.
INSTALLATION
• Apply grease to the sliding portion, and install it to the
brake pedal bracket.
• Install the idling control cable to the lever of the
accelerator pedal bracket.
• After confirming that the idling control knob is turned
fully to the left, install the accelerator control cable.
1. Switch Connector
6C-80-2.tif
IDLING CONTROL CABLE
6C-81-1.tif
REMOVAL
1. Idling Control Knob
• Loosen the idling control knob screw and remove the
knob from cable.
2. Idling Control Cable Nut
3. Wave Washer
INSTALLATION
• Install control cable to Accelerator pedal bracket.
3. Wave Washer
• Insert the idling control cable into the specified hole of
the instrument panel.
• Install the washer to the cable, and tighten it with a nut.

• Insert the idling control knob into the cable, and tighten
the screw.
Inspection:
• With the idling control knob not in use, check to see if
the injection pump lever is at the idle position (with the
lever in contact with the stopper bolt).
• With the idling control knob turned fully to the right,
check to see if the number of the engine idling rotations
gets to 1,500 rpm or more.
AIR CLEANER ELEMENT
6C-83-1.tif
REMOVAL
1. Cover Wing Nut
2. End Cover
3. Filter Wing Nut
4. Air Cleaner Element
Clean
• Wipe out the inside of the Air cleaner assembly
• Wipe off the Cover
Inspection
• The air filter with a light for fears or holes.
6C-83-2.tif
Cleaning Method
Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
2
Compressed air pressure Kpa (Kg/cm /Psi)
392 - 490 (4 - 5/57 - 71)
6C-83-3.tif CAUTION
Do not bang the element against another object in an
attempt to clean it. Damage to the element will result.
Carbon and Dust Fouled Element

1. Prepare a cleaning solution of Isuzu Genuine Element
Cleaner (Donaldson D1400) diluted with water.
2. Submerge the element in the solution for twenty
minutes.
6C-84-1.tif
3. Remove the element from the solution and rinse it well

with running water.
Water pressure must not exceed 274 Kpa (2.8
2
kg/cm /40 Psi)
6C-84-2.tif
4. Dry the element in a well ventilated area.

An electric fan will hasten drying.
NOTE:
Do not use compressed air or an open flame to dry the
element quickly. Damage to the element will result.
It will usually take two or three days for the element to
dry completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.
6C-84-3.tif
INSTALLATION
3. Filter Wing Nut
2. End Cover
1. Cover Wing Nut
MEMO
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LG4H-WE-9691



Issued by
Tokyo, Japan
First edition Feb., 1999 9911-13K-1

No. HGSTG-WE-661 PRINTED IN JAPAN
WORKSHOP MANUAL
NHR • NKR • NPR
ENGINE
4J SERIES
SECTION 6
MEMO
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NOTICE

MANUAL”.
All material contained in this Manual is based on the latest

product information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model : NHR55. NKR55. NPR55. NPR69
This manual is applicable to 1994 year model and later vehicles.

00 Service Information
6A Engine Mechanical
6A1 4JB1/4JB1T/4JB1-TC/4JG2 Engine
6B Engine Cooling
6C Fuel System
6D Engine Electrical
6E Exhaust Gas Recirculation (EGR) System
6F Exhaust
6G Turbocharger
HOME
SERVICE INFORMATION 00 – 1
SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Troubleshooting .............................................................................................................. 00 - 2
Main Data and Specifications ......................................................................................... 00 - 30
Service Standard ............................................................................................................. 00 - 34
Servicing........................................................................................................................... 00 - 38
Fixing Torque ................................................................................................................... 00 - 51
Special Tools.................................................................................................................... 00 - 60
00 – 2 SERVICE INFORMATION
TROUBLESHOOTING
CONTENTS
PAGE
Hard Starting .................................................................................................................... 00 - 3
Starter Inoperative....................................................................................................... 00 - 3
Starter Motor Operates but Engine Does Not Turn Over ......................................... 00 - 3
Engine Turns Over but Does Not Start ...................................................................... 00 - 4
Quick-on Start System ................................................................................................ 00 - 5
Unstable Idling ................................................................................................................. 00 - 6
Insufficient Power............................................................................................................ 00 - 7
Excessive Fuel Consumption ......................................................................................... 00 - 9
Excessive Oil Consumption............................................................................................ 00 - 9
Overheating...................................................................................................................... 00 - 10
White Exhaust Smoke ..................................................................................................... 00 - 10
Dark Exhaust Smoke ....................................................................................................... 00 - 11
Oil Pressure Does Not Rise ............................................................................................ 00 - 11
Abnormal Engine Noise .................................................................................................. 00 - 12
Engine Knocking ......................................................................................................... 00 - 12
Gas Leakage Noise...................................................................................................... 00 - 12
Continuous Noise........................................................................................................ 00 - 12
Slapping Noise............................................................................................................. 00 - 13
Engine Cooling Trouble .................................................................................................. 00 - 14
Engine Electrical Part Trouble........................................................................................ 00 - 15
Turbocharger ................................................................................................................... 00 - 20
Lubrication Chart............................................................................................................. 00 - 29
1. HARD STARTING
1. STARTER INOPERATIVE
Checkpoint Possible cause Correction

Battery Loose battery cable terminal poor Clean and/or retighten the battery
connections due to rusting cable terminal
Battery discharged or weak Recharge or replace the battery
Fan belt loose or broken Adjust or replace the fan belt
Fusible link Fusible link shorted Replace the fusible link
Starter switch Defective starter switch or starter relay Replace the starter switch or the
Starter relay
Starter motor Defective magnetic switch or starter relay Repair or replace the magnetic switch
Defective starter motor Repair or replace the starter motor
2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

Battery Loose battery cable terminal Clean and/or retighten the battery
cable terminal
Poor connections due to rusting Recharge or replace the battery
Battery discharged or weak Recharge or replace the battery
Fan belt loose or broken Adjust or replace the fan belt
Starter Defective pinion gear Replace the pinion gear
Defective magnetic switch Repair or replace the magnetic switch
Brush wear, Weak brush spring Replace the brush and/or the brush
spring
Engine Piston, crank bearing seizure, or other Repair or replace the related parts
damage
3. ENGINE TURNS OVER BUT DOES NOT START

Engine stop Defective fuel cut solenoid valve Replace the fuel cut solenoid valve
mechanism
FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP

Fuel Fuel tank is empty Fill the fuel tank
Fuel piping Clogged or damaged fuel lines. Loose fuel Repair or replace the fuel lines
line connection Retighten the fuel line connection
Fuel filter Fuel filter overflow valve does not close Repair or replace the fuel filter
overflow valve
Clogged fuel filter element Replace the fuel filter element or the
filter cartridge
Fuel system Air in the fuel system Bleed the air from the fuel system
Fuel feed pump Defective feed pump Repair or replace the feed pump
FUEL IS BEING DELIVERED TO THE INJECTION PUMP

Fuel Use of the wrong fuel Use the correct fuel
Water particles in the fuel Change the fuel
Fuel system Air in the injection pump Bleed the air from the fuel system
Injection nozzle Injection nozzle sticking
Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Improper spray condition
Injection pump Defective fuel injection nozzle resulting in the Replace the delivery valve
fuel drippage after fuel injection
Defective injection pump control rack Repair or replace the injection pump
operation control rack
Injection pump plunger worn or stuck Replace the injection pump plunger
assembly
Injection pump drive shaft seizure or other Replace the injection drive shaft
damage
Injection pump governor spring seizure Replace the injection pump governor
spring
4. QUICK-ON START SYSTEM

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

Glow plug indicator Defective indicator light bulb Replace the indicator light bulb
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
Glow plug indicator Defective quick-on start timer Replace the quick-on start timer
light turns on the 0.3
seconds
Glow plug indicator Return the starter switch to the “ON” position Replace the quick-on start timer
light turns on for 3.5 from the “START” position after the engine
seconds starts if the glow plug relay remains on less
than 14 seconds, the quick-on start timer is
defective
Move the starter switch from the “OFF” Replace the quick-on start timer
position to the “ON” position if the glow plug
relay remains on less than 14 seconds, the
quick-on start timer is defective
Thermoswitch Defective thermoswitch Replace the thermoswitch
Glow plug continuity No glow plug continuity Replace the glow plugs
GLOW PLUGS ARE NOT RECEIVING POWER

Glow plug indicator Broken indicator light fuse Replace the fuse
light does not turn on
Quick-on start timer Defective quick-on start timer Replace the quick-on start timer
GLOW PLUGS ARE NOT RECEIVING POWER (Cont’d)

Glow plug indicator Defective glow plug relay Replace the glow plug relay
light turns on for 3.5 The glow plug relay does not turn on after the
seconds starter switch is moved from the “OFF”
position to the “ON” position
Defective quick-on start timer Replace the quick-on start timer
Defective glow plug relay wiring harness Repair or replace the wiring harness
Defective fusible link or wiring harness Replace the fusible link or the wiring
The glow plug relay turns on when the starter harness
switch is moved from the “OFF” position to
the “ON” position
2. UNSTABLE IDLING

Idling system Idling improperly adjusted Adjust the idling
Fast idling speed Defective fast idling speed control device Repair or replace the fast idling speed
control device
Accelerator control Accelerator control system improperly Adjust the accelerator control system
system adjusted
Fuel system Fuel system leakage or blockage Repair or replace the fuel system
Air in the fuel system Bleed the air from the fuel system
Water particles in the fuel system Change the fuel
Fuel filter Clogged fuel filter element Replace the fuel filter element or the
fuel filter cartridge
Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump
Injection nozzle Injection nozzle sticking Replace the injection nozzle
too low
Injection pump Defective delivery valve resulting in fuel Replace the delivery valve
drippage after fuel injection

Injection pump Injection timing improperly adjusted Adjust the injection timing
(Cont’d)
Insufficient injection volume Adjust the injection volume
Defective idle spring Replace the idle spring
Defective governor lever operation Repair or replace the governor lever
Regulator valve improperly adjustment Adjust or replace the regulator valve
Broken plunger spring Replace the plunger spring
Worn plunger Replace the plunger assembly
Worn cam disc Replace the cam disc
Valve clearance Valve clearance improperly adjusted Adjust the valve clearance
Compression pressure Blown out cylinder head gasket. Worn Replace the related parts
cylinder liner.
Piston ring sticking
3. INSUFFICIENT POWER

Air cleaner Clogged air cleaner element Clean or replace the air cleaner
element
Fuel Water particle in the fuel Replace fuel
Fuel filter Clogged fuel filter element Replace the fuel filter element or the
fuel filter cartridge
Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump
Injection nozzle Injection nozzle sticking Replace the injection nozzle
too low
Fuel injection pipes Fuel injection pipes damaged or obstructed Replace the fuel injection pipes

Injection pump Defective regulating valve Repair or replace the regulating valve
Defective delivery valve Replace the delivery valve
Defective timer Repair or replace the timer
Worn cam disc Replace the cam disc
Improper control lever operation Adjust or replace the control lever
Defective injection timing Adjust the injection timing

Repair or replace the injection pump
timer
Weak governor spring Replace the governor spring
Worn plunger Replace the plunger assembly
cylinder liner.
Valve spring Valve spring weak or broken Replace the valve spring
Exhaust system Exhaust pipe clogged Clean the exhaust pipe
Full load adjusting Open and improperly set adjusting screw Adjust and reseal the adjusting screw
screw seal seal
4. EXCESSIVE FUEL CONSUMPTION

Fuel system Fuel leakage Repair or replace the fuel system
related parts
element
Idling speed Poorly adjusted idling speed Adjust the idling speed
Injection nozzle Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing
Injection pump Defective Delivery valve resulting is fuel Replace the delivery valve
cylinder liner.
Valve spring Valve spring weak or broken Replace the valve spring
5. EXCESSIVE OIL CONSUMPTION

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

Cooling water Insufficient cooling water Replenish the cooling water
Fan clutch Oil leakage from the fan clutch Replace the fan clutch
Fan belt Fan belt loose or cracked causing slippage Replace the fan belt
Radiator Defective radiator cap or clogged radiator Replace the radiator cap or clean the
core radiator core
Water pump Defective water pump Repair or replace the water pump
Cylinder head and Defective sealing cap resulting in water Replace the sealing cap
cylinder body sealing leakage
cap
Thermostat Defective thermostat Replace the thermostat
Cooling system Cooling system clogged by foreign material Clean the foreign material from the
cooling system
Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing
7. WHITE EXHAUST SMOKE

Cooling water Insufficient cooling water Replace the cooling water
Fuel Water particles in the fuel Replace the fuel
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing
cylinder liner.
Inlet and exhaust valve Defective valve seals. Replace the valve seals, the valves,
Valves seals Worn valves stems and valve guides and the valve guides
8. DARK EXHAUST SMOKE

element
Injection nozzle Injection nozzle injection starting pressure Adjust or replace the injection nozzle
too low
Injection pump Defective delivery valve resulting in fuel Replace the delivery valve
Excessive injection volume Adjust the injection volume
9. OIL PRESSURE DOES NOT RISE

Engine oil Improper viscosity engine oil. Replace the engine oil
Insufficient engine oil Correct the engine oil volume
Oil pressure gauge or Defective oil pressure gauge or unit Repair or replace the oil pressure
unit gauge or unit
Oil pressure indicator Defective indicator light Replace the indicator light
light
Oil filter Clogged oil filter element Replace the oil filter element or the oil
filter cartridge
Relief valve and by- Relief valve sticking and/or weak by-pass Replace the relief valve and/or the by-
pass valve valve spring pass valve spring
Oil pump Clogged oil pump strainer Clean the oil pump strainer
Worn oil pump related parts Replace the oil pump related parts
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing
Camshaft Worn camshaft and camshaft bearing Replace the camshaft and the
camshaft bearing
Crankshaft and Worn crankshaft and bearings Replace the crankshaft and/or the
bearings bearings
10. ABNORMAL ENGINE NOISE
1. ENGINE KNOCKING
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

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

Exhaust pipes Loosely connected exhaust pipes. Broken Tighten the exhaust pipe connections
exhaust pipes Replace the exhaust pipes
Injection nozzles Loose injection nozzles and/or glow plugs Replace the washers
and/or glow plugs Tighten the injection nozzles and/or
the glow plugs
Exhaust manifold Loosely connected exhaust manifold and/or Tighten the exhaust manifold
glow plugs connections
Cylinder head gasket Damaged cylinder head gasket Replace the cylinder head gasket
3. CONTINUOUS NOISE
Fan belt Loose fan belt Readjust the fan belt tension
Cooling fan Loose cooling fan Retighten the cooling fan
Water pump bearing Worn or damaged water pump bearing Replace the water pump bearing
Generator or vacuum Defective generator or vacuum pump Repair or replace the generator or the
pump vacuum pump
Valve clearance Clearance improperly adjust Adjust the valve clearances

4. SLAPPING NOISE

Rocker arm Damaged rocker arm Replace the rocker arm
Flywheel Loose flywheel bolts Retighten the flywheel bolts
Crankshaft and thrust Worn or damaged crankshaft and/or thrust Replace the crankshaft and/or the
bearings bearings thrust bearings
Crankshaft and Worn or damaged crankshaft and/or Replace the crankshaft and/or the
connecting rod connecting rod bearings connecting rod bearings
bearings
Connecting rod Worn or damaged connecting rod bushing Replace the connecting rod bushing
bushing and piston pin and piston pin and/or the piston pin
Piston and cylinder Worn or damaged piston and cylinder liner. Replace the piston and the cylinder
liner liner.
11. ENGINE COOLING TROUBLE

Engine overheating Low coolant level Replenish
Thermo unit faulty Replace
Faulty thermostat Replace
Faulty coolant unit Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of improper Replenish or change oil

engine oil Replenish
Damaged cylinder head gasket Replace
Clogged exhaust system Clean exhaust system or replace

faulty parts
Loose fan belt Adjust
Excessive fuel injected Adjust
Improper injection timing Adjust
Engine overcooling Faulty thermostat Replace
Too long engine Faulty thermostat Replace

warm-up time
Thermo unit faulty Replace
12. ENGINE ELECTRICAL PART TROUBLE
STARTER DOES NOT RUN
CHECK BATTERY
CHARGING FAILURE OR LIFE BATTERY IS NORMAL
CHECK BATTERY
CHECK TERMINAL CONNECTION
CONNECTION FAILURE TERMINAL CONNECTION IS NORMAL
CLEAN BATTERY TERMINALS, AND RECONNECT CHECK STARTER OR STARTER SWITCH
FAILURE
REPAIR OR REPLACE
TURN ON HEAD LAMP AND STARTER SWITCH
HEAD LAMP DOES NOT COME ON HEAD LAMP ILLUMINATES

OR IT IS EXTREMELY DARK
a) DISCONNECT STARTER CIRCUIT

a) LACK OF BATTERY CHARGING b) DISCONNECT STARTER COIL
b) SHORT-CIRCUIT IN STARTER OIL c) FAULTY STARTER SWITCH
c) FAULTY STARTER PARTS
FAULTY MESHING OF PINION AND RING GEAR
CHECK IF BATTERY VOLTAGE IS PRESENT AT

MAGNETIC SWITCH TERMINAL “S” WHEN
STARTER SWITCH IS TURNED TO “START (ST)”
YES NO
OR
UNDER THIS CONDITION, CHECK IF VOLTAGE
OF CONNECTOR 3BW ON MAGNETIC SWITCH
OF RESTART RELAY IS NORMAL
EXTREME WEAR OF STARTER SLIDING
PINION AND RING RESISTANCE IS
GEAR LARGE
YES NO
REPAIR OR REPLACE REPAIR OR REPLACE
STARTER, REPLACE STARTER
RING GEAR
DISCONNECTION OR CHECK IF VOLTAGE IS
FAULTY CONNECTION PRESENT AT WIRING
BETWEEN STARTER CONNECTOR 3BW ON
SWITCH AND MAGNETIC STARTER SWITCH OF
SWITCH RESTART RELAY
REPAIR
YES NO
FAULTY CONNECTION OF DISCONNECTION OR

STARTER SWITCH FAULTY CONNECTION
BETWEEN STARTER
SWITCH AND BATTERY
REPLACE STARTER
SWITCH
REPAIR
MAGNETIC SWITCH DOES NOT OPERATE THOUGH

STARTER SWITCH IS TURNED TO “START (ST)”
CHECK IF VOLTAGE IS PRESENT AT MAGNETIC

SWITCH TERMINAL “S” WHEN STARTER SWITCH IS
TURNED TO “START (ST)”
YES
YES NO
CHECK GROUND CABLE CHECK IF INDICATOR LAMP ON

METER COMES ON NORMALLY
YES NO
YES NO
REPAIR
CHECK CONTINUITY DISCONNECTION OR
STARTER SWITCH AND FAULTY CONNECTION
OR MAGNETIC SWITCH BETWEEN BATTERY
TERMINAL “S” AND STARTER SWITCH
PINION MAGNETIC SWITCH

SLIDING OR COIL IS
PART DOES DISCONNECTED OR REPAIR
NOT MOVE BURNED OUT
CHECK STARTER FAULTY CONNECTION
RELAY OR STARTER SWITCH
REPAIR OR REPLACE STARTER CHECK CLUTCH REPLACE STARTER

START SWITCH
PINION MESHES WITH RING GEAR BUT

ENGINE DOES NOT RUN
CHECK GROUND CABLE
YES NO
REPAIR OR REPLACE
GROUND CABLE
FAULTY CONNECTION BURNED-OUT DISCONNECTION DISCONNECTION SLIP OF

OF BRUSH AND MAGNETIC OR DAMAGE OF OR DAMAGED OF PINION
COMMUTATOR STARTER SWITCH FIELD COIL ARMATURE COIL CLUTCH
REPAIR OR REPLACE STARTER

STARTER DOES NOT STOP THOUGH STARTER

SWITCH IS RETURNED TO “ON” FROM “START”
DISCONNECTED STARTER SWITCH WIRING CONNECTOR, AND CHECK STARTER SWITCH OPERATION.
KEY BATTERY IGNITION BATTERY ACCESSORIES IGNITION STARTER

POSITION B1 IG1 B2 ACC IG2 ST
LOCK
OFF
ACC
ON
START
THERE MUST BE NO CONTINUITY EXCEPT ABOVE LINES.
YES NO
MAGNETIC SWITCH CONTACTS ARE REPLACE STARTER SWITCH

FUSED AND NOT MOVED, OR A
RETURN SPRING IS BROKEN OR
DETERIORATED
REPLACE MAGNETIC SWITCH

13. TURBOCHARGER
1) ENGINE HAS LESS THAN NORMAL POWER
Checkpoint Trouble Cause Countermeasure
NG
Air cleaner Restricted Clean or replace
OK
NG
Intake pipe and hose Restricted Clean or replace
OK
NG
Compressor/Intake manifold Loose (Leaking) Repair
OK
NG
Exhaust manifold/turbine inlet Loose (Leaking) Repair
OK
NG
Exhaust piping and silencers Restricted Clean or replace
OK
NG
Air breather Restricted Clean or replace
OK
Boost compensator NG
Defective Repair or replace
(Injection pump)
Continued on the next page

Continued from the previous page

OK
NG
Compressor wheel Impact damage Replace
OK
NG
Turbine wheel Impact damage Replace
NG
Carbon build-up Replace
OK
NG
Rotating assembly Dragging or seized Replace
2) BLUE OR BLACK SMOKE
NG
Air cleaner or intercooler Restricted Clean, repair, or replace
OK
NG
Turbocharger oil seal Leakage Replace
OK
NG
Turbocharger oil drain pipe Restricted Repair or replace
OK
NG
Air breather Restricted Clean
OK
NG
Boost compensator Defective Repair or replace
(Injection pump)
OK
NG
OK
NG


OK
NG
Center housing oil drain passage Restricted Clean or replace
3) EXCESSIVE OIL CONSUMPTION
NG
Air breather Restricted Clean
OK
Boost compensator NG
Defective Repair or replace
(Injection pump)
OK
NG
Turbocharger oil seal Leakage Replace
OK
NG
Turbocharger oil drain pipe Restricted Clean or replace
OK
NG
OK
NG
OK
NG
Oil pressure Excessive Repair


OK
Center housing oil drain passage NG

Restricted Clean or replace
4) EXCESSIVE TURBOCHARGER NOISE
Intake and exhaust NG

Restricted Repair
system joints
OK
Intake and exhaust system NG

Damaged Replace
gaskets
OK
NG
Turbocharger rotating parts Rough rotation Replace
NG
Compressor wheel Rubbing against housing Repair or replace
NG
Damaged Replace
OK
NG
Turbine wheel Rubbing against housing Repair or replace
NG
Damaged Replace
NG
Carbon deposits Clean or replace


OK
NG
Oil level Too low Correct
NG
Contaminated Replace oil
OK
NG
Turbocharger oil feed pipe Restricted Repair or replace
OK
NG
Turbine housing Carbon deposits Clean
OK
NG
Compressor housing Dirty Clean
OK
NG
Turbine shaft bearings Worn Replace
5) EXCESSIVE ROTATING PART WEAR
NG
Engine oil Contaminated Change
NG
Wrong grade or type Change
OK
NG
Turbocharger oil feed pipe Restricted Clean or replace
OK
NG
Turbocharger oil seal Defective Replace
OK
NG
Center housing oil Restricted Clean or replace
drain passage
OK
NG
Turbine shaft Oil sludge and coking Replace
OK
NG
Engine lubrication system Inadequate oil supply Correct
LUBRICATION CHART
4JB1, 4JB1TC, 4JG2, Oil Filter & Oil Cooler
2
kPa (Kg/cm /psi)
! Oil filter relief valve opening pressure : 559 - 0618 (5.7 - 6.3/81 - 90)
" Oil cooler safety valve opening pressure : 314 - 373 (3.2 - 3.8/46 - 54)
# Oil filter safety valve opening pressure : 78 - 118 (0.8 - 1.2/11 - 19)
$ Oil pressure switch opening pressure : 29.4 - 49.0 (0.3 - 0.5/4.3 - 7.1)
Lubu Chart 5J.tif
The 4J Series engine lubricating system is a full flow type.

Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter
(replaceable type oil filters have on oil cooler). It is then delivered to the vital parts of the engine from the cylinder
body oil gallery.

Engine Model 4JB1 / 4JB1T / 4JB1TC 4JG2 (G. EXP & EC)
Item
Engine type Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection In direct injection
Cylinder liner type Dry type, chrome plated, stainless steel tube
Timing train system Gear drive Gear and Belt Drive
No. of cylinders - Bore x stroke mm (in) 4 - 93 x 102 4 - 95.4 x 107
(3.66 x 4.02) (3.76 x 4.21)
No. of piston rings Compression rings: 2 / Oil ring: 1
3 3
Total piston displacement cm (in ) 2,771 (169.0) 3,059 (186.6)
Compression ratio (to 1) 18.2 (4JB1) 20.1
18.1 (4JB1T/4JB1TC)
2
Compression pressure kPa (kg/cm /psi) 3,038 (31 / 441) 3,334 (34 / 483.8)
(For EC 2,363 (24.1 / 531))
Engine weight (Dry) N (kg/lb) Approximately Approximately
2,245 (229 / 505) (4JB1) 2,403 (245 / 540)
2,511 (256 / 564)
(4JB1T/4JB1TC)
Fuel injection order 1-3-4-2
Fuel injection timing deg BTDC 14 (4JB1) ATDC 1 (Belt ’91/542A)
BTDC 12 (’91/542A) (4JB1) TDC 0° (Belt ’91/542B)
BTDC 11 (4JB1T) ATDC 2 (Gear ’91/542A)
BTDC 4 (4JB1TC)
Specified fuel type SAE No. 2 diesel fuel
Idling speed rpm 750 - 790 700 – 740
Valve clearances (At cold): Intake mm(in) 0.40 (0.016)
Exhaust mm(in) 0.40 (0.016)
Valve clearances (At hot): Intake mm(in) 0.45 (0.018)
Exhaust mm(in) 0.45 (0.018)
Intake valves Open at (BTDC) deg 24.5
Close at (ATDC) deg 55.5
Exhaust valves Open at (BTDC) deg 54
Close at (ATDC) deg 26
NOTE: G.EXP : General Export Model

EC : European Countries
Emission Gas Control Standard
’91/542A : Euro 1
’91/542B : Euro 2
Engine Model 4JB1 / 4JB1T / 4JB1TC 4JG2 (G. EXP & EC)
Item
Lubricating system
Lubrication method Pressurized circulation
Specified engine oil (API grade) CC (4JB1) CC
CD (4JB1T/4JB1TC)
Oil pump type Gear
Oil filter type Disposable cartridge (Spin-on) Paper element
Oil capacity (Including oil filter)
lit (US/UK gal) 6.6 - 7.1 (1.74 - 1.87/2.62 - 2.82)
(For EC 6.2 - 8.2 (2.17 - 1.64 / 1.36 - 1.80))
Oil cooler type Water cooled
Fuel system
Injection pump type Bosch distributor
Governor type Mechanical (Partially variable speed) (For EC Variable speed)
Injection nozzle type Hole Pinttle
2
Injection nozzle kPa (kg/cm /psi) 18,142 (185 / 2,631) 14,710 (150/2,133)
opening pressure (4JB1/4JB1T)
1st: 19,500 (199 / 2,830)
2nd: 26,500 (270 / 3,840)
(4JB1TC)
Main fuel filter type Cartridge paper element and water separator
Air cleaner type Dry paper element
Generator capacity V-A (W) 12 - 40 (480) and 12 - 50 (600) 12 - 50 (600)
(For EC 12 - 60 (720))
Starter motor output V-kW 12 - 2.0 and 12 - 2.2 12 - 2.2
(For EC 12 - 2.0)
Turbocharger IHI RHB5 (4JB1T)
IHI RHF4 (4JB1TC)
Engine Cooling
Cooling system Coolant forced circulation

Radiator (2 tube in row) Tube type Corrugated
Heat radiation capacity kcal/h 71400
2 2
Heat radiation area m (ft ) 11.78 (126.8)
2 2
Front area m (ft ) 0.216 (2.325)
Dry weight N (Kg/lb) 105 (10.7/23.6)
Radiator cap
2
Valve opening pressure kPa (Kg/cm /psi) 88.2 - 116.7 (0.899 - 1.199/12.78 - 17.05)
Coolant capacity lit (Imp.qt./US qt.) 3.1 (2.73/3.28)
(For EC 5.8 (5.1/6.13))
Coolant pump
Pulley type Centrifugal impeller type
Pulley ratio 1.2
Thermostat type wax pellet with jiggle valve.
Without jiggle valve (Thailand only)
Valve opening °C (°F) 82 (180)
Valve full open °C (°F) 95 (203)
Coolant total capacity Iit (Imp.qt./US qt.) 10 (8.80/10.57) (For EC 7.3 (6.42/7.71))
Starting System
Manufacturer DENSO
Engine Model 4JB1 / 4JB1T / 4JB1TC 4JG2 (G.EXP & EC)
Rating
Voltage V 12
Output kW 2.0 2.2
Time Sec 30
Number of tooth of pinion 9
Rotating direction (as viewed from pinion) Clockwise
Weight (approx.) kg 4.6 5.4
No-load characteristics
Voltage/current V/A 11.5/100 or less
Speed rpm 3700 or more
Load characteristics
Voltage/current V/A 7.5/500 or less
Torque N•m(Kg•m/lb•ft) 13.7 (1.4/10.1)
Speed rpm 1200 or more 1400 or more
Locking characteristics
Voltage/current V/A 2.4/800 or less 2.0/850 or less
Torque N•m(Kg•m/lb•ft) 18 (1.8/13) or more 16 (1.6/12) or more
Charging System
Manufacturer HITACHI LR150-449B DENSO
Rated voltage V 12 12
Rated output A 50 40
Rotating direction
Clockwise Clockwise
(As viewed from pulley)
Pulley effective diameter mm (in) 80 (3.15) 82 (3.23)
Weight (with pump) kg (lb) 6.0 (13.27) 6.7 (14.77)
4JB1TC for G.E 4JB1TC for Thailand
4JB1TC for EC
SERVICE STANDARD
Engine Mechanical mm (in)
Service standard Service limit

Parts Items 4JB1 / 4JB1T / 4JB1 / 4JB1T / Remarks
4JG2 4JG2
4JB1TC 4JB1TC
Cylinder Cylinder head deck, and
Head exhaust manifold mating 0.05 (0.002) or less 0.2 (0.0079)
surface for flatness
Cannot be
Cylinder head height 92.0 (3.622) 91.55 (3.6043) Reground
Cylinder Head Lower Face 0.05 (0.002)or less 0.20 (0.008)

Warpage.
Manifold Warpage. 0.05 (0.002) or less 0.20 (0.008)
Hot plug sinking - 0.02 (0.0008)
Hot plug exert pressure 4,500 – 5,500 kg

(9922.5 - 12127.5 lbs) -
Valve Free height 48.0 (1.891) 47.10 (1.856)
Spring
Squareness - 1.7 (0.067)
Spring tension N (kg/lb) 296 (30.2/66.4) 257.9 (26.3/57.9) At installed

height
38.9 (1.531)
Valve Diameter Valve Stem
and IN 7.946 - 7.961 7.880 (0.3102)
Valve (0.3128 - 0.3134)
Guide EX 7.921 - 7.936 7.850 (0.3090)
(0.3118 - 0.3124)
Valve and valve guide
clearance IN 0.039 - 0.069 0.200 (0.0079)
(0.0015 - 0.0027)
EX 0.064 - 0.096 0.250 (0.0098)
(0.0025 - 0.0038)
Valve guide upper end
height (Measured from the 13.0 (0.512) -
Cylinder head upper face)
Valve guide margin 1.1 (0.0433) 1.6 (0.0630)
Valve thickness IN 1.41 (0.0556) 1.79 (0.0705) 1.1 (0.0433) 1.5 (0.06)
EX 1.39 (0.0547) 1.83 (0.0720) 1.1 (0.0433) 1.5 (0.06)
Valve seat contact surface 45°

angle
Valve seat contact width

IN 1.7 (0.0669) 2.2 (0.0866)
EX 2.0 (0.0787) 2.5 (0.0984)

mm (in)
4JG2 4JG2
4JB1TC 4JB1TC
Push rod Curvature - 0.4 (0.0157) or less
Camshaft End play 0.08 (0.0031) 0.2 (0.0079)
Cam lobe height 42.02 (1.6543) 41.65 (1.6397)
Journal diameter 49.945 - 49.975(1.9663-1.9675) 49.60 (1.9527)
Runout 0.02 (0.0008) or less 0.10 (0.0039)
Camshaft bearing inside 50.000 - 50.030 50.08(1.9716)

diameter (1.9685 - 1.9697)
Camshaft oil clearance 0.025 - 0.085 0.12 (0.0047)

(0.0098 - 0.00334)
Tappet Outside diameter 12.97 - 12.99 (0.5106 - 0.5114) 12.95 (0.5098)
Oil clearance
(Between tappet and 0.03 (0.0118) 0.10 (0.0039)
cylinder body)
Rocker Rocker shaft outside 18.98 - 19.00 18.90 (0.7440)
arm diameter (0.7472 - 0.7480)
Assembly
Rocker arm inside 19.036 - 19.060 19.10 (0.7520)
diameter (0.7494 - 0.7504)
Oil clearance 0.06 - 0.08

(Between rocker arm and (0.00235 - 0.00315) 0.10 (0.004)
rocker shaft)
Rocker shaft runout - 0.2 (0.0079) or less

Oil pump Oil clearance 0.14 (0.0055) 0.13 - 0.14 0.20 (0.0079) 0.15 (0.0059)
Body and gear (0.0051-0.0055)
Body cover and gear 0.06 (0.0024) 0.02 - 0.07 0.15 (0.0059)
(0.0008-0.0028)
Crankshaft Thrust clearance 0.10 (0.0039) 0.30 (0.018)
Main bearing clearance 0.031-0.063 0.035-0.080 0.11

(Between main bearing (0.0012-0.0025) (0.0014-0.0032) (0.0043)
and Crankshaft)
Crankshaft runout 0.05 (0.00197) or less 0.08 (0.0031)
Main journal diameter 69.917 - 69.932 (2.7526 - 2.7532) 69.91 (2.7524)
Crankshaft pin diameter 52.915 - 52.930 (2.0833 - 2.0839) 52.90 (2.0827)
Crankshaft Journal and 0.05 (0.002) or less 0.08 (0.003)

Crank Pin uneven wear
Crank Pin and Bearing 0.029 - 0.066 (0.0011 - 0.0026) 0.100 (0.0039)
Clearance.
mm (in)
4JG2 4JG2
4JB1TC 4JB1TC
Piston, Piston diameter 95.365 - 95.404 92.985 - 93.024 -
Piston (3.7545-3.9039) (3.6600-3.6623)
pin, Piston Clearance 0.047 - 0.065 0.025 - 0.045 -
Piston (Between piston and (0.0019-0.0026) (0.0010-0.0018)
ring and Cylinder liner)
Connect-
ing rod Piston ring gap 1st 0.20 - 0.35 0.20 - 0.40 1.5 (0.0591)
(0.0079 – (0.0079 –
0.0138) 0.0157)
2nd 0.37 - 0.52 0.20 - 0.40 1.5 (0.0591)

(0.0146 - (0.0079 -
0.0205) 0.00157)
Oil 0.20 - 0.40 0.10 - 0.30 1.5 (0.0591)

(0.0079 - (0.0039 -
0.00157) 0.0118)
Piston ring clearance 1st 0.09 - 0.13 0.090 - 0.125

(0.0035 - (0.0035 -
0.0051) 0.0049)
2nd 0.05 - 0.09 0.050 - 0.075 0.15 (0.0059)

(0.002 - (0.0020 -
0.0035) 0.0030)
Oil 0.03 - 0.07 0.15 (0.0059)

(0.0012 - 0.0028)
Piston pin diameter 33.995 - 34.000 30.995 - 31.000 33.970 30.970
(1.3384-1.3386) (1.2202-1.2204) (1.3374) (1.2190)
Fitting interference 0.008 - 0.020 0.05 (0.0020)

(Between connecting (0.0003 - 0.0008)
rod and piston pin)
Fitting interference 0.002 - 0.015 0.04 (0.0016)

(Between piston and (0.0001 - 0.0006)
piston pin)
Connecting rod
alignment Bend 0.08 (0.0031) or less 0.20 (0.0079) Per 100
(3.94)
Twist 0.05 (0.0020) or less 0.15 (0.0059) Per 100

(3.94)
Piston pin and Connecting 0.008 - 0.020 0.050 (0.0020)
Rod Bushing Clearance (0.0003 - 0.0008)
Connecting rod thrust 0.230 (0.0091) 0.35 (0.0138)

clearance
Oil clearance 0.029 -0.083 0.029 - 0.066 0.100 (0.0039)

(Between crank pin and (0.0014 - (0.0011 -
Connecting rod) 0.0033) 0.0026)
mm (in)
4JG2 4JG2
4JB1TC 4JB1TC
Cylinder Warpage - 0.20 (0.0079)
Block (Upper surface of the
cylinder block)
Cylinder bore diameter 97.000 - 97.040 95.011 - 95.040

(3.8189 - (3.7406 -
3.8205) 3.7417)
Cylinder liner projection 0.0-0.1

(0.00-0.0039)
Cylinder liner inside 95.420 - 95.460 93.020 - 93.060

diameter (3.7567 - (3.6622 -
3.7583) 3.6638)
Cylinder liner outside 97.011-97.050 95.011 - 95.050

diameter (3.8193 - (3.7405 -
3.8209) 3.7421)
SERVICING
Servicing refers to general maintenance procedures to be
performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the front left hand side
of the cylinder body.
0038-1.tif
AIR CLEANER
Dry Type Paper Element
Element cleaning procedures will vary according to the
condition of the element.
Dust fouled Element

Rotate the element with your hand while applying
compressed air to the inside of the element. This will
blow the dust free.
2
Compressed air pressure kPa (kg/cm /Psi)
392 - 490 (4 - 5/57 - 71)
0038-2.tif
CAUTION

minutes.
0038-3.tif
3. Remove the element from the solution and rinse it

well with running water.
2
Water pressure must not exceed 274 kPa (2.8 kg/cm
/40Psi)
0039-1.tif

NOTE:
Do not use compressed air or an open flame to dry
the element quickly. Damage to the element will
result. It will usually take two or three days for the
element to dry completely. Therefore, it is a good idea
to have a spare on hand to use in the interim.
0039-2.tif
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
1. Loosen the used oil filter by turning it
2. Clean the oil filter fitting face.
This will allow the new oil filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
5. Use the filter wrench to turn in the filter an additional 1
and 1/4 turns.
Filter Wrench : 5-8840-0200-0 (89mm/3.5in)
5-8840 0202-0 (106mm/4.2in)
050LX001.tif 5-8840-2209-0 (100.6mm/4.0in)
6. Check the engine oil level and replenish to the

specified level if required.
Replenishment Engine Oil lit (Imp qt/US qt)
0.7 (0.62/0.74)
7. Start the engine and check for oil leakage from the
main oil filter.
0039-4.tif
FUEL SYSTEM
Fuel Filter
1. Loosen the used fuel filter by turning it
Filter Wrench: 5-8840-0253-0 (J-22700)
0040-1.tif
2. Clean the filter cover fitting faces.

This will allow the new fuel filter to seat properly.
0040-2.tif
3. Turn in the fuel filter until the sealing face comes in

contact.
4. Turn in the fuel filter an additional 2/3 of a turn with a
filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
0040-3.tif
5. Loosen the bleeder plug on the injection pump

overflow valve.
6. Operate the priming pump until fuel begins to flow
from the fuel filter.
7. Retighten the bleeder plug.
8. Operate the priming pump several times and check
for fuel leakage.
NOTE:
The use of an ISUZU genuine fuel filter is strongly
recommended.
0040-4.tif
Fuel Filter Water Draining Procedure

The indicator light will come on when the water level in
the water separator exceeds the specified level.
Drain the water and foreign material from the water
separator with the following procedure.
0041-1.tif
1. Find a safe place to park the vehicle.

2. Open the engine hood and place a container
(Approximately 0.2 liter capacity) at the end of the
vinyl hose beneath the drain plug on the separator.
3. Loosen the drain plug by turning it counterclockwise
(Approximately 5 turns) and operate the priming pump
up and down about 10 times until water is drained
approximately 0.1 liter.
4. After draining, securely tighten the drain plug by
turning it clockwise and operate the priming pump
0041-2.tif manually up and down several times.
5. After starting the engine, check to see that there is no
fuel leak from the drain plug. Also check to see that
the fuel filter water indicator light has turned off.
If water separator requires frequent draining, have the
fuel tank drained for removal of water at your Isuzu
Dealer.
Air Bleeding
1. Loosen the bleeder screw on the injection pump
overflow valve.
2. Operate the priming pump until fuel mixed with foam
flows from the bleeder screw.
3. Tighten the bleeder screw.
4. Operate the priming pump several times and check
for fuel leakage.
0041-3.tif
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.
0041-4.tif
Engine coolant change procedure

1. To change engine coolant, make sure that the engine
is cool.
WARNING:
When the coolant is heated to a high
temperature, be sure not to loosen or remove
the radiator cap. Otherwise you might get
scalded by hot vapor or boiling water. To open
the radiator cap, put a piece of thick cloth on the
0042-1.tif
cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
2 Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE:
For best result it is suggested that the engine
cooling system be flushed at least once a year.
it is advisable to flush the interior of the cooling
system including the radiator before using anti-
freeze (ethylene-glycol based).
Replace damaged rubber hoses as the engine
anti-freeze coolant is liable to leak out even
minor cracks. Isuzu recommends to use lsuzu
genuine anti-freeze (ethylene-glycol based) or
equivalent, for the cooling system and not add
any inhibitors or additives.
CAUTION:
A failure to correctly fill the engine cooling
system in changing or topping up coolant may
sometimes cause the coolant to overflow from
the filler neck even before the engine and
radiator are completely full. If the engine runs
under this condition, shortage of coolant may
possibly result in engine overheating. To avoid
such trouble, the following precautions should
be taken in filling the system.
3 To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter of the filler neck.
Othewise air between the filler neck and the filling
hose will block entry, preventing the system from
completely filling up.
4 Keep a filling rate of 9 liter/min. or less. Filling over
this maximum rate may force air inside the engine
and radiator. And also, the coolant overflow will
increase, making it difficult to determine, whether or
not the system is completely full.
5 After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
dislodged and the coolant level goes down. Should
the coolant level go down, repeat topping-up until
there is no more drop in the coolant level.
6 After directly filling the radiator, fill the reservoir to the
maximum level.
7 Install and tighten radiator cap and start the engine.
After idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
WARNING:
When the coolant is heated to a high
temperature, be sure not to loosen or remove
the radiator cap. Otherwise you might get
scalded by hot vapor or boiling water. To open
the radiator cap, put a piece of thick cloth on the
cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
8 After tightening radiator cap, warm up the engine at
about 2,000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
circulate also into heater water system.
9 Check to see the thermostat has opened through the
needle position of water thermomete, conduct a

5 minutes idling again and stop the engine.
10 When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, Check the
coolant system and reservoir tank hose for leakage.
11 Fill the coolant into the reservoir tank up to “MAX”
line.
Cooling System Inspection
Install a radiator filler cap tester to the radiator. Apply testing
pressure to the cooling system to check for leakage.
The testing pressure must not exceed the specified pressure.
2
Testing Pressure kPa (Kg/cm /psi)
147 (1.5/21)
0042-2.tif
Radiator Cap Inspection

The radiator filler cap is designed to maintain coolant
2
pressure in the cooling system at 1.05 kg/cm (15 psi / 103
kPa). Check the radiator filler cap with a radiator filler cap
tester. The radiator filler cap must be replaced if it fails to
hold the specified pressure during the test procedure.
Radiator Filler Cap Pressure
2
Pressure Valve kPa (Kg/cm /psi)
88 - 118 (0.9 - 1.2/12.8 - 17.1)
2
0042-3.tif
Negative Valve (Reference) kPa (Kg/cm /psi)
1.0 - 13.9 (0.01 - 0.04/0.14 - 0.57)
Thermostat Operating Test

1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly by suitable wood bar (2) to
avoid direct heat being applied use wood plate (3) to
the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial
Opening Temperature °C (°F)
82 (180)
0042-4.tif
4. Check the thermostat full opening temperature.

Thermostat Full
Opening Temperature °C (°F)
95 (203)
Valve Lift at Fully Open Position mm (in)

10 (0.39)
Drive Belt Adjustment

Depress the drive belt mid portion with a 98N (10 kg/22
lb) force.
Drive Belt Deflection mm (in)
10 (0.39)
Check the drive belt for cracking and other damage.

1. Crankshaft damper pulley
2. Generator pulley
0043-1.tif
3. Cooling fan pulley
4. Oil pump pulley or idler pulley
5. Compressor pulley or idle pulley
Cooling Fan Pulley Drive Belt

Fan belt tension is adjusted by moving the generator.
lb) force.
2. Generator pulley
3. Cooling fan pulley
0043-2.tif
Compressor Pulley Drive Belt

Move the idler pulley as required to adjust the compressor
drive belt tension.
If the vehicle is equipped with power steering, move the
oil pump as required.
lb) force.
Belt Deflection mm (in)
14 - 17 (0.55 - 0.67)
0043-3.tif

2. Oil pump pulley or idler pulley
Power Steering Oil Pump Pulley Drive Belt

Move the oil pump as required to adjust the oil pump drive
belt tension.
On air conditioner equipped models, both drive belts
pulley must always be replaced as a set.
lb) force.
Belt Deflection mm (in)
14 - 17 (0.55 - 0.67)
0043-4.tif

2. Oil pump pulley
3. Compressor pulley or idler pulley
ENGINE CONTROL
Idling Speed Inspection
1. Set the vehicle parking brake and choke the drive
wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to warm up.
4. Disconnect the engine control cable from the control
lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed rpm
4JB1 / 4JB1T / 4JB1TC 750 - 790
4JG2 700 - 740
Idling Speed Adjustment

1. Loosen the idling set bolt lock nut on the injection
pump idling set bolt.
2. Adjust the idling speed to the specified range by
turning the idling set bolt.
3. Lock the idling set bolt with the idling set bolt lock nut.
4. Check that the idling control cable is tight (free of
slack).
If required, remove the slack from the cable.
0044-1.tif
Accelerator Control Cable Adjustment

1. Loosen the accelerator cable clamp bolt.
2. Check that the idling control knob on the instrument
panel is in the engine idling position.
3. Hold the accelerator lever in the fully closed position
and stretch the control cable in the direction indicated
by the arrow to remove any slack.
Accelerator Pedal Adjustment

1. Loosen the lock nut.
2. Adjust bolt height from floor.
Adjust Bolt Height A mm (in)
18 - 28 (0.71 - 1.1)
0044-2.tif
1. Hold the accelerator pedal pad securely by hand, and

give it a full stroke.
2. Adjust the stopper bolt so that the clearance between
the pad stopper bolt and the rear side of the pad
becomes the specified length.
mm (in)
0 - 2 (0 - 0.079)
3. Check to see if the accelerator pedal play is in the

0045-1.tif
range of 5 to 10mm above the pedal pad.
4. Press down on the accelerator pedal fully and check
to see if the engine rotates at its maximum speed with
each of the linkage in the smooth operation.
5. In the operating range of accelerator pedal and the
injection pump lever returns to their respective original
positions without fail.
VALVE CLEARANCE ADJUSTMENT

1. Bring the piston in either the No. 1 cylinder or the No.
4 cylinder to TDC on the compression stroke by
turning the crankshaft until the crankshaft damper
pulley TDC line is aligned with the timing pointer.
0045-2.tif
2. Check the rocker arm shaft bracket nuts for

looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.
Rocker Arm Shaft
Bracket Nut Torque N∙m (kg∙m/lb∙ft)
54 (5.5/40)
0045-3.tif
3. Check for play in the No. 1 intake and exhaust valve

push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.
0045-4.tif
Adjust the No. 1 or the No. 4 cylinder valve clearance

while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)
4. Loosen each valve clearance adjusting screw as
shown in the illustration.
5. Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.
0046-1.tif
6. Turn the valve clearance adjusting screw until a slight

drag can be felt on the feeler gauge.
7. Tighten the lock nut securely.
8. Rotate the crankshaft 360°.
9. Realign the crankshaft damper pulley TDC notched
line with the timing pointer.
10. Adjust the clearance for the remaining valves as
0046-2.tif

1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing gear
case notched line.
0046-3.tif
2. Bring the piston in the No. ! cylinder to TDC 1 on the

compression stroke by turning the crankshaft until the
crankshaft pulley TDC line is aligned with the timing
mark ".
Note:
Check for play in the No. 1 intake and exhaust valve
push rods.
rods have play, the No. 1 piston is at TDC on the
compression stroke.
0046-4.tif
3. Disconnect the injection pipe from the injection pump.

4. Remove one bolt from the distributor head.
5. Insert a screwdriver into a hole in the fast idle lever
and turn the lever to release the W-C.S.D. function. (If
so equipped)
6. Install the static timing gauge #.
The probe of the gauge should be depressed inward
approximately 2 mm (0.079 in).
Static Timing Gauge : 5-8840-0145-0 (J-28827)
0046-5.tif
7. Rotate the crankshaft to bring the piston in the No. 1

cylinder to a point 30 - 40° BTDC.
8. Set the timing gauge needle to zero.
9. Move the crankshaft pulley slightly in both directions
to check that the gauge indication is stable.
0047-1.tif
10. Turn the crankshaft clockwise and read the gauge

indication when the crankshaft pulley timing mark is
aligned with the pointer.
mm (in)
4JB1 BTDC 14°
4JB1T BTDC 11°
4JB1TC BTDC 4°
4JG2 ATDC 2°
0047-2.tif
Standard Reading mm (in)
0.5 (0.02)
If the injection timing is outside the specified range,

continue with the following steps.
11. Loosen the injection pump fixing nuts and bracket

bolts.
12. Adjust the injection pump setting angle.
When large than When smaller than
standard value standard value
Gear drive A B
A : Move the injection pump toward the engine.

B : Move the injection pump away from the engine.
0047-3.tif Tighten the pump fixing nut, adjust bolt and pump
distributor head plug to the specified torque.
Pump Fixing Bolt N∙m (kg∙m/lb∙ft)
24 (2.4/17)
Adjust Bolt N∙m (kg∙m/lb∙ft)

19 (1.9/14)
Injection Pump
Distributor Head Plug N∙m (kg∙m/lb∙ft)
17 (1.7/12)
CAUTION
• When installing the distributor head/plug, be sure
to use new copper washer.
COMPRESSION PRESSURE MEASURE-

MENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 - 80°C (158 - 176°F).
2. Remove the following parts.
* Glow plugs
* Fuel cut solenoid connector
* QOS (Quick-On Start System) fusible link wire at
0048-1.tif the connector.
3. Set the adapter and compression gauge to the No. 1
cylinder glow plug hole.
Compression Gauge
(with Adapter): 5-8840-2008-0 (J-29762)
Adapter: 5-8531-7001-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
2
Compression Pressure at 200 rpm kPa (Kg/cm /psi)
Standard Limit
4JB1 3,038 (31/441) 2,157 (22/313)
4JG2 3,334 (34/484) 2,452 (25/356)
5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.
0048-2.tif
If the measured value is less than the specified limit,
refer to “Troubleshooting” in this Manual.
QUICK-ON START II SYSTEM

(4JB1 / 4JB1T / 4JB1TC only)
Quick-On Start System Inspection Procedure
1. Disconnect the thermo-sensor connection on the
thermostat outlet pipe.
2. Turn the starter switch to the “ON” position.
If the Quick-On Start II System is operating properly,
the glow relay will make a clicking sound within 15
0048-3.tif
seconds after the starter switch is turned on.
3. Measure the glow plug terminal voltage with a circuit
tester immediately after turning the starter switch to
the “ON” position.
Glow Plug Terminal Voltage V
Approx. 11
0048-4.tif
QUICK-ON START III SYSTEM

(4JG2 only)
Quick-On Start System Inspection Procedure
1. Disconnect the thermo-sensor connection on the
thermostat outlet pipe.
2. Turn the starter switch to the “ON” position.
If the Quick-On Start III System is operating properly,
the glow relay will make a clicking sound within seven
0049-1.tif
seconds after the starter switch is turned on.
3. Measure the glow plug terminal voltage with a circuit

tester immediately after turning the starter switch to
the “ON” position.
Glow Plug Terminal Voltage V
8–9
NOTE:
Electrical power to the quick-on start system will be
cut after the starter has remained in the “ON”
0049-2.tif position for twenty seconds.
Turn the starter switch to the “OFF” position and
back to the “ON” position.
This will reset the Quick-On Start III System.
FIXING TORQUE
CYLINDER HEAD COVER, CYLINDER HEAD ROCKER,
SHAFT BRAKER N∙m (kg∙m/lb∙ft)
011LX002.tif
Crankshaft, Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper

Pulley, Flywheel, Oil Pan N∙m (kg∙m/lb∙ft)
0051-1.tif
Timing Pulley Housing, Timing Pulley, Timing Gear,

Camshaft Oil Seal Retainer N∙m (kg∙m/lb∙ft)
014LX001.tif
Cooling System and Lubrication System N∙m (kg∙m/lb∙ft)

Intake Manifold, Exhaust Manifold, Exhaust Pipe N∙m (kg∙m/lb∙ft)
150LX004.tif
036LX003.tif
Engine Electricals N∙m (kg∙m/lb∙ft)
0056-1.tif
Engine Fuel N∙m (kg∙m/lb∙ft)
0057-1.tif
Engine Mounting Bracket N∙m (kg∙m/lb∙ft)
0058-1.tif
SPECIAL TOOLS
5-8840-2035-0 Crank Timing Pulley (4JG2 Belt Drive only)
5-8840-0200-0 Oil Filter Wrench (89.0 mm/3.5 in)
9-8523-1423-0 (J-29760) Valve Spring Compressor
5-8840-2033-0 Oil Seal Installer
5-8840-9018-0 Piston Ring Compressor
5-8840-2093-0 Tacho Meter
9-8523-1212-0 Valve Guide Replacer
Camshaft Timing Pulley Remover

5-8840-0086-0
(4JG2 Belt Drive only)
5-8840-0199-0 Rubber Hardness Tester

SPECIAL TOOLS (CONT.1)

5-8840-2675-0 Compression gauge
5-8531-7001-0 Gauge Adapter
5-8531-7002-0 Gauge Adapter
5-8840-0145-0 Measuring Device
Crankshaft Timing Pulley Installer

5-8522-0024-0
(4JG2 Belt Drive only)
5-8840-0266-0 Angle Gauge
5-8840-9016-0 Injection Nozzle Tester
5-8840-2034-0 Nozzle Holder Remover (4JB1 only)
5-8840-2038-0 Camshaft Bearing Replacer
Front Oil Seal Installer

5-8840-2036-0
(4JB1, 4JG2, Gear Drive only)
SPECIAL TOOLS (CONT.2)

LLUSTRATION TOOL NO. TOOL NAME
5-8840-0259-0 Nozzle Holder Wrench (4JG2 only)
5-8840-0253-0 (J-22700) Fuel Filter Wrench
5-8840-2362-0 Front Oil Seal Remover (4JG2, Belt Drive only)
5-8840-2361-0 Front Oil Seal Installer (4JG2, Belt Drive only)
5-8840-2360-0 Rear Oil Seal Remover
5-8840-2359-0 Rear Oil Seal Installer
5-8840-2040-0 Cylinder Liner Installer (4JB1 only)
5-8840-2313-0 Cylinder Liner Installer (4JG2 only)
5-8840-2039-0 Cylinder Liner Remover (4JB1 only)
5-8840-2304-0 Cylinder Liner Remover Ankle (4JG2 only)
5-8840-2000-0 Pilot Bearing Remover
5-8840-0019-0 Sliding Hammer
5-8522-0024-0 Pilot Bearing Installer

MEMO
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HOME
GENERAL ENGINE MECHANICAL 6A – 1
SECTION 6A
GENERAL ENGINE MECHANICAL
CONTENTS
PAGE
Cylinder Head................................................................................................................. 6A - 2
Valve Spring, Valve Guide Oil Seal, Valve Guide, Push Rod ..................................... 6A - 10
Camshaft, Tappet........................................................................................................... 6A - 17
Rocker Arm Assembly................................................................................................... 6A - 24
Oil Pump ......................................................................................................................... 6A - 27
Crankshaft ...................................................................................................................... 6A - 31
Piston and Connecting Rod.......................................................................................... 6A - 47
Cylinder Block................................................................................................................ 6A - 56
6A – 2 GENERAL ENGINE MECHANICAL
CYLINDER HEAD
Disassembly steps
1. Thermostat housing Assembly
2. Injection nozzle holder (4JG2)
2a. Injection nozzle holder (4JB1・
(4JB1)
4JB1TC)
3. Glow plug and plug connector
(4JG2)
3a. Glow plug and plug connector
(4JB1・4JB1TC)
4. Rocker arm shaft and rocker arm
5. Push rod
6. Cylinder head
Reassembly steps
To reassemble, follow the
disassembly steps in the reverse
order.
6A-2-1.tif
NOTE:
• During disassembly, be sure that the valve train
components are kept together and identified so
that they can be re-installed in their original
locations.
• Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
make a compression test and note the results.
DISASSEMBLY
1. Thermostat Housing Assembly
2. Injection Nozzle Holder (4JG2)
2a. Injection Nozzle Holder (4JB1, 4JB1TC)
1) Remove the nozzle holder bracket nuts.
6A-2-2.tif
2) Use the nozzle holder remover and the sliding

hammer to remove the nozzle holder together with
the holder bracket.
Nozzle Holder Remover: 5-8840-2034-0
Sliding Hammer: 5-8840-0019-0
6A-3-1.tif
3. Glow Plug and Glow Plug Connector (4JG2)

3a. Glow Plug and Glow Plug Connector (4JB1,
4JB1TC)
4. Rocker Arm Shaft and Rocker Arm
5. Push Rod
6. Cylinder Head
• Loosen the cylinder head bolts a little at a time in
the numerical order shown in the illustration.
NOTE:
Failure to loosen the cylinder head bolts a little at
a time in numerical order will adversely effect the
cylinder head lower surface.
CLEAN
6A-3-2.tif
• Cylinder head bolts

• Cylinder head
Carefully remove all varnish, soot and carbon to
the bare metal. Do not use a motorized wire brush
on any gasket sealing surface.

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
• Cylinder head gasket and mating surfaces for leaks,
corrosion and blow-by. If the gasket has failed,
determine the cause;
- Improper installation
- Loose or warped cylinder head
- Insufficient torque on head bolts
- Warped case surface
1. Cylinder head bolts for damaged threads or stretching
and damaged heads caused by improper use of tools.
CAUTION:
Suspected bolts must be replaced.
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:
Do not attempt to weld the cylinder head. Replace it.
4. Cylinder head deck, intake and exhaust manifold
mating surfaces for flatness.
These surfaces may be re-conditioned by milling
(except cylinder head lower face). If the surfaces are
“out of flat” by more than specification, the surface
should be grinded to within specifications. If more than
limit of specification, it should be replaced.
NOTE:
6A-4-1.tif
The cylinder head lower face cannot be reground.
mm (in)
Standard Limit
Cylinder Head
0.05 (0.002)
Lower Face 0.20 (0.0079)
or less
Warpage
Cylinder Head
92 (3.622) 91.55 (3.6043)
Height
5. Water jacket sealing plugs seating surfaces.

6. Use a straight edge and a feeler gauge to measure the
manifold cylinder head lifting face warpage.
Regrind the exhaust manifold cylinder head lifting
surfaces if the measured values are between the
specified limit and the standard.
If the measured values exceed the specified limit, the
manifold must be replaced.
Exhaust Manifold Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.0079)
6A-4-2.tif
Hot plug depression (4JG2 only)

1. Clean the cylinder head lower side, taking care not to
damage the hot plug surfaces.
2. Use a straight edge and feeler gauge to measure hot
plug depression in a straight line from the No. 1 hot
plug to the No. 4 hot plug.
If the measured value exceeds the limit, the hot plugs
must be replaced.
Depression Limit mm (in)
6A-4-3.tif 0.02 (0.0008)
Hot plug removal (4JG2 only)

1. Insert a 3.0 - 5.0 (0.12 - 0.20.) diameter bar into the
nozzle holder fitting hole unit it makes contact with the
hot plug.
2. Lightly tap the bar with a hammer to drive the hot plug
free.
If the measured value exceeds the limit, the hot plugs
must be replaced.
6A-4-4.tif
Combustion chamber inspection (4JG2 only)

1. Remove the carbon adhering to the inside of the
combustion chamber. Take care not to damage the
hot plug fitting positions.
2. Inspect the inside of the combustion chamber, the hot
plug, and the hot plug machined faces for cracking
and other damage.
If cracking or damage is present, the cylinder head
must be replaced.
6A-5-1.tif NOTE:
Be absolutely certain that there are no scratches or
protuberance on the combustion chamber surfaces
which will be in contact with the hot plug after it is
installed. There flaws will prevent the hot plug from
seating correctly.
Hot plug inspection

Inspection the hot plugs for excessive wear and other
damage. Replace the hot plugs if either of these
conditions are discovered.
Hot plug installation (4JG2 only)

1. Align the hot plug knock ball ! with the cylinder head
groove " and tap it temporarily into position with a
plastic hammer.
6A-5-2.tif
2. Place an appropriate metal plate # thick over the hot

plug upper surface $
3. Use a press % to exert a pressure of 44130 - 53937N
(4500 - 5500 kg/9923 - 12128 lbs.) on the metal plate
covering the hot plug upper surface. This will drive the
hot plug into position.
4. Lightly tap the hot plug heads to make sure that they
are firmly seated.
5. Repeat the procedure Steps 1-4 for the remaining hot
plugs.
6A-5-3.tif
CAUTION:
Do not apply pressure greater than that specified.
Damage to the cylinder head will result.
6. Use a surface grinder to grind off any hot plug surface
protuberances.
The hot plug surfaces must be perfectly flush with the
cylinder head.
7. After grinding, make sure that the hot plug surfaces
are completely free of protuberances.
The hot plug surfaces must also be free of
depressions.
Once again, lightly tap the hot plug heads to make sure
that they are firmly seated.
6A-6-1.tif
Heat shield removal (4JG2 only)

After removing the hot plugs, use a hammer ! and a
brass bar " to lightly tap the lower side of the heat shield
# and drive it free.
6A-6-2.tif
Heat shield installation (4JG2 only)

Install the heat shield washer and the heat shield to the
cylinder head from the nozzle holder installation hole side.
Lightly tap the flange into place with a brass bar.
The heat shield flange side must be facing up.
NOTE:
Always install a new heat shield. Never reuse the old
heat shield.
6A-6-3.tif
REASSEMBLY
6. Cylinder Head
1) Hot plug
• Set the nock ball in the positioning groove on the
cylinder head side according to the order of the
cylinders, and hit it lightly with a plastic hammer.
NOTE:
After being pressed into the cylinder head, the hot
plugs were provided with surface grinding.
Accordingly, their dimensions are different
individually among them, and take care not confuse
the order of the cylinders.
When replacing the hot plug with new one:

When assembling a new hot plug, set the knock ball in the
positioning groove on the cylinder side and hit it lightly with
a plastic hammer until the hot plug is set in stably.
With patch attached to the hot plug to prevent it from
being damaged, press it in with a force of 4.5 to 5.5 ton
applied.
After pressing the hot plug, grind its surface to the cylinder
head.
And finally, hit the hot plug lightly with a plastic hammer
and check it for any excessive sinking, protrusion or
backlash.
2) Valve Seat Insert Installation

1. Carefully place the attachment ! (having a smaller
outside diameter than the valve seat insert) on the
valve seat insert ".
NOTE:
The smooth side of the attachment must contact the
valve seat insert.
2. Use the bench press # to gradually apply pressure to

6A-7-1.tif the attachment and press the valve seat insert into
place.
NOTE:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat will
result.
Measure the height of the valve guide upper end from the
upper face of the cylinder head.
Valve Guide Upper End Height (H) (Reference) mm (in)

13 (0.51)
6A-7-2.tif
NOTE:
If the valve guide has been removed, both the valve
and the valve guide must be replaced as a set.
3) Spring lower seat

4) Valve stem oil seal
• Install a new oil controller in the valve.
• Guide using special tool
Oil seal installer: 5-8840-2003-0
5) Valve
• Apply engine oil to the outside of the valve stem before
installing it.
6A-7-3.tif
6) Valve Spring
• Attach the valve spring to the upper spring seat.
CAUTION
• The painted area of the valve spring should be
facing downward.
• Apply compressed air to cylinder from the glow
plug hole to hold the valve in place.
• Install split collar by special tool.
Valve spring compressor: 9-8523-1423-0 (J-29760)
6A-8-1.tif
7) Split Collar
• Use a spring compressor to push the valve spring into
position.
• Install the spring seat split collar.
• Set the split collar by tapping lightly around the head of
the collar with a rubber hammer.
5. Push Rod
4. Rocker Arm Shaft and Rocker Arm
6A-8-2.tif
• Tighten rocker arm shaft fixing bolts
54 (5.5/40)
3a. Glow Plug and Glow Plug Connector (4JB1/4JB1T

only)
3. Glow Plug and Glow Plug Connector
• Tighten glow plugs
23 (2.3/17)
2a. Injection Nozzle Holder (4JB1/4JB1T/4JB1TC only)

1) Install the injection nozzle gasket ! and the O-ring "
to the injection nozzle holder #.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2) Apply engine oil to the cylinder head nozzle holder
hole.
3) Install the nozzle holder together with the nozzle holder
bracket $ to the cylinder head.
6A-8-3.tif N∙m (kg∙m/lb∙ft)
37 (3.8/27)
2. Injection Nozzle (4JG2 only)

• Lightly tighten the holder nut to suck extent that the
nozzle holder can turn one word and one word.
• Set positioning confirmation drilled hole (ø2) within a
nozzle turning angle of ±5° against the cylinder head-
side positioning boss.
• Apply a wrench as illustrated and tighten the holder nut
to the specified torque using a special tool.
CAUTION
• After tightening the holder nut, make sure that the
040LX016.tif
drilled hole makes ±5° or smaller with the cylinder
head-side positioning boss.
• When mounting leak off pipe, injection nozzle and
pipe, clean then with air so that dust may not
enter.
Nozzle Fixing Torque N∙m (kg∙m/lb∙ft)

64 (6.5/47)
Wrench: Nozzle holder 5-8840-0259-0
6A-9-1.tif
1. Thermostat Housing Assembly

• Tighten thermostat housing assembly fixing bolt.
19 (1.9/14)
VALVE SPRING, VALVE GUIDE OIL SEAL, VALVE GUIDE, PUSH ROD
6A-10-1.tif
DISASSEMBLY
1. Rocker Arm Assembly
2. Split Collar
Using special Tool, compress valve spring
3. Valve Spring
4. Valve
5. Valve Guide Oil Seal
6. Valve Guide
Valve Guide Replacer: 9-8523-1212-0
6A-10-2.tif

during inspection.
Valve spring
CAUTION:
Visually inspect the valve springs and replace them if
damage or abnormal wear is evident.
1. Free height
• Measure the free height of the springs. The springs
must be replaced if the height is below the specified
limit.
6A-11-1.tif
Free Height mm (in)
Standard Limit
48.0 (1.891) 47.100 (1.8560)
2. Squareness
• Measure the valve spring squareness with a steel
square.
• Replace the valve springs if the measured value
exceeds the specified limit.
Limit mm (in)
1.7 (0.067)
6A-11-2.tif
3. Spring tension
• Use spring tester to compress the springs to the
installed height. Measure the compressed spring
tension.
Replace the springs if the measured tension is below
the specified limit.
Tension N (kg/lb)
At installed height Standard Limit
38.9 mm (1.5 in) 296.2 (30.2/66.6) 257.9 (26.3/57.9)
6A-11-3.tif
Valve Guide
CAUTION:
Taking care not to damage the valve seat contact
surface, when removing carbon adhering to the valve
head.
Carefully inspect the valve stem for scratching or
abnormal wear. If these conditions are present, the
valve and the valve guide must be replaced as a set.
1. Valve Guide Clearance

• Measure the valve stem diameter with a micrometer.
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced
as a set.
mm (in)
Standard Limit
7.946 - 7.961 7.880
Inlet
Diameter of (0.3128 - 0.3134) (0.310.2)
6A-12-1.tif
Valve stem 7.921 - 7.936 7.850
Exhaust
(0.3118 - 0.3124) (0.3091)
• Measure the inside diameter of the valve guide with a

micrometer.
• Subtract the measured outer diameter of the valve
stem from the measured inner diameter of the valve
guide. If the valve exceeds of the valve guide.
If the valve exceeds the specified limit, the valve and
the valve guide must be replaced as a set.
Valve Guide Clearance mm (in)
Standard Limit
0.039 - 0.069 0.200
Inlet clearance
(0.0015 - 0.0027) (0.0079)
0.064 - 0.096 0.250
Exhaust clearance
(0.0025 - 0.0038) (0.0098)
Valve Guide Replacement

1. Using special tool, drive out the valve guide from the
combustion chamber side.
Valve guide replacer: 9-8523-1212-0
6A-13-1.tif
2. Apply engine oil to the outside of the valve guide.

Using special tool, drive in a new valve guide from
cylinder head upper face side, and check the valve
guide height.
Height mm (in)
13 (0.51)
NOTE:
6A-13-2.tif If the valve guide has been removed, both the valve
Valve Thickness
1. Measure the valve thickness
2. If the measured value is less than the specified limit
the valve and the valve guide must be replaced as a
set.
Valve Thickness mm (in)
Standard Limit
4JB1 Inlet 1.79 (0.0705)
4JB1T 1.5 (0.06)
6A-13-3.tif
4JB1TC Exhaust 1.83 (0.0720)
Inlet 1.41 (0.0555)
4JG2 1.1 (0.043)
Exhaust 1.39 (0.0547)
Contact surface angle on valve seat on valve

1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace valve
guide and valve seat as a set.
Standard Degrees
45°
6A-13-4.tif
Valve depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head
lower surface.
If the measured value exceeds the specified limit, the
valve seat insert must be replaced.
Valve Depression mm (in)
Standard Limit
6A-14-1.tif 4JB1 Inlet 0.73 (0.029) 1.28 (0.050)
4JB1T
4JB1TC Exhaust 0.70 (0.028) 1.20 (0.047)
Inlet
4JG2 1.1 (0.043) 1.6 (0.063)
Exhaust
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact surfaces.
2. Measure the valve contact width.
valve seat insert must be replaced.
Contact Width mm (in)
Standard Limit
Inlet 1.7 (0.0670) 2.2 (0.0866)
6A-14-2.tif
Exhaust 2.0 (0.0788) 2.5 (0.0984)
Valve Seat Insert Replacement

Valve Seat Insert Removal
1. Arc weld the tire inside circumference ! of the valve
seat insert ".
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the
valve seat insert easier.
3. Use a screwdriver # to pry the valve seat insert free.
Take care not to damage the cylinder head $.
6A-14-3.tif
4. Carefully remove carbon and other foreign material
from the cylinder head insert bore.
Valve Seat Insert Installation

NOTE:
valve seat insert.
2. Use a bench press # to gradually apply pressure to
the attachment and press the valve seat insert into
place.
6A-14-4.tif
NOTE:
the bench press. Damage to the valve seat insert will
result.
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15°, 45°, and 75° blades) to
minimize scratches and other rough areas, this will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do not
cut away too much. Take care not to cut away
unblemished area of the valve seat surface.
6A-15-1.tif
Valve Seat Angle degree

45°
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
3. Apply abrasive compound to the valve seat insert
surface.
6A-15-2.tif 4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contract width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
6A-15-3.tif
Push Rod Curvature

1. Lay the push rod on a surface plate.
2. Roll the push rod along the surface plate and measure
the push rod curvature with a thickness gauge.
If the measure value exceeds the specified limit, the
push rod must be replaced.
Push Rod Curvature Limit mm (in)
0.4 (0.0157) or less
6A-15-4.tif
3. Visually inspect both ends of the push rod for
excessive wear and damage. The push rod must be
replaced if these conditions are discovered during
inspection.
REASSEMBLY
6. Valve Guide
• Apply engine oil to the outside of the valve guide.
Using special tool, drive in a new valve guide from the
rocker arm shaft side.
• Using special tool, drive in a new oil seal
Oil special tool, drive in a new oil seal
Oil seal installer: 5-8840-2033-0
6A-16-1.tif
4. Valve
• Apply engine oil to the outside of the valve stem.
3. Valve Spring
• Attach the valve seat to the upper spring seat. The
painted area of the valve spring should be facing
downward.
6A-16-2.tif
2. Split Collar
• Use a spring compressor to push the valve spring into
position.
• Install the spring seat split collar.
• Set the split collar by tapping lightly around the head of
the collar with a rubber hammer.
6A-16-3.tif
1. Rocker Arm Assembly

54 (5.5/40)
6A-16-4.tif
CAMSHAFT, TAPPET
6A-17-1.tif
DISASSEMBLY
1. Cylinder Head Assembly
2. Flywheel
3. Cylinder Block Rear Plate
4. Oil Pan Assembly
5. Oil Pump Assembly
6. Camshaft Timing Gear (Gear Drive Model)
• Remove the camshaft timing gear bolt from the
camshaft.
NOTE:
Hold the camshaft stationary to prevent the camshaft
from turning.
• Use the universal puller ! to pull out the camshaft
timing gear ".
• Universal Puller: 5-8521-0002-0
6A-17-2.tif
Remove the thrust plate #.
6a. Camshaft Timing Pulley (Belt Drive Model)

• Use the timing pulley puller " to remove the pulley.
Timing Pulley Puller: 5-8840-0086-0
• Remove the stopper bolt.
7. Camshaft Thrust Plate (Gear Drive Model)
7a. Camshaft Pulley Center (Belt Drive Model)
8. Camshaft
9. Tappet
6A-18-1.tif

Make the necessary adjustment, repairs, and part
during inspection.
1. Measure the Camshaft Thrust Clearance

• Use a dial indicator to measure the camshaft end play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.
Camshaft End Play mm (in)
Standard Limit
0.08 (0.0031) 0.2 (0.0079)
6A-18-2.tif
2. Camshaft Journal Diameter

• Use a micrometer to measure each camshaft journal
diameter in two directions ! and ". If the measured
value is less than the specified limit, the camshaft
must be replaced.
Journal Diameter mm (in)
Standard Limit
49.945 - 49.975 (1.9663 - 1.9675) 49.60 (1.9528)
6A-18-3.tif
3. Cam Height
• Measure the cam height H with a micrometer. If the
measured value is less than the specified limit, the
camshaft must be replaced.
Cam Height mm (in)
Standard Limit
42.02 (1.6543) 41.65 (1.6398)
6A-18-4.tif
4. Camshaft Run-Out
• Mount the camshaft on V-blocks.
• Measure the run-out with a dial indicator.
camshaft must be replaced.
Run-Out mm (in)
Standard Limit
0.02 (0.008) or less 0.10 (0.0039)
6A-19-1.tif
5. Camshaft and Camshaft Bearing Clearance

• Use an inside dial indicator to measure the camshaft
bearing inside diameter.
Camshaft Bearing Inside Diameter mm (in)
Standard Limit
50.00 - 50.03
50.08 (1.9716)
(1.9685 - 1.9696)
Camshaft Bearing Clearance mm (in)

6A-19-2.tif Standard Limit
0.025 - 0.085
0.12 (0.005)
(0.0010 - 0.0033)
• If the clearance between the camshaft bearing inside

diameter and the journal exceeds the specified limit,
the camshaft bearing must be replaced.
Camshaft Bearing Replacement

Camshaft Bearing Removal
1. Remove the cylinder body plug plate.
2. Use the bearing replacer to remove the camshaft
bearing.
Bearing Replacer: 5-8840-2038-0
6A-19-3.tif
Camshaft Bearing Installation

1. Align the bearing oil holes with the cylinder body oil
holes.
2. Use the replacer to install the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
6A-19-4.tif
TAPPET
Visually inspect the tappet camshaft contact surfaces for
pitting, cracking, and other abnormal conditions. The
tappet must be replaced if any of these conditions are
present.
Refer to the illustration at the left.
! Normal contact
" Cracking
6A-20-1.tif
# Pitting
$ Irregular contact
% Irregular contact
NOTE:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort
to repair the tappet. If the tappet is damaged, it must
be replaced.
Tappet Outside Diameter

1. Measure the tappet outside diameter with a
micrometer. If the measured value is less than the
specified limit, the tappet must be replaced.
Tappet Outside Diameter mm (in)
Standard Limit
12.97 - 12.99 12.95 (0.509)
(0.510 - 0.511)
6A-20-2.tif
2. Measure the inside diameter tappet on the cylinder

block and calculate the clearance.
If the clearance exceeds the limit, replace tappet
or/and cylinder block.
Tappet and Cylinder Body Clearance mm (in)
Standard Limit
0.03 (0.001) 0.10 (0.004)
6A-20-3.tif
REASSEMBLY
9. Tappet
1) Apply a coat of engine oil to the tappet 1 and the
cylinder body tappet insert holes 2.
2) Locate the position mark applies at disassembly (if the
tappet is to be reused).
NOTE:
The tappet must be installed before the camshaft.
6A-20-4.tif
8. Camshaft
1) Apply a coat of engine oil to the camshaft and the
camshaft bearings.
2) Install the camshaft to the cylinder body.
Take care not damage the camshaft bearings.
6A-21-1.tif
7a. Camshaft Timing Pulley Center (Belt Drive Model)

• Apply engine oil to the oil seal lip portion of the oil seal
retainer.
• Apply the recommended liquid gasket or its equivalent
to the retainer.
• Install the oil seal retainer to the cylinder body.
• Tighten the retainer bolts to the specified torque.
Oil Seal Retainer Bolt Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6A-21-2.tif
• Align the camshaft timing pulley center with the

camshaft key.
• Tighten the timing pulley bolts to the specified torque.
Timing Pulley Bolt Torque N∙m (kg∙m/lb∙in)
8 (0.8/69)
6A-21-3.tif
7. Camshaft Thrust Plate (Gear Drive Model)

Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to specified torque.
Thrust Plate Bolt Torque N∙m (kg∙m/lb∙ft)
18 (1.8/13)
6A-21-4.tif
6a. Camshaft Timing Pulley (Belt Drive Model)

• Prevent the camshaft from turning when tightening the
timing center bolt.
• Tighten the timing pulley center bolt to the specified
torque.
Center Bolt Torque N∙m (kg∙m/lb∙ft)
64 (6.5/47)
6A-21-5.tif
6. Camshaft Timing Gear (Gear Drive Model)

1) Install the camshaft timing gear to the camshaft.
The timing gear mark (“Y-Y”) must be facing outward.
2) Tighten the timing gear to the specified torque
Timing Gear Bolt Torque N∙m (kg∙m/lb∙ft)
64 (6.5/47)
6A-22-1.tif

4. Oil Pan Assembly
Above works refer to “OIL PUMP” Section in this manual.
• Tighten cylinder block rear plate fixing bolts to the
specified torque.
Rear Plate Bolt Torque N∙m (kg∙m/lb∙ft)
82 (8.4/61)
2. Flywheel
• Apply engine oil to fixing bolts.
• Tighten the flywheel bolts to the specified torque in two
steps using the Angular Tightening Method.
Follow the numerical order shown in the illustration.
Flywheel Bolt Torque N∙m (kg∙m/lb∙ft)
1st Step (Snug Torque) 2nd Step (Final Torque)
59 (6.0/43) 60° - 90°
6A-22-2.tif

1) Hot plug
• Set the nock ball in the positioning groove on the
cylinder head side according to the order of the
cylinders, and hit it lightly with a plastic hammer.
NOTE:
After being pressed into the cylinder head, the hot
plugs were provided with surface grinding.
Accordingly, their dimensions are different
individually among them, and take care not confuse
the order of the cylinders.
When replacing the hot plug with new one:

When assembling a new hot plug, set the knock ball in the
positioning groove on the cylinder side and hit it lightly with
a plastic hammer until the hot plug is set in stably.
With patch attached to the hot plug to prevent it from
being damaged, press it in with a force of 4.5 ~ 5.5 ton
applied.
2) Valve Seat Insert Installation
NOTE:
valve seat insert.
2. Use the bench press # to gradually apply pressure to
the attachment and press the valve seat insert into
6A-23-1.tif
place.
NOTE:
the bench press. Damage to the valve seat insert will
result.
Measure the height of the valve guide upper end from
the upper face of the cylinder head.
Valve Guide Upper End Height (H) (Reference) mm (in)
13 (0.51)
6A-23-2.tif NOTE:
If the valve guide has been removed, both the valve
3) Spring Lower Seat
4) Valve Stem Oil Seal
5) Valve
6) Valve Spring
7) Split Collar
Above works refer to “VALVE” Section in this manual.
ROCKER ARM ASSEMBLY
6A-24-1.tif
DISASSEMBLY
1. Rocker Arm Shaft Assembly
2. Rocker Arm Shaft Snap Ring
3. Rocker Arm
4. Rocker Arm Shaft Bracket
5. Rocker Arm
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft

during inspection.
Use a micrometer to measure the rocker shaft outside

diameter at the point where the rocker arm moves on the
rocker shaft.
Replace the rocker shaft if the diameter exceeds the
specified limit.
mm (in)
Standard Limit
18.98 - 19.00
18.9 (0.744)
(0.7472 - 0.7480)
6A-24-2.tif
Oil Clearance
1. Use either a vernier caliper or a dial indicator to
measure the rocker arm inside diameter.
Rocker Arm Inside Diameter mm (in)
Standard Limit
19.036 - 19.060
19.100 (0.7519)
(0.7494 - 0.7503)
2. Measure the rocker arm shaft outside diameter.

6A-25-1.tif If the measured value exceeds the specified limit,
replace either the rocker arm or the rocker arm shaft.
Rocker Arm and
Rocker Shaft Clearance mm (in)
Standard Limit
0.06 - 0.08
0.10 (0.0039)
(0.0024 - 0.0031)
3. Check that the rocker arm oil port is free is

obstructions.
If necessary, use compressed air to clean the rocker
arm oil port.
6A-25-2.tif
Rocker Arm Correction

Inspection the rocker arm valve stem contact surface for
step wear ! and scoring ".
If the contact surfaces have light step wear or scoring,
they may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must
be replaced.
6A-25-3.tif
Rocker Arm Shaft Run-Out

1. Place the rocker arm shaft on a V-block.
2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm shaft
run-out with a bench press. The rocker arm must be at
cold condition.
If the measured rocker arm shaft run-out exceeds the
specified limit, the rocker arm shaft must be replaced.
Rocker Arm Shaft Run-Out mm (in)
6A-26-1.tif
Limit
4JB1 / 4JB1T / 4JB1TC
0.2 (0.008)
4JG2
REASSEMBLY
7. Rocker Arm Shaft
• Apply a light coat of engine oil to the rocker arm
shafts.
• Position the rocker arm shaft with the large oil hole
(4ø) facing the front of the engine.
• Install the rocker shaft together with the rocker arm,
the rocker arm shaft bracket, and the spring.
6. Rocker Arm Shaft Spring
6A-26-2.tif
5. Rocker Arm
4. Rocker Arm Shaft Bracket
3. Rocker Arm
2. Rocker Arm Shaft Snap Ring

• Install the rocker arm shaft assembly in cylinder head.
• Tighten the rocker arm shaft fixing bolts to the
specified torque.
6A-26-3.tif
OIL PUMP
Disassembly steps
1. Vacuum pump oil hose
2. Stiffener and space rubber
3. Oil pan Assembly
4. Oil pump Assembly
5. Strainer
6. Pump cover
7. Driven gear
8. Oil pump body
6A-27-1.tif
DISASSEMBLY
1. Vacuum Pump Oil Hose
• Remove the oil hose ! from oil pan.
2. Stifner & Space Rubber
• Remove the stiffener from of the oil pan left & right
side.
• Take out space rubber.
3. Oil Pan Assembly
6A-27-2.tif

5. Strainer
6. Pump Cover
7. Driven Gear
8. Oil Pump Body

during inspection.
Body and gears

The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
• Badly worn or damaged driven gear guide.
• Badly worn or damaged gear teeth.
Gear Teeth and Body Inner Wall Clearance

• Use a feeler gauge to measure the clearance between
the gear teeth and the body inner wall.
• If the clearance between the gear teeth and the body
inner wall exceeds the specified limit, either the gear
or the body must be replaced.
Gear Teeth and Body
Internal Wall Clearance mm (in)
Standard Limit
6A-28-1.tif 0.14 (0.0055) 0.20 (0.0079)
Gear and Body Clearance

• Use a feeler gauge to measure the clearance between
the body and the gear.
• If the clearance between the gear and the body
exceeds the specified limit, the body must be
replaced.
Gear and Body Clearance mm (in)
Standard Limit
0.06 (0.024) 0.15 (0.0059)
6A-28-2.tif
REASSEMBLY
8. Oil Pump Body
7. Driven Gear
6 Pump Cover
5. Strainer
• Install the strainer assembly and tighten the strainer
assembly fixing bolts.
16 (1.6/12)
6A-29-1.tif

• Apply molybdenum mixed engine oil to drive gear of
camshaft and driven gear of oil pump.
• Tighten the oil pump fixing bolt to the specified torque.
19 (1.9/14)
3. Oil Pan Assembly

to the No. 5 bearing cap arches, the grooves, the
cylinder block and the timing gear case filting face at
the positions shown in the illustration.
6A-29-2.tif
• Fit the gasket rear lipped portion into the No. 5 groove.
• Be absolutely sure that the lipped portion is fitted
snugly into the groove.
• Install the oil pan to the cylinder body.
• Tighten the oil pan bolts to the specified torque.
Oil Pan Bolt Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6A-29-3.tif
2. Stiffener & Space Rubber

• Install the space rubber.
• Install the stiffener tighten to the specified torque.
Engine Body Side N∙m (kg∙m/lb∙ft)
37 (3.8/27)
Clutch Housing Side N∙m (kg∙m/lb∙ft)

78 (8.0/58)

• Install the oil hose to oil pan.
CRANKSHAFT
Disassembly steps
1. Cylinder head Assembly and
gasket
2. Oil pan Assembly
3. Timing gear
3a. Timing Belt and Pulley
4. Front oil seal
5. Timing gear housing
5a 5a. Timing pulley housing
7. Piston cooling oil pipe
8. Piston and connecting rod
9. Flywheel
10. Cylinder block rear plate
11. Crankshaft rear oil seal
12. Main bearing cap
13. Crankshaft
Reassembly steps
order.
6A-31-1.tif
DISASSEMBLY
1. Cylinder Head Assembly and Gasket
2. Oil Pan Ambly
3. Timing Gear (Gear Drive Model)
3a. Timing Belt and Pulley (Belt Drive Model)
4. Front Oil Seal
• With the oil seal pushed in deep, install the special tool
as shown in the illustration to remove the oil seal.
Remover: 5-8840-2362-0
5. Timing Gear Housing

5a.Timing Pulley Housing
7. Piston Cooling Oil Pipe
8. Piston and Connecting Rod
9. Flywheel
11. Crankshaft Rear Oil Seal (Gear and Belt Drive Model)
Remover: Rear Oil Seal 5-8840-2360-0
NOTE:
Take care not to damage sealing surface of rear plate
and crankshaft when removing oil seal.
12. Main Bearing Cap
13. Crankshaft
6A-32-1.tif

during inspection.
1. Crankshaft
Thrust clearance
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified limit, replace
the thrust bearing as a set.
Thrust clearance mm (in)
Standard Limit
0.10 (0.0039) 0.30 (0.0118)
6A-32-2.tif
2. Main bearing clearance

1) Remove the main bearing caps in the sequence
Arrange the removed main bearing caps in the cylinder
number order.
2) Remove the crankshaft. Remove the main bearings.
3) Clean the upper and lower bearings as well as the
crankshaft main journal.
4) Check the bearings for damage or excessive wear.
The bearings must be replace as a set if damage or
6A-33-1.tif
excessive wear is discovered during inspection.
5) Set the upper bearings and the thrust washers to their
original positions. Carefully install the crankshaft.
6) Set the lower bearings to the bearing cap original
position.
7) Apply plastigage to the crankshaft journal unit as
8) Install the main bearing caps. Apply engine oil to the
bolt threads and the seats. Tighten the bolts to the
specified torque.
167 (17/123)
6A-33-2.tif
NOTE:
Do not allow the crankshaft to rotate.
9) Remove the main bearing caps.
10) Measure the plastigage width and determine the oil
clearance. If the oil clearance exceeds the specified
limit, replace the main bearings as a set and/or
replace the crankshaft.
11) Clean the plastigage from the bearings and the
crankshaft.
12) Remove the crankshaft and the bearings.
6A-33-3.tif
Oil Clearance mm (in)
Standard Limit
4JB1
0.035 - 0.080
/4JB1T
(0.0014 - 0.0036)
4JB1TC 0.11 (0.0043)
0.031 - 0.063
4JG2
(0.0012 - 0.0025)
3. Run-out
1) Carefully set the crankshaft on the V-blocks.
Slowly rotate the crankshaft and measure the runout.
If the crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Run-Out mm (in)
Standard Limit
0.05 (0.0020)
0.08 (0.0031)
or less
6A-34-1.tif
Measure the diameter and the uneven wear of main

journal and crank pin.
If the crankshaft wear exceeds the specified limit,
crankshaft must be replaced.
mm (in)
Standard Limit
Main journal 69.917-69.932 69.91 (2.7524)
diameter (2.7526 - 2.7532)
Crank pin 52.915 - 52.930 52.90 (2.0843)
6A-34-2.tif
diameter (2.0833)
Uneven wear 0.05 (0.0020) 0.08 (0.0031)
limit or less
Crankshaft inspection
Inspect the surface of the crankshaft journals and crank
pins for excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear and
damage.
Inspect the oil ports for obstructions.
Crankshaft tufftriding inspection

The portion to be tested must be held horizontally so as
not let the test solution flow.
Test liquid should not be applied to the area around the oil
port.
The sliding surface of the pin or journal.
Approximately 10mm
NOTE:
To increase crankshaft strength, Tufftride Method
(Soft nitriding) has been applied. Because of this, it is
6A-34-3.tif
not possible to regrind the crankshaft surfaces.
1. Use an organic cleaner to thoroughly clean the
crankshaft. There must be no traces of oil the surfaces
to be inspected.
2. Prepare a 5-10% solution of ammonium cupric
chloride (dissolved in distilled water).
3. Use a syringe to apply the solution to the surface to be

inspected.
Hold the surface to be inspected perfectly horizontal to
prevent the solution from running.
NOTE:
Do not allow the solution to come in contact with the
oil ports and their surrounding area.
Testing
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty seconds,
the crankshaft is usable.
If discoloration appears (the surface being tested will
become the color copper), the crankshaft must be
replaced.
2. Steam clean the crankshaft surface immediately after
completing the test.
NOTE:
The ammonium cupric chloride solution is highly
corrosive. Because of this, it is imperative that the
surfaces being tested be cleaned immediately after
completing the test.
CRANKSHAFT BEARING SELECTION

When installing new crankshaft bearings or replacing old
bearings, refer to the selection table.
6A-35-1.tif
NOTE:
Please note that some Crankshaft No. 4 journals made
during a limited production period have their number
(No. 4) marked on either their front or rear side of
webs as shown below.
6A-35-2.tif
NOTE:
Although all upper journal bearings (cylinder body
side) have oil grooves and holes, all lower bearings
(bearing cap side) have no groove and hole.
Play close attention to the distinction during the
installation procedure.
6A-35-3.tif
Main Bearing Crankshaft Crankshaft

Bore Diameter mm (in.) Main Journal Diameter mm (in.) Oil Clearance
Bearing
mm (in.)
Size Mark Inside Diameter Size Mark Outside Diameter Size Mark
69.927~69.942 0.035~0.061
1 or - Black
(2.7530~2.7536) (0.0014~0.0024)
73.987~74.000 69.922~69.927 0.032~0.058
1 2 or -
(2.9129~2.9134) (2.7528~2.7530) (0.0013~0.0023)
Blue
69.917~69.922 0.037~0.063
3 or -
(2.7526~2.7528) (0.0015~0.0025)
69.927~69.942 0.031~0.056
1 or -
(2.7530~2.7536) (0.0012~0.0022)
Green
73.975~73.987 69.922~69.927 0.036~0.048
2 2 or -
(2.9124~2.9129) (2.7528~2.7530) (0.0014~0.0019)
69.917~69.922 0.033~0.058
3 or - Black
(2.7526~2.7528) (0.0013~0.0023)
REASSEMBLY
13. Crankshaft
• Install the main bearings to the cylinder body and the
main bearing caps.
• Be sure that they are positioned correctly.
• Apply new engine oil to the upper and lower main
bearing faces.
• Carefully mount the crankshaft.
• Apply engine oil to the thrust washer.
6A-36-1.tif
• Assemble the thrust washer to the No.3 bearing

journal. The oil grooves must face the crankshaft.
6A-36-2.tif

to the No. 5 crankshaft bearing cap ! as shown in the
illustration.
• Install the arch gasket " to the No. 5 bearing cap.
Use your fingers to push the arch gasket into the
bearing cap groove.
6A-37-1.tif
NOTE:
Be sure that the bearing cap fitting surface is
completely free of oil before applying the liquid
gasket.
Do not allow the liquid gasket to obstruct the cylinder
thread holes and bearings.
6A-37-2.tif
• Install the bearing caps with the bearing cap head

arrow mark facing the front of the engine.
• Apply engine oil to the crankshaft bearing cap bolts.
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
167 (17.0/123)
6A-37-3.tif NOTE:
Check to see that the crankshaft turns smoothly by
rotating it manually.
11. Crankshaft Rear Oil Seal (Gear and Belt Drive Model)
Use the oil seal installer to install the oil seal to the cylinder
body.
Installer: Rear Oil Seal 5-8840-2359-0
NOTES:
Wipe off rust and scraps clean from the press-in
portion of the oil seal.
Take note of the press-in direction of the oil seal.
1) Install the adapter of the special tool to the rear end of
6A-38-1.tif
the crankshaft with two bolts.
2) Install the oil seal to the outer circumference of the
adapter.
3) Insert the slave into the adapter portion, and tighten it
in with the bolt (M12 x 1.75L=70) until the adapter
section hits the slave.
4) Remove the adapter and the slave.
5) After installing the oil seal, check the measurement of
the oil seal.
Standard mm (in)
12.2 - 12.8 (0.48 - 0.50)

Align the rear plate with the cylinder body knock pins.
Tighten the rear plate to the specified torque
82 (8.4/61)
9. Flywheel
1) Thoroughly clean the remove the oil from the threads
of crankshaft.
2) Mount the flywheel on the crankshaft and then install
the washer.
3) Apply a coat of engine oil to the threads of the flywheel
bolts.
4) Align the flywheel with the crankshaft dowel pin.
5) Tighten the flywheel bolts to the specified torque in two
6A-38-2.tif
1st Step 2nd Step
59 (6.0/43) 60° - 90°


Above works refer to “PISTON AND CONNECTING ROD”
Section in this manual.
5a. Timing Pulley Housing
1) Install the timing pulley housing to the cylinder body.
NOTE:
Take care not to twist the front oil seal.
2) Tighten the timing pulley housing bolt together with the
timing pulley housing gasket to the specified torque.
19 (1.9/14)
3) Cut away the gasket protruding above the fitting

surfaces (as shown in the illustration)
6A-39-1.tif

1) Install the timing gear housing to the cylinder body.
2) Tighten the timing gear housing bolt together with the
timing gear housing gasket to the specified torque.
19 (1.9/14)
3) Cut away the gasket protruding above the fitting

surface (as shown in the illustration).
4. Front Oil Seal (Gear Drive Model)
• Install oil seal using special tool.
Installer: 5-8840-2061-0
6A-39-2.tif
4. Front Oil Seal (Belt Drive Model)

Installer: 5-8840-2361-0
NOTE:
1) With the oil seal attached to the sleeve, put it in the
front end of the crankshaft.
6A-39-3.tif 2) With the edge of the oil seal attached securely to the
crankshaft, tighten it with the center bolt until the
sleeve hits securely against the reference plane at the
3) Remove the sleeve.
4) After pressing in the oil seal, check the measurement

of the oil seal.
Standard mm (in)
0.6 - 1.2 (0.024 - 0.047)
3a. Timing Belt and Pulley (Belt Drive Model)
7) Camshaft Timing Pulley
• Apply engine oil to the oil seal lip portion of the oil seal
retainer.
to the retainer.
• Install the oil seal retainer to the cylinder body.
• Tighten the retainer bolts to the specified torque.
Oil Seal Retainer Bolt Torque N∙m (kg∙m/lb∙ft)
6A-40-1.tif 19 (1.9/14)
• Align the camshaft timing pulley center with the

camshaft key.
• Tighten the timing pulley bolts to the specified torque.
Timing Pulley Bolt Torque N∙m (kg∙m/lb∙in)
8 (0.8/69)
6A-40-2.tif
• Prevent the camshaft from turning when tightening the

timing center bolt.
• Tighten the timing pulley center bolt to the specified
torque.
Center Bolt Torque N∙m (kg∙m/lb∙ft)
64 (6.5/47)
• Install the crank pulley.

• Install the idle pulley and idler pulley.
76 (7.8/56)
• Install the injection pump assembly and install timing

pulley.
• Align the timing pulley with the pump shaft key.
• Install the stopper bolt to the timing pulley.
This will prevent the timing pulley from moving.
• Tighten the timing pulley nut to the specified torque.
Injection Pump Timing Pulley Nut Torque
64 (6.5/47)
6A-40-4.tif
• Remove the stopper bolt from the injection timing.

6) Timing Belt
NOTE:
• When the timing belt is removed, be sure to replace it
with a new one.
• The tension of the timing belt may be affected by the
changes in temperature. Be sure to install it while the
engine cold.
• When the timing belt is bent forcibly, the cord may got
snapped, thus resulting in the reduced strength. Do
not bend it unnecessarily.
! Check that the stopper bolts are properly installed to

the camshaft timing pulley and the injection pump
timing pulley.
" Check that the timing pulley housing mark and the
crankshaft timing pulley mark are aligned.
The No. 1 cylinder should be at TDC on the
compression stroke.
Rotate the crankshaft damper pulley clockwise to align
the marks.
6A-41-1.tif
# Install the timing belt to the crankshaft timing pulley !,

the camshaft timing pulley ", the tensioner idler #,
and the injection timing pulley $.
Follow the numerical order.
$ Install the timing belt tensioner % to the timing pulley
housing.
% Temporarily tighten the tensioner bolt.
The tensioner should move freely
NOTE:
6A-41-2.tif The timing belt is easily damaged. Be careful.
NOTE:
After completion of the installation of the timing belt,
check to see if the alignment mark of the crankshaft
timing pulley is in line with the alignment mark
provided on the housing.
• When the alignment marks are not in line with each
other, set them together and reinstall the timing belt.
6A-41-3.tif & Set the tensioner adjusting lever to the timing pulley
housing.
' Remove the stopper bolts from the camshaft timing
pulley and the injection pump timing pulley.
( Attach the spring balancer.
) Adjust the timing belt tension by pulling straight down
on the spring balancer with the specified force.
Tension Adjusting Lever Force N (kg/lb)
98 - 118 (10 - 12/22 - 26)
6A-42-1.tif
NOTE:
Timing belt tension must be adjusted.
Failure to adjust the timing belt tension will result in
timing belt damage.
* Tighten the tension bolt.
11 Rotate the crankshaft 45 degrees counterclockwise.
NOTE:
Never rotate the crankshaft clockwise when adjusting
the timing belt.
6A-42-2.tif
12 Readjust the timing belt tension.

Refer to Step 9
This will remove any remaining timing belt slack.
13 Tighten the tensioner bolt to the specified torque.
Tensioner Bolt Torque N∙m (kg∙m/lb∙ft)

76 (7.7/56)
6A-42-3.tif
14 Tighten the tension adjusting lever nut and bolt.
NOTE:
If on-vehicle timing belt replacement is performed, the
crankshaft must not be allowed to turn.
If the crankshaft is allowed to turn, piston and valve
damage will result.
6A-42-4.tif
5) Flange: Camshaft Pulley

4) Flange: Injection Pump Pulley
• Install the timing pulley flange to the camshaft and
injection pump timing pulley.
• Tighten the timing pulley flange bolts to the specified
torque.
Timing Pulley Flange Bolt Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6A-43-1.tif
3) Timing Pulley Lower Cover

to the timing pulley lower cover.
• Install the lower cover to the timing pulley housing.
• Use the lower cover guide bolts to prevent the liquid
gasket from running.
2) Timing Pulley Upper Cover
• Install the upper cover to the lower cover and the
pulley housing.
6A-43-2.tif
• Tighten the timing pulley cover bolts to the specified

torque a little at a time.
Timing Pulley Cover Bolt Torque N∙m (kg∙m/lb∙ft)
8 (0.81/6)
• Remove the lower cover guide pin.

Crankshaft Center Pulley Torque N∙m (kg∙m/lb∙ft)
206 (21/152)
6A-43-3.tif
1) Crankshaft Damper Pulley

• Install the damper pulley and tighten bolts to the
specified torque.
Pulley Bolts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6A-43-4.tif

11) Crank Shaft Gear
! Install the crankshaft gear.
" Use the crankshaft gear installer ! to install the
crankshaft gear ".
The crankshaft gear timing mark (“X – X”) must be
facing outward.
Crankshaft Gear Installer: 9-8522-0020-0
6A-43-5.tif
10) Crankshaft Timing Gear

! Install the camshaft timing gear to the camshaft.
The timing gear mark (“Y – Y”) must be facing
outward.
" Tighten the timing gear to the specified torque.
64 (6.5/47)
6A-44-1.tif
9) Idle Gear
! Apply engine oil to the idle gear and the idler gear
shaft.
The idler shaft oil hole must be facing up.
" Position the idler gear setting marks “X” and “Y” so
that they are facing the front of the engine.
6A-44-2.tif
# Align the idler gear “X” setting mark with the

crankshaft timing gear ! “X – X” setting mark.
$ Align the idler gear “Y” setting mark with the camshaft
timing gear ! “Y – Y” setting mark.
% Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
& Tighten the idler gear bolt to the specified torque.
19 (1.9/14)
8) Idler Gear “B” and Shaft

! Apply engine oil to the idler gear and the idler gear
shaft.
" Align the idler gear “B” # “Z” setting mark with the
idler gear “A” $ “Z-Z” setting mark.
# Tighten the idler gear bolt to the specified torque.
76 (7.7/56)
6A-44-4.tif
7) Injection Pump
! Install the O-ring ! to the injection pump flange ".
" Install the injection pump to the timing gear case.
Align the idler gear “B” # “V-V” mark.
6A-44-5.tif
# Temporarily tighten the six injection pump nuts %.

The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.
6A-45-1.tif
$ Install the injection pump rear bracket & and the rear
bracket bolts ' to the cylinder body.
% Install the rear bracket bolts ( to the injection pump
bracket ).
Do not tighten the bolts.
The rear bracket bolts ' and ( will be finally
tightened to the specified torque.
19 (1.9/14)
040LV001.tif
6) Timing Gear Oil Pipe

! Install the oil pipe to the timing gear case and idler
gear “A”.
" Tighten the oil pipe eye bolt ! and bolt " to the
specified torque.
13 (1.3/9)
6A-45-3.tif
5) Timing Gear Case Cover

! Align the gear case with the timing gear case knock
pin and then install the timing gear case cover.
" Tighten the gear case cover bolts to the specified
torque.
8 (0.8/69)
6A-45-4.tif

Tighten the crankshaft damper pulley bolt to the
specified torque.
NOTE:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley.
206 (21/152)
6A-45-5.tif
3) Cooling Fan Assembly

• Mount fan pulley, distance piece, and cooling fan asm
(in this order) on the water pump, and tighten to the
specified torque.
8 (0.8/69)
2) AC Generator, Power Steering Pump Drive Belt

• Install AC Generator, Power Steering pump drive belt
and adjust belt tension.
• Depress the drive belt mid-portion with a 98 N (10
kg/22 lb) force.
8 (0.31) - 12 (0.47)
• Tighten the idler lock nut to the specified torque.

27 (2.8/20)
1) Fan Shroud
• Install the fan shroud and reservoir tank hose.
• Pour coolant
• Start the engine and check coolant leakage.
2. Oil Pan Assembly
• Piston Head Projection Measurement Point
• Cylinder Head Assembly
• Push Rod
• Rocker Arm Shaft Assembly
Valve clearance adjustment.
Above works refer to “CYLINDER BLOCK” Section in this
manual.
PISTON AND CONNECTING ROD
Disassembly steps
1. Cylinder head Assembly
2. Oil pan Assembly
5. Connecting rod bearing cap
7. Piston ring
8. Piston pin snap ring
9. Piston pin
10. Piston
11. Connecting rod
Reassembly steps
order.
6A-47-1.tif
DISASSEMBLY
2. Oil Pan Assembly
5. Connecting Rod Bearing Cap
• Remove carbon deposits from the upper portion of the
cylinder wall with a scraper before removing the piston
and connecting rod.
7. Piston Ring
Remove the piston rings with a piston ring expander.
Arrange the removed piston rings in the cylinder number
order.
6A-48-1.tif
8. Piston Pin Snap Ring

• Use a pair of pliers to remove the piston pin snap
rings.
9. Piston Pin
NOTE:
Keep the parts removed from each cylinder separate.
All parts must be reinstalled in their original positions.
10. Piston
11. Connecting Rod
6A-48-2.tif

PISTON AND PISTON RING
Pistons
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
NOTE:
Never use a wire brush to clean the pistons. Damage will
result.
Visually check each piston for cracking, scoring, and other
signs of excessive wear.
If any of the above conditions are present, the piston must
be replaced.
Piston Diameter
1. Measure the piston outside diameter with micrometer
at the piston grading position.
Piston Grading Position mm (in)
4JB1 / 4JB1T / 4JB1TC 74 (2.913)
4JG2 71.00 (2.797)
6A-48-3.tif
4JB1 / 4JB1T / 4JB1TC mm (in)

Size Mark Outside Diameter
A 92.985 - 92.994 (3.6608 - 3.6612)
B 92.995 - 93.004 (3.6612 - 3.6616)
C 93.005 - 93.014 (3.6616 - 3.6620)
D 93.015 - 93.024 (3.6620 - 3.6624)
4JG2 mm (in)
6A-49-1.tif
Size Mark Outside Diameter
A 95.365 - 95.374 (3.7545 - 3.7549)
B 95.375 - 95.384 (3.7549 - 3.7553)
C 95.385 - 95.394 (3.7553 - 3.7557)
D 95.395 - 95.404 (3.7557 - 3.7561)
The grading position for piston outside diameter is

represented by the ‘G’ as shown in Figure.
Measure the cylinder bore inside diameter (refer to
“inspection of the cylinder Block” in this Section).
If the piston clearance does not conform to the specified
valve, the piston and/or cylinder liners must be replaced.
Piston Clearance mm (in)
4JB1 / 4JB1T / 4JB1TC 0.061 (0.0024)
4JG2 0.066 (0.0026)
Selection method of piston grade for service parts.

If you find piston grade A from size mark or piston outside
diameter measurement result, you will select AX for
service piston grade.
The stamped piston grade on the head of piston for
service parts.
Service piston grade
Piston Size Mark Service Parts Grade
A AX
B AX
C CX
D CX
Service piston diameter mm (in)

Piston Grade 4JB1 / 4JB1T / 4JB1TC
AX 92.989 - 93.004 (3.6610 - 3.6616)
CX 93.005 - 93.020 (3.6616 - 3.6622)
Piston Grade 4JG2

AX 95.369 - 95.384 (3.7547 - 3.7553)
CX 95.385 - 95.400 (3.7553 - 3.7559)
NOTE:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will
result in engine failure. Always measure the cylinder
bore and select the correct piston grade.
Piston rings
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
• Insert the piston ring into the bore.
• Push the ring by the piston, at a right angle to the wall,
into the point ring at which the cylinder bore diameter
is the smallest.
6A-50-1.tif
• The top mark of the piston ring are shown in the

illustration.
4JB1 / 4JB1T / 4JB1TC mm.(in)
Standard Limit
Compression 1st 0.20 - 0.40
ring (0.0079 - 0.0157)
2nd 0.20 - 0.40 1.5
(0.0079- 0.0157) (0.059)
0.10 - 0.30
6A-50-2.tif
Oil ring
(0.0039 - 0.0118)
4JG2 mm.(in)
Standard Limit
ring (0.0079 - 0.0138)
2nd 0.37 - 0.52 1.5
(0.0146 - 0.0205) (0.059)
0.20 - 0.40
Oil ring
(0.0079 - 0.0157)
2. Measure the clearance between the piston ring groove

and the piston ring with a feeler gauge. If the piston
ring groove/piston ring clearance exceeds the
specified limit, the piston must be replaced.
Standard Limit
ring (0.0035 - 0.0049)
2nd 0.050 - 0.075 0.15
6A-50-3.tif
(0.0020 - 0.0030) (0.0059)
0.03 - 0.07
Oil ring
(0.0012 - 0.0028)
4JG2 mm (in)
Standard Limit
Compression 1st 0.09-0.13
ring (0.0035 - 0.0051)
2nd 0.05 - 0.07 0.15
(0.0020 - 0.0028) (0.0059)
0.03-0.07
Oil ring
(0.0012-0.0028)
Piston pin
Visually inspect the piston pin for cracks, flaws, and other
damage and replace if necessary.
1. Use a micrometer to measure the piston pin outside
diameter in both directions at three different positions.
If the measurement exceed the specified limit the
piston pin must be replaced.
Piston pin outside diameter mm (in)
Standard Limit
6A-51-1.tif 4JB1 /
30.995 - 31.000
4JB1T 30.970 (1.2190)
(1.2202 - 1.2204)
4JB1TC
33.995 - 34.000
4JG2 33.970 (1.3374)
(1.3384 - 1.3386)
2. Measure the inside diameter of the connecting rod

small end. If the clearance between the small end and
pin does not conform to the specified value, the
connecting rod or bushing and pin must be replaced.
mm (in)
Standard Limit
0.008 - 0.020 0.05
Clearance
(0.0003 - 0.0008) (0.0020)
3. Insert the piston pin into the piston and rotate it. If the
6A-51-2.tif
pin rotates smoothly with no backlash, the clearance is
normal. If there is backlash or roughness, measure the
clearance. If the clearance exceeds the specified limit,
the piston and the piston pin must be replaced.
mm (in)
Standard Limit
0.002 - 0.004 0.04
Clearance
(0.00008 - 0.00016) (0.0016)
Bushing replacement
Removal: Use a suitable bar and bench press or
hammer.
Installation: Use a suitable bar and bench press.
NOTE:
Align the bushing with the connecting rod oil port.
After installing a new bushing, finish the bushing bore
with a pin hole grinder.
6A-52-1.tif
Connecting rods
1. Check the connecting rod alignment with a connecting
rod aligner.
If either the bend or the twist exceeds the specified
limit, the connecting rod must be replaced.
mm (in)
Standard Limit
Bend per 100 (3.94) 0.08 (0.0031) or less 0.20 (0.0079)
6A-52-2.tif
Twist per 100 (3.94) 0.05 (0.0020) or less 0.15 (0.0059)
2. Measure the connecting rod thrust clearance.

Use a feeler gauge to measure the thrust clearance at
the big end of the connecting rod.
If the clearance exceeds the specified limit, the
connecting rod must be replaced.
Thrust Clearance mm (in)
Standard Limit
0.230 (0.0091) 0.350 (0.0138)
6A-52-3.tif
3. Measure the oil clearance between the connecting rod

and the crankshaft by:
1) Remove the connecting rod cap nuts and the rod
caps.
Arrange the removed rod caps in the cylinder
number order.
2) Clean the rod bearings and the crankshaft pins.
3) Carefully check the rod bearings.
If even one bearing is found to be damaged or
badly worn, the entire bearing assembly must be
6A-52-4.tif
replaced as a set. Reinstall the bearings in their
original positions.
Apply plastigage to the crank pin.
4) Reinstall the rod caps to their original positions
5) Tighten the cap nuts in 2 steps, using angular

tightening method as shown in the following
specifications. (4JG2)
4JG2 N∙m (kg∙m/lb∙ft)
1st Steps 2nd Step
29 (3.0/22) 45° - 75°
4JA1, 4JB1, 4JB1TC N∙m (kg∙m/lb∙ft)

83 (8.5/61)
NOTE:
Do not allow the crankshaft to rotate.
6) Remove the rod caps.

7) Measure the width of the plastigage and determine
the oil clearance. If the oil clearance exceeds the
limit, replace the rod bearings as a set.
8) Clean the plastigage from the bearings and the
crankshaft pins.
Crankshaft Journal and Bearing Clearance mm (in)
Standard Limit
4JB1 /
6A-53-1.tif 0.029 - 0.066
4JB1T /
(0.0011 - 0.0026)
4JB1TC 0.100 (0.0039)
0.029 - 0.083
4JG2
(0.0011 - 0.0033)
REASSEMBLY
11. Connecting Rod
10. Piston
9. Piston Pin
Apply a cost of engine oil to the piston pin and the piston
pin hole.
8. Piston Pin Snap Ring
Apply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin hole with
normal finger pressure.
Weigh each piston and connecting rod assembly.
Select piston and connecting rod combinations so that the
weight variation of the different assemblies a held within
the specified limits.
g (oz)
Variance in weight Less than 3
after assembly (0.1058)
NOTE:
When changing piston/connecting rod combinations,
do not change the piston/piston pin combination
• Attach the piston to the connecting rod with the piston

front mark and the connecting rod ISUZU mark on the
same side.
6A-54-1.tif
7. Piston Ring
• Install the piston rings with the piston ring expander.
The compression ring must be set with the 1N, 2N
mark (4JG2) facing up.
• Discrimination mark is painted as shown in the
illustration.
6A-54-2.tif
• Install piston rings in the following sequence.

1) Oil ring
! Expander ring
" Upper side rail
# Lower side rail
2) 2nd compression ring
3) 1st compression ring
• The compression ring must be set with the 1N or 2N
6A-54-3.tif
• 1st compression ring: 1N (4JG2), N (4JB1)

• 2nd compression ring: 2N (4JG2), N (4JB1)
• After installation, apply engine oil to the entire
circumference of the piston rings.
Check to see that all the rings rotate smoothly.
• Insert the bearings into the connecting rods and caps.
Apply new engine oil to the bearing faces.
Cap side bearings have no oil hole.
Conn rod side bearings oil hole should be aligned with
6A-54-4.tif
oil hole on the conn rod.

• Apply engine oil to the cylinder bores, the connecting
rod bearings and the crankshaft pins.
• Check to see that the piston ring end gaps are
correctly positioned.
• Insert the piston/connecting rod assemblies into each
cylinder with the piston ring compressor.
• The front marks must be facing the front of the engine.
• Tighten the cap nuts in 2 steps, using angular
6A-55-1.tif
tightening method as shown in the following
specifications.
4JG2 N∙m (kg∙m/lb∙ft)
1st Steps 2nd Step
29 (3.0/22) 45° - 75°
4JA1, 4JB1, 4JB1TC N∙m (kg∙m/lb∙ft)

83 (8.5/61)
After tightening the cap nuts, check to see that the

crankshaft rotates smoothly.

• Install the piston cooling oil pipe to the cylinder body.
• Tighten the oil pipe bolts and relief valve to the
specified torque.
Oil Pipe Bolt Torque N∙m (kg∙m/lb∙ft)
(1) M8 x 1.25 19 (1.9/14)
(2) M6 x 1.00 8 (0.8/69)
6A-55-2.tif
Oil Pressure Regulating

Valve Torque N∙m (kg∙m/lb∙ft)
(3) M16 x 1.5 29 (3.0/22)
NOTE:
Check that there is no interference between the piston
and the oiling jet pipe by slowly rotating the
crankshaft.
2. Oil Pan Assembly
• Piston Head Projection Measurement Point
• Cylinder Head ASM
• Push Rod
• Rocker Arm Shaft ASM
Valve clearance adjustment.
Above works refer to “CYLINDER BLOCK” Section in this
manual.
CYLINDER BLOCK
Disassembly steps
gasket
2. Oil pan Assembly
3. Timing gear
3a. Timing belt and pulley
4. Front oil seal
5a 5a. Timing pulley housing
9. Flywheel
10. Cylinder block rear plate
11. Crankshaft rear oil seal
12. Main bearing cap
13. Crankshaft
14. Camshaft
15. Tappet
16. Cylinder block
Reassembly steps
order.
6A-56-1.tif
DISASSEMBLY
2. Oil Pan Assembly
3. Timing Gear

9. Flywheel
11. Crankshaft Rear Oil Seal
13. Crankshaft
14. Camshaft
15. Tappet
16. Cylinder Block

during inspection.
1. Remove the gasket and any other material adhering
the upper surface of the cylinder block.
Be very careful not to allow any material to accidental
drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, Rear Seal retainer and
oil pan installation surface seal.
3. Wipe the cylinder block clean.
Cylinder Liner Projection Inspection

1. Hold a straight edge ! along the top edge of the
cylinder liner to be measured.
2. Use a feeler gauge " to measure each cylinder line
projection.
The difference in the cylinder liner projection height
between any two adjacent cylinders must not exceed
0.03 mm (0.0012 in).
Standard mm (in)
6A-57-1.tif
0.0 - 0.1 (0.0000 - 0.0039)
Flatness
1. Remove the cylinder body dowel.
2. Set the cylinder liner remover to the cylinder liner.
3. Check that the remover shaft ankle is firmly gripping
the cylinder liner bottom edge.
4. Slowly turn the remover shaft handle counterclockwise
to pull the cylinder liner free.
Cylinder Liner Remover Ankle: 5-8840-2304-0 (4JG2)
5-8840-2039-0
6A-57-2.tif
(4JB1/4JB1T/4JB1TC)
NOTE:
Take care not to damage the cylinder body upper
during the cylinder liner removal procedure.
5. Use a straight edge ! and a feeler gauge " to

measure the four sides and the two diagonals of the
cylinder body upper face.
If the measured values exceeds the limit, the cylinder
body must be replaced.
6A-58-1.tif
Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder liner bore
at measuring point ! in the thrust " - " and axial #
direction of the crankshaft.
Measuring Point ! 20mm (0.79 in)
cylinder liner must be replaced.
NOTE:
The inside of the dry type cylinder liner is chrome
6A-58-2.tif
plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.
Cylinder Liner Grade Selection

Measure the cylinder body inside diameter and select the
appropriate cylinder liner grade.
Standard Lifting Interference mm (in)
0.01 - 0.019 (0.0004 - 0.0007)
If the cylinder liner fitting interference is too small, engine

cooling efficiency will be adversely effected.
If the cylinder liner fitting interference is too large, it will be
6A-58-3.tif
difficult to insert the cylinder liner into the cylinder body.
6A-58-4.tif
Cylinder Body Bore Measurement

1) Take measurements at measuring point (A) across
positions ! - !, " - ", # - #, and $ - $.
Measuring Point (A) 98mm (3.86 in).
2) Calculate the average value of the four measurements
to determine the correct cylinder grade.
3) Consult the following table with the resultant diameter
for the correct liner application.
6A-59-1.tif
6A-59-2.tif
Selection method of cylinder liner and piston grade for

service parts.
The production line stamped cylinder liner grade on the
top of cylinder body, the cylinder liner outside diameter
grade 1, 2, 3, 4.
If you find cylinder liner outside diameter grade 1 and
piston outside diameter B on the cylinder body or result of
measurement for each parts, you will select service parts
grade for cylinder liner 1, AX grade and for piston AX
grade.
The stamping grade code on the service parts are;
For cylinder liner grade stamped on the outside of cylinder
liner.
For piston grade stamped on the head of piston.

Liner Liner
Cylinder bore Liner outside
outside bore Service liner bore measurement
diameter average diameter
Grade Grade
95.001 - 95.010 95.011 - 95.020 AX 93.035 (3.6628) - 93.050 (3.6634)

1
(3.7402 - 3.7406) (3.7406 - 3.7409) CX 93.051 (3.6634) - 93.066 (3.6640)
95.011 - 95.020 95.021 - 95.030 AX 93.035 (3.6628) - 93.050 (3.6634)

2
(3.7406 - 3.7409) (3.7410 - 3.7413) CX 93.051 (3.6634) - 93.066 (3.6640)
95.021 - 95.030 95.031 - 95.040 AX 93.035 (3.6628) - 93.050 (3.6634)

3
(3.7410 - 3.7413) (3.7414 - 3.7417) CX 93.051 (3.6634) - 93.066 (3.6640)
95.031 - 95.040 95.041 - 95.050 AX 93.035 (3.6628) - 93.050 (3.6634)

4
(3.7414 - 3.7417) (3.7418 - 3.7421) CX 93.051 (3.6634) - 93.066 (3.6640)
4JG2 mm (in)
Liner Liner
Cylinder bore Liner outside
outside bore Service liner bore measurement
diameter average diameter
Grade Grade
97.001 - 97.010 97.011 - 97.020 AX 95.435 (3.7573) - 95.450 (3.7579)

1
(3.8189 - 3.8193) (3.8193 - 3.8197) CX 95.451 (3.7579) - 95.466 (3.7585)
97.011 - 97.020 97.021 - 97.030 AX 95.435 (3.7573) - 95.450 (3.7579)

2
(3.8193 - 3.8197) (3.8197 - 3.8201) CX 95.451 (3.7579) - 95.466 (3.7585)
97.021 - 97.030 97.031 - 97.040 AX 95.435 (3.7573) - 95.450 (3.7579)

3
(3.8197 - 3.8201) (3.8201 - 3.8205) CX 95.451 (3.7579) - 95.466 (3.7585)
97.031 - 97.040 97.041 - 97.050 AX 95.435 (3.7573) - 95.450 (3.7579)

4
(3.8201 - 3.8205) (3.8205 - 3.8209) CX 95.451 (3.7579) - 95.466 (3.7585)
NOTE:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will
result in engine failure. Always measure the cylinder
bore and select the correct piston grade.
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in
slight decreases in cylinder liner clearances. Always
measure the cylinder liner clearance after installation
to be sure that it is correct.
Cylinder Liner Installation

1. Cylinder Liner Installation Using The Special Tool.
1) Use new kerosene or diesel oil to thoroughly clean
the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder liner
and bore surfaces.
Cylinder Liner Installer: 5-8840-2313-0 (4JG2)
: 5-8840-2040-0 (4JB1 / 4JB1T/
4JB1TC)
6A-60-1.tif
NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
3) Insert the cylinder liner ! into the cylinder body "

from the top of the cylinder body.
6A-60-2.tif
4) Set the cylinder liner installer 3 to the top of the

cylinder liner.
Position the cylinder body so that the installer
center is directly beneath the bench press shaft
center 4.
Cylinder Liner Installer: 5-8840-2313-0 (4JG2)
: 5-8840-2040-0 (4JB1/4JB1T/
4JB1TC)
NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
5) Use the bench press to apply a seating force of 500 kg
(1,102.5 lb/4,900 N) to the cylinder liner.
6) Apply a force 2,500 kg (5,512.5 lb/24,500 N) to fully
seat the cylinder liner.
7) After installing the cylinder liner, measure the cylinder
liner projection.
8) After installing the cylinder liner, measure the cylinder
liner projection.
Refer to “Cylinder Liner Projection Inspection” in this
Section.
Measure the cylinder liner bore inside diameter and
select the appropriate piston grade.
REASSEMBLY
16. Cylinder Block
15. Tappet
14. Camshaft
• Apply a coat of engine oil to the tappet and the cylinder
body tappet insert holes.
• Locate the position mark applied at disassembly (if the
• Apply a coat of engine oil to the camshaft and the
camshaft bearings.
• Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
6A-61-1.tif
13. Crankshaft
9. Flywheel
Above works refer to “CRANKSHAFT” Section in this
manual.

1) Try to insert the piston pin into the piston pin hole with
Select piston and connecting rod combinations so that
the weight variation of the different assemblies is held
within the specified limits.
g (oz)
Variance in weight Less than 3
after assembly (0.1058)
2) Clamp the connecting rod in a vise.

Take care not to damage the connecting rod.
3) Use a pair of pliers to install the piston pin snap ring to
the piston.
NOTE:
6A-62-1.tif
do not change the piston/piston pin combination.
4) Install the piston to the connecting rod.

The piston head front mark ! and the connecting rod
“ISUZU” casting mark " must be facing the same
direction.
6A-62-2.tif
5) Apply a coat of engine oil to the piston pin and the

piston pin hole.
Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
6A-62-3.tif
6) Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
Check that the connecting rod moves smoothly on the
piston pin.
6A-62-4.tif
7) Install the piston rings with the piston ring expander.

Discrimination mark is painted as shown in the
illustration.
6A-63-1.tif
8) Use a piston ring replacer to install the three piston

rings.
Piston Ring Replacer:
Install the piston rings in the numerical order shown in
the illustration.
! Oil ring
" 2nd compression ring
# 1st compression ring
6A-63-2.tif
NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
6A-63-3.tif
9) Apply engine oil to the piston ring surfaces.

10) Check that the piston rings rotate smoothly in the
piston ring grooves.
11) Position the piston ring gaps as shown in the

illustration.
6A-63-4.tif
12) Carefully wipe any oil or other foreign material from

connect rod bearing back face and the connecting rod
bearing fitting surface.
13) Apply a coat of engine oil to the upper bearing
surfaces.
Apply a coat of engine oil to the cylinder wall.
6A-64-1.tif
14) Position the piston head from mark so that it is facing

the front of engine.
Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0 (J-8037)
15) Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
6A-64-2.tif
16) Position the bearing cap front mark so that it is facing

the front of the engine.
17) Install the connecting rod bearing caps.
Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
6A-64-3.tif
18) Apply a coat of engine oil to the threads and setting

faces of each connecting rod cap bolt.
19) Tighten the connecting rod bearing cap bolts to the
specified torque in two steps using the Angular
Tightening Method.
Connecting Rod Bearing Cap Bolt
1st Step 2nd Step
4JG2 29 (3.0/22) 45° - 75°
6A-64-4.tif
4JB1/4JB1TC 83 (8.5/61)
NOTE

1) Fix the oil jet pipes with knock pins on the cylinder
block.
2) Install the oil pipe for piston cooling in the cylinder
block, tightening a relief valve ! and four joint bolts "
Oil pipe fixing bolts N∙m (kg∙m/lb∙ft)
M8: 19 (1.9/14)
M6: 8 (0.8/69 lb∙in.)
6A-65-1.tif
Relief valve fixing bolt N∙m (kg∙m/lb∙ft)

29 (3.0/22)
CAUTION:
After installed the piston assembly. Check and see
that there is appropriate clearance between pistons
and oil jet pipes by rotating crankshaft slowly.
6) Camshaft Timing Pulley
5) Timing Belt
4) Flange: Camshaft Pulley
3) Timing Pulley Lower Cover
2) Timing Pulley Upper Cover
11) Crankshaft Gear
10) Crankshaft Timing Gear
9) Idle Gear
8) Idler Gear "B" and Shaft
7) Injection Pump
6) Timing Gear Oil Pipe
5) Timing Gear Case Cover
3) Cooling Fan Assembly
2) AC Generator, Power Steering Pump Drive Belt
1) Fan Shroud
Above works refer to “CRANKSHAFT” Section in this
manual.
2. Oil Pan Assembly

Above works refer to “OIL PUMP” Section in this
manual.

! Cylinder head gasket is determined by the piston
head projection from the cylinder body upper
surface, in order to improve engine performance.
Three types of gasket are provided by the
difference of thickness. Select the adequate one
out of three grades of gasket, according to the
following procedure.
Before measurement, clear off carbon from the
piston head and cylinder body surface and also
6A-66-1.tif clean the place where a gasket was installed.
Piston Head Projection Measurement Point

" Use a dial indicator to measure the piston
projection amount.
# Refer to the illustration for the piston head
projection measuring positions.
All measuring positions should be as close as
possible to the cylinder liner.
$ Measure the points ! " # $ and obtain two
difference ! - " and # - $ on each cylinder.
6A-66-2.tif
Calculate the average value of the piston head
projection on each cylinder.
% Obtain the maximum value in the four cylinders.
& Determine the gasket grade required to the
maximum value described above in accordance
with the following table.
4JB1 / 4JB1T / 4JB1TC

Cylinder Head Gasket Thickness mm (in)
Gasket
Gasket Grade Piston
Thickness
Mark Projection
(Reference)
0.758-0.813
A 1.60 (0.0630)
(0.030-0.032)
0.813-0.859
B 1.65 (0.0650)
(0.032-0.034)
6A-66-3.tif
0.859-0.914
C 1.70(0.0670)
(0.034-0.036)
NOTE:
The difference between the highest measured piston
head projection and the lowest measured piston head
projection must not exceed 1.0mm (0.039 in).
4JG2 Cylinder Head Gasket Thickness mm (in)

Grade Average Piston Gasket
mark projection thickness
0. 658-0.713 1.60
A
(0.0259-0.0281) (0.0630)
0.713-0.759 1.65
B
(0.0281-0.0299) (0.0650)
0.759-0.814 1.70
C
6A-67-1.tif
(0.0299-0.0320) (0.0670)
NOTE:
projection must not exceed 1.0mm (0.039 in).
Cylinder Head Assembly

! Install the dowel in cylinder block.
" Install the cylinder head gasket with top mark up.
# Clean up cylinder head lower surface and cylinder
body upper surface.
$ Install the cylinder head as softly.
% Apply molybdenum disulfide grease to screw and seat
of cylinder head bolts.
& Tighten the cylinder head bolts to the specific torque in
6A-67-2.tif
three step following the numerical and shown in the
illustration.
Cylinder Head Bolts Torque N∙m (kg∙m/lb∙ft)
1st Step 2nd Step 3rd Step
49 (5.0/36) 60° - 75° 60° - 75°
Push Rod
• Apply engine oil to push rod and into the cylinder head.
Rocker Arm Shaft Assembly

! Loosen all adjusting screws.
" Position the rocker arm shaft with the large oil hole
6A-67-3.tif
# Tighten the rocker arm shaft bracket bolts to the

specified torque in the numerical order shown in the
illustration.
Rocker Arm Shaft Bracket Bolt Torque N∙m (kg∙m/lb∙ft)
54 (5.5/40)
• Valve clearance adjustment.
6A-68-1.tif
HOME
4JB1/4JB1T/4JB1TC/4JG2 – ENGINE 6A1 – 1
SECTION 6A1
4JB1/4JB1T/4JB1TC/4JG2-ENGINE
CONTENTS
PAGE
General Description.................................................................................................... 6A1- 2
Engine Mount (RH)...................................................................................................... 6A1- 4
Engine Mount (LH) ...................................................................................................... 6A1- 6
Inlet Manifold............................................................................................................... 6A1- 8
Exhaust Manifold ........................................................................................................ 6A1- 10
Oil Cooler..................................................................................................................... 6A1- 12
Oil Filter Cartridge ...................................................................................................... 6A1- 14
Cylinder Head Cover................................................................................................... 6A1- 15
Rocker Arm Shaft Assembly...................................................................................... 6A1- 17
Valvestem Oil Controller and Valve Spring .............................................................. 6A1- 20
Timing Gear................................................................................................................. 6A1- 23
Timing Belt .................................................................................................................. 6A1- 30
Cylinder Head Assembly and Gasket........................................................................ 6A1- 37
Oil Pan ......................................................................................................................... 6A1- 48
Oil Pump Assembly .................................................................................................... 6A1- 51
Piston, Piston Ring and Connecting Rod ................................................................ 6A1- 54
Camshaft and Tappet ................................................................................................. 6A1- 63
Crankshaft Front Oil Seal (Gear Drive Type) ............................................................ 6A1- 71
Crankshaft Front Oil Seal (Belt Drive Type) ............................................................. 6A1- 73
Crankshaft Rear Oil Seal (Gear & Belt Drive Type).................................................. 6A1- 76
Flywheel and Pilot Bearing ........................................................................................ 6A1- 83
Crankshaft and Main Bearings .................................................................................. 6A1- 85
Engine Assembly ........................................................................................................ 6A1- 96
6A1 – 2 4JB1/4JB1T/4JB1TC/4JG2 - ENGINE
GENERAL DESCRIPTION
6A1-2-1.tif
4JB1-TC
F06LX002.tif F06LX005.tif
The 4JB1 Model engine employs a square troidal type Take care not to damage the oiling jet when removing
combustion chamber provided with a fence around it. or installing the piston and the connecting assembly.
These designs employed allow a superior fuel The 4JG2 engine use a single spring pintle type
economy over a wide range of driving conditions. injection nozzle.
The 4JG2 Model engine employs, for its combustion The 4JB1 Model employs a direct injection type engine
chamber, the RECARD Comet V Type swirl provided with a nozzle with four holes, which makes it
combustion chamber which provides a superior driving possible to obtain an excellent mixing ratio of intake air
performance, fuel economy and silent combustion over and fuel spray.
a wide range of driving conditions. 4JB1-TC engine has two springs injection nozzle
For the cylinder head gasket steel sheets, laminated system for efficient control.
steel sheets are employed. The turbocharger increase air intake efficiency, the
Three grades of the gaskets according to the piston results in increased engine power, reduced fuel
head projection measured from the cylinder block are consumption and minimal engine noise.
employed to minimize the fluctuation of the engine Turbocharger rotating parts operate at very high
compression ratio. speeds and temperatures. The parts materials have
The Angular Tightening Method is employed to tighten been carefully selected and machined to extremely
the cylinder head fixing bolts, connecting rod fixing high precision.
bolts and flywheel fixing bolts. The 4JB1 Model engine employs the QOS II
The chrome-plated steel dry type (Chromard) cylinder preheating system which features a quick-on glow to
liners provide the highest durability. control the glow time and the afterglow time by the
Auto-thermic pistons with cast steel struts are used to thermometer.
reduce thermal expansion and resulting engine noise The 4JG2 engine employs the QOS III system which
experienced while the engine is cold. allows the most suitable starting conditions for the
The tufftrided crankshaft has a long service life. glow time to change according to the engine water
Because it is tufftrided, it cannot be reground. temperature, and the optimum for the glow time to
The crankshaft main bearings and the connecting rod change according to the engine water temperature,
bearings are of aluminum alloy. These bearings are and the optimum changes according to the water
especially vulnerable to foreign materials such as metal temperature immediately after the start of the engine.
scraps. It is very important to keep the oil ports and The belt-driven type timing drive belt of the 4JG2
other related surfaces clean and free of foreign Model engine is a very important functional part, and
materials. requires the specified maintenance.
The tufftriding treatment (nitriding treatment) of the
crankshaft for the increased strength eliminates the
regrinding of crankpins and journals.
An oiling jet device for piston cooling is provided in the
lubricating oil circuit which runs through the check
valve from the cylinder block oil gallery.
ENGINE MOUNT (RH)
Rigid sus
6A1-4-1.tif
REMOVAL
Preparation:
1. Fan Shroud
• Remove reservoir tank hose and fan shroud.
2. Fan Belt
• Remove adjust plate lock bolt.
• Loosen generator fixing bolt then remove fan belt.
6A1-4-2.tif
3. Support Rubber
• Remove two fixing nuts at the crossmember side.
6A1-4-3.tif
• Separate the generator from the engine.

• Remove the support rubber nut from engine foot side.
• Remove the support rubber while raising the engine.
6A1-5-1.tif
INSTALLATION
3. Support Rubber
• Install the support rubber while raising the engine.
• Tighten the fixing nuts to the specified torque.
Engine foot side N∙m(kg∙m/lb∙ft)
82(8.4/61)
Crossmember side N∙m(kg∙m/lb∙ft)

40(4.1/30)
2. Fan Belt
• Install the fan belt.
• Depress the fan belt mid-portion with a 98N
(10kg/22lb) force.
• Tighten the fixing bolt to the specified torque.
Adjust plate lock bolt N∙m(kg∙m/lb∙ft)

19(1.9/14)
Generator fixing bolt N∙m(kg∙m/lb∙ft)

6A1-5-2.tif
40(4.1/30)
1. Fan Shroud
• Install the fan shroud and clip the reservoir tank hose.
ENGINE MOUNT (LH)
Rigid sus
6A1-6-1.tif
REMOVAL
Preparation:
1. Air Intake Duct
• Remove the intake duct.
2. Fan Shroud
• Remove reservoir tank hose and fan shroud.
6A1-6-2.tif
3. Support Rubber
• Remove two fixing bolts at the crossmember side.
6A1-6-3.tif
• Remove the support rubber nut from engine foot side.

• Remove the support rubber while raising the engine.
6A1-7-1.tif
INSTALLATION
3. Support Rubber
• Install the support rubber while raising the engine.
Engine foot side N∙m (kg∙m/lb∙ft)

82 (8.4/61)
Crossmember side N∙m (kg∙m/lb∙ft)

6A1-7-2.tif
40 (4.1/30)
2. Fan shroud
• Install the fan shroud and clip the reservoir tank hose.
1. Air Intake Duct
• Install the air intake duct.
6A1-7-3.tif
INLET MANIFOLD
Removal steps
1. Vacuum hose
2. Air intake duct
3. PCV hose
4. Injection pipe
5. Oil level gauge guide tube
6. Oil cooler water pipe (Oil
Cooler Model)
7. Inlet manifold
Installation steps
To install, follow the removal
steps in the reverse order.
6A1-8-1.tif
REMOVAL
Preparation:
• Drain coolant.
1. Vacuum Hose
2. Air Intake Duct
3. PCV Hose
4. Injection Pipe
• Release injection pipe clip.
• Loosen the flare nut on the injection pump side.
• Loosen the flare nut on the injection nozzle side,
disconnect and put a side the pipe.
6A1-8-2.tif

• Remove the fixing bolt and remove level gauge guide
tube.
6. Oil Cooler Water Pipe (Oil Cooler Model)

• Remove the water pipe bracket bolt.
• Remove the inlet manifold fixing nut.
7. Inlet Manifold
• Remove the manifold fixing bolt and nut.
6A1-9-1.tif
INSTALLATION
7. Inlet Manifold
• Tighten the fixing bolts and nuts to the specified
torque.
Bolt & Nut N∙m(kg∙m/lb∙ft)
19(1.9/14)

• Install the water pipe and tighten the manifold with
water pipe.
• Tighten the pipe bracket bolt of cylinder head rear
side.
• Install the guide tube and tighten the manifold with
guide tube.
6A1-9-2.tif
4. Injection Pipe
• Connect the injection pipe and tighten flare nut to the
specified torque.
Flare nut torque N∙m(kg∙m/lb∙ft)
29(3.0/22)
• Install the pipe clip to the original position.

3. PCV Hose
2. Air Intake Duct
6A1-9-3.tif 1. Vacuum Hose
• Pour coolant.
EXHAUST MANIFOLD
6A1-10-1.tif
REMOVAL
Preparation:
1. Vacuum Hose (Exhaust Brake Model)
• Remove the vacuum actuator hose.
2. Front Exhaust Pipe Nut
• Remove the fixing nuts from exhaust manifold side.
3. Front Exhaust Pipe Stay Bolt
6A1-10-2.tif
4. Heat Protector
5. Exhaust Manifold
• Remove the manifold bolt and nut, then remove the
manifold and gasket.
INSTALLATION
5. Exhaust Manifold
• Tighten the fixing nuts and bolts to the specified
torque.
Manifold Bolt Torque N∙m(kg∙m/lb∙ft)
26 (2.7/20)
4. Heat Protector
• Remove the heat protector and tighten to the specified
torque.
Heat Protector Bolt Torque N∙m(kg∙m/lb∙ft)
19 (1.9/14)
3. Front Exhaust Pipe Stay Bolt

• Tighten the fixing bolts to the specified torque.
Stay Bolt Torque N∙m(kg∙m/lb∙ft)
40 (4.1/30)
2. Front Exhaust Pipe Nut

Without Exhaust Brake N∙m(kg∙m/lb∙ft)
69 (7/51)
With Exhaust Brake N∙m(kg∙m/lb∙ft)

69 (7/51)
1. Vacuum Hose (Exhaust Brake Model)

• Install the two hose a vacuum actuator.
OIL COOLER (Oil Cooler Model)
6A1-12-1.tif
REMOVAL
Preparation:
• Drain coolant
• Put rag to beneath side of oil cooler to prevent oil
leaking.
1. Water Hose
• Disconnect water inlet and outlet hose.
2. Oil Cooler Fixing Bolt
3. Oil Cooler
INSPECTION
Relief Valve
1. Attach an oil pressure gauge to the oil gallery near the
oil filter.
2. Start the engine to check the relief valve opening
pressure.
2
Relief Valve Opening Pressure kPa (kg/cm /psi)
Type1 559-618 (5.7-6.3/81.0-89.6)
6A1-13-1.tif
Type2 422-461 (4.3-4.7/61.1-66.8)
Oil Cooler
Check for water leakage at the water passage.
1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
2
3. Apply compressed air (2 kg/cm (28.5psi/196.0kPa)) to
the other side of the oil cooler water passage.
If air bubbles rise to the surface, there is water
leakage.
6A1-13-2.tif
INSTALLATION
3. Oil Cooler
• Install the O-ring to oil filter body and set the oil cooler.
2. Oil Cooler Fixing Bolt
Oil Cooler Bolt Torque N∙m (kg∙m/lb∙ft)
29 (3.0/22)
1. Water Hose
6A1-13-3.tif • Connect water hose.
OIL FILTER CARTRIDGE
6A1-14-1.tif
REMOVAL
• Place a receptacle beneath the oil filter to contain the
drained oil.
• Remove the oil filter cartridge using filter wrench.
6A1-14-2.tif
INSTALLATION
• Lightly oil the O-ring of oil filter cartridge.
• Turn in the new oil filter cartridge by hand until the
sealing face is fiffted against the O-ring.
• Use the filter wrench to turn in the oil filter and
additional one and 1.1/8 turns.
• Start the engine and check for oil leakage from oil
filter.
CYLINDER HEAD COVER
Removal steps
1. PCV hose
2. Cylinder head cover
Installation steps
To install, follow the removal steps in
the reverse order.
6A1-15-1.tif
REMOVAL
Preparation:
1. PCV Hose
• Disconnect the PCV hose from intake pipe side.
2. Cylinder Head Cover
INSTALLATION
6A1-15-2.tif

• Apply engine oil to the rocker arms and the valve
springs.
• Install the cylinder head cover gasket to the cylinder
head cover.
• The gasket must be perfectly smooth with no loose
areas.
• Tighten the cylinder head cover nuts to the specified
torque.
13 (1.3/9)
1. PCV Hose
• Connect the PCV hose to the intake pipe.
ROCKER ARM SHAFT ASSEMBLY
Removal steps
1. PCV hose
3. Rocker arm shaft Assembly
Installation steps
the reverse order.
6A1-17-1.tif
REMOVAL
Preparation:
1. PCV Hose
• Loosen bolts and nuts of rocker shaft bracket by turns
and remove rocker shaft assembly.
6A1-17-2.tif
INSTALLATION
• Install rocker arm shaft with larger oil hole (φ4) to the
front of engine.
• Align fixing bolt with nut of rocker arm shaft and
tighten fixing bolts to the specified torque.
54 (5.5/40)
6A1-17-3.tif
Valve Clearance Adjustment

! Bring the piston in either the No.1 cylinder or the No.4
cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.
6A1-18-1.tif
" Check the rocker arm shaft bracket nuts for

looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.
Rocker Arm Shaft Bracket Nut Torque N∙m (kg∙m/lb∙ft)
54 (5.5/40)
6A1-18-2.tif
# Check for play in the No.1 intake and exhaust valve

push rods.
If the No.1 cylinder intake and exhaust valve push rods
have play, the No.1 piston is at TDC on the
compression stroke.
If the No.1 cylinder intake and exhaust valve push rods
are depressed, the No.4 piston is at TDC on the
compression stroke.
6A1-18-3.tif
Adjust the No.1 or the No.4 cylinder valve clearances

while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)
$ Loosen each valve clearance adjusting screw as

% Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.
6A1-18-4.tif
& Turn the valve clearance adjusting screw until a slight

drag can be felt on the feeler gauge.
' Tighten the lock nut securely.
( Rotate the crankshaft 360°.
) Realign the crankshaft damper pulley TDC notched
line with the timing pointer.
* Adjust the clearances for the remaining valves as
6A1-18-5.tif

• Install cylinder head cover and tighten bolts to the
specified torque.
13 (1.3/113)
1. PCV Hose
VALVESTEM OIL CONTROLLER & VALVE SPRING
Removal steps
2. Rocker arm shaft Assembly
3. Valve spring
4. Valve guide oil seal
Installation steps
6A1-20-1.tif
REMOVAL
Preparation:
• Loosen bolts and nuts of rocker shaft
• Bracket by turns and removal rocker shaft assembly.
3. Valve Spring
• Apply compressed air to cylinder from the glow plug
hole hold the valve in place.
• Using special tool, compress valve spring and removal
split collar.
6A1-20-2.tif
CAUTION
• Put removed valve springs in the order of cylinder
number.

• Removal valve guide oil seal by pliers.
CAUTION
• Removed oil controller should not be reused.
6A1-21-1.tif
INSTALLATION
• Install new valve guide oil seal in valve.
• Guide using special tool.
Special tool: 5-8840-2033-0
3. Valve Spring
• Attach the valve spring to the upper spring seat.
6A1-21-2.tif
CAUTION
• The painted area of the valve spring should be facing
toward.
• Apply compressed air to cylinder from the glow plug
hole to hold the valve in place.
• Install split collar by special tool.
6A1-21-3.tif
2. Rocker Shaft Assembly

• Install rocker arm shaft with a larger oil hole (φ4) to the
front of engine.
• Align fixing bolt with not of rocker arm shaft and
tighten fixing bolt to the specified torque.
54 (5.5/40)
• Valve clearance adjustment

6A1-21-4.tif

Above works refer to “ROCKER ARM SHAFT
ASSEMBLY” Section in this manual.

spring.
head cover.
The gasket must be perfectly smooth with no loose
areas.
• Install cylinder head cover and tighten bolt to the
specified torque.
Head Cover Bolt Torque N∙m (kg∙m/lb∙in)
6A1-22-1.tif
13 (1.3/113)
• Connected PCV hose.

TIMING GEAR (4JB1, 4JB1TC, 4JG2 Gear Type)
6A1-23-1.tif
REMOVAL
Preparation:
• Drain coolant.
1. Fan Shroud
2. Power Steering Pump Drive Belt (P/S Model)
• Loosen power steering pump mounting bolt and adjust
bolt, and remove the drive belt.
3. AC Generator Drive Belt
• Loosen AC Generator mounting bolt (under side) and
adjust plate lock bolt, and remove the drive belt.
4. Cooling Fan Assembly
• Remove clamp nut, and remove cooling fan assembly,
distant pipe, and fan pulley.
5. Crankshaft Damper Pulley
6. Noise Shield Cover
7. Noise Cover Spacer

8. Timing Gear Case Cover
9. Oil Pipe
10. Idler Gear
1) Measure the camshaft timing gear backlash and the
crankshaft timing gear backlash before removing the
idler gear.
2) Measure the idler gear end play before removing the
idler gear.
NOTE:
Refer to the following items for details on the
backlash and end play measurement procedures.
6A1-24-1.tif
Timing Gear Backlash Measurement

1) Set a dial indicator to the timing gear to measured.
Hold both the gear to be checked and the adjoining
gear stationary.
2) Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
timing gear must be replaced.
6A1-24-2.tif
Timing Gear Backlash mm (in)
Standard Limit
0.10-0.17 (0.0039-0.0067) 0.30 (0.012)
Idler Gear "A" End Play Measurement

Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
thrust collar must be replaced.
Idle Gear End Play mm (in)
Standard Limit
6A1-24-3.tif 0.07 (0.0028) 0.2 (0.0079)
11. Idle Gear

12. Injection Pump
1) Remove the six injection pump bracket bolts ! from
the timing gear case.
6A1-25-1.tif
2) Remove the injection pump rear bracket bolts " from

the injection pump bracket #.
3) Remove the injection pump rear bracket bolts $ and
the bracket % from the cylinder body.
4) Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.
NOTE:
Plug the injection pump delivery holder ports with the
shipping caps (or the equivalent) to prevent the entry
of foreign material.
040LV002.tif
13. Camshaft Timing Gear

1) Use a dial indicator to measure the camshaft end play.
This must be done before removing the camshaft
gear.
the thrust plate must be replaced.
Camshaft End Play mm (in)
Standard Limit
0.050-0.114
0.2 (0.008)
6A1-25-3.tif
(0.002-0.0044)
2) Remove the camshaft timing gear bolt from the

camshaft.
NOTE:
Hold the camshaft stationary to prevent the camshaft
from turning.
3) Use the universal puller ! to pull out the camshaft
timing gear ".
Universal Puller: 5-8521-0002-0
4) Remove the thrust plate #.
6A1-25-4.tif
14. Crankshaft Gear

INSTALLATION
14 Crankshaft Gear
1) Install the crankshaft gear.
2) Use the crankshaft gear installer ! to install the
crankshaft gear ".
The crankshaft gear timing mark ("X-X") must be
facing outward.
6A1-26-1.tif
13. Camshaft Timing Gear

1) Install the thrust plate to the cylinder body.
2) Tighten the thrust plate bolts to the specified torque.
18 (1.8/13)
3) Install the camshaft timing gear to the camshaft.

The timing gear mark ("Y-Y") must be facing outward.
4) Tighten the timing gear to the specified torque.
6A1-26-2.tif
64 (6.5/47)
12. Injection Pump

1) Install the O-ring ! to the injection pump flange ".
2) Install the injection pump to the timing gear case.
Align the idler gear "B" # "V-V" mark with the injection
pump timing gear $ "V" mark.
6A1-27-2.tif
3) Temporarily tighten the six injection pump nuts %.

The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.
6A1-27-3.tif
4) Install the injection pump rear bracket & and the rear
bracket bolts ' to the cylinder body.
5) Install the rear bracket bolts ( to the injection pump
bracket ).
Do not tighten the bolts.
The rear bracket bolts ' and ( will be finally
tightened to the specified torque after tighten the
injection pump nuts.
040LV001
6) Tighten the injection pump nuts to the specified torque.

19 (1.9/14)
7) Tighten the injection pump bracket bolts to the

specified torque.
19 (1.9/14)
11. Idler Gear

1) Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole must be facing up.
2) Position the idler gear setting marks "X" and "Y" so
that they are facing the front of the engine.
6A1-26-3.tif
3) Align the idler gear "X" setting mark with the

crankshaft timing gear ! "X-X" setting mark.
4) Align the idler gear "Y" setting mark with the camshaft
timing gear " "Y-Y" setting mark.
5) Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
6) Tighten the idler gear bolt to the specified torque.
6A1-26-4.tif
19 (1.9/14)
10. Idler Gear

1) Apply engine oil to the idler gear and the idler gear
shaft.
2) Align the idler gear "B" # "Z" setting mark with the
idler gear "A" $ "Z-Z" setting mark.
3) Tighten the idler gear bolt to the specified torque.
76 (7.7/56)
6A1-27-1.tif
9. Oil Pipe
1) Install the oil pipe to the timing gear case and idler
gear "A".
2) Tighten the oil pipe eye bolt ! and bolt " to the
specified torque.
Oil Pipe Eye Bolt Torque N∙m (kg∙m/lb∙ft)
13 (1.3/9)
6A1-28-1.tif
8. Timing Gear Case Cover

1) Align the gear case with the timing gear case knock
pin and then install the timing gear case cover.
2) Tighten the gear case cover bolts to the specified
torque.
6A1-28-2.tif

Tighten the crankshaft damper pulley bolt to the specified
torque.
NOTE:
pulley.
Pulley Boss Bolt Torque N∙m (kg∙m/lb∙ft)
206 (21/152)
6A1-28-3.tif

• Mount fan pulley, distance piece, and cooling fan
assembly (in this order) on the water pump, and
tighten to the specified torque.
8 (0.8/69)

• Install AC Generator drive belt and adjust belt tension.
• Depress the drive belt mid-portion with a 98N
(10kg/22lb) force.
8 (0.31) - 12 (0.47)

27 (2.8/20)

• Install Power Steering pump drive belt and adjust belt
tension.
(10kg/22lb) force.
8 (0.31)-12(0.47)

27 (2.8/20)
1. Fan shroud
• Pour coolant
TIMING BELT (4JG2 Belt Type)
6A1-30-1.tif
REMOVAL
Preparation:
• Drain coolant.
• Remove clamp nut, and remove cooling fan asm,
2. Fan Shroud
6A1-30-2.tif • Removal reservoir tank hose and fan shroud.
• Loosen power steering pump idle pulley lock nut and
adjust bolt, and remove the drive belt.
4. A/C Compressor Drive Belt (A/C Model)
• Loosen A/C compressor idle pulley lock nut and adjust
6A1-30-3.tif

6A1-31-1.tif
6. Power Steering Pump Bracket Assembly (P/S Model)

• Loosen power steering oil pipe bracket and clip.
• Remove power steering pump bracket assembly and
hang the power steering pump bracket assembly.
6A1-31-2.tif
6A1-31-3.tif
8. Timing Pulley Upper Cover

9. Timing Pulley Lower Cover
6A1-31-4.tif
10. Flange; Camshaft Pulley

11. Timing Belt

• Prepare a fixing bolt (M8x40, P=1.25)
• Turn crankshaft timing pulley in the normal direction
pulley side mark to timing pulley housing side mark.
• Make sure that the camshaft pulley and injection
timing pulley fixing bolt holes are set to each other.
Then fit in a fixing bolt and lightly tighten.
• No.1 cylinder should be at top dead center.
If the fixing bolt holes are not set (No.4 cylinder is at
6A1-32-1.tif
top dead center) give another turn.
• Remove tensioner and timing belt.
WARNING
IF CRANKSHAFT AND CAMSHAFT AND TURNED
WITH TIMING BELT BEING NOT MOUNTED, PISTON
AND VALVE WILL INTERFERE WITH EACH OTHER.
THEREFORE, THE SHAFTS MUST NOT BE TURNED.
6A1-32-2.tif
INSTALLATION
11. Timing Belt
• When removing the belt, make sure the marks on the
bolt fixed camshaft, injection pulley and crankshaft
timing pulley are set to each other.
CAUTION
Do not turn crankshaft because otherwise piston and
valve will interfere with each other.
6A1-32-3.tif
CAUTION
For accurate mounting, be sure to mount the belt in
the direction that letters on the belt are readable.
6A1-32-4.tif
• Mount new timing belt on pulleys in the following steps.

Crankshaft timing pulley ! → camshaft
Timing pulley " → Idle pulley # → Injection
Pump pulley $ → tensioner %
• Set the belt on crankshaft timing pulley and hold with
one hand.
• Stretch and pass the belt round each pulley with the
other hand.
• After passing it round injection pump pulley, install
6A1-33-1.tif
tensioner while taking care not to slacken the belt.
CAUTION
• On completion of belt passing, make sure that the
setting mark on crankshaft timing pulley is set.
• If not set, reset the mark and repeat the belt passing.
• Remove tension adjust, lever mounting bolt, and
loosen the fulcrum bolt to such extent that the lever is
movable.
• Hung a spring balance from the end hole of tension
adjust lever, and with the balance pulled down with
9kg., loosen once the tensioner mounting bolt and
6A1-33-2.tif
there retighten it.
• Turn the crankshaft by 45° counterclockwise to shift
belt slackness on to the tensioner.
• Again hang the spring balance from the end hole of
tension adjust lever and pull it down with the specified
force. Under this condition, loosen tensioner mounting
bolt to absorb belt slackness and retighten is to
specified torque.
Belt N∙(kg/lb)
Tension 98 - 118 (10 - 12/22 - 26)
6A1-33-3.tif
Bolt N∙m (kg∙m/lb∙ft)

76 (7.8/56)
• Fix the tension adjust lever.
6A1-33-4.tif
CAUTION
• In case where the timing belt has been replaced with
the actuation of warning light, put off the light with
change over switch on the reverse side of meter.
• Refer to Chassis Electrical in Section 8.
• Tighten the tension adjusting lever nut and bolt.
6A1-34-1.tif

• Install the timing pulley flange ! to the camshaft
timing pulley ".
Flange Bolts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6A1-34-2.tif

• Install timing pulley lower cover and tighten bolt to the
specified torque.
Cover Bolts Torque N∙m (kg∙m/lb∙in)
8 (0.8/69)
6A1-34-3.tif

• Install timing pulley upper cover and tighten bolt to the
specified torque.
Cover Bolts Torque N∙m (kg∙m/lb∙in)
8 (0.8/69)
6A1-34-4.tif

• Install crankshaft damper pulley and tighten bolt to the
specified torque.
19 (1.9/14)
6A1-34-5.tif

• Install the pipe bracket & clip and tighten bolts to the
specified torque.
Pipe Bracket Bolts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
Pipe Clip Bolts Torque N∙m (kg∙m/lb∙in)

10 (1.0/87)
6A1-35-1.tif
• Install the P/S pump & bracket assembly.
10M bolts N∙m (kg∙m/lb∙ft)
40 (4.1/30)
8M bolts N∙m (kg∙m/lb∙ft)

19 (1.9/14)
Lock nut N∙m (kg∙m/lb∙ft)

27 (2.8/20)

(10kg/22lb) force.
8 (0.31) - 12(0.47)
• Install fixing bolt and tighten bolts to the specified

torque.
6A1-35-2.tif Generator Fixing Bolt N∙m (kg∙m/lbvft)
40 (4.1/30)
Adjust Plate Fixing Bolt N∙m (kg∙m/lb∙ft)

19 (1.9/14)
4. A/C Compressor Drive Belt (A/C type)

• Install A/C compressor drive belt and adjust belt
tension.
(10kg/22lb) force.
8 (0.31) - 12 (0.47)

27 (2.8/20)
3. Power Steering Pump Drive Belt (P/S pump model)

• Install PS pump drive belt and adjust belt tension.
(10kg/22lb) force.
8 (0.31) - 12 (0.47)

6A1-36-1.tif
27 (2.8/20)
2. Fan Shroud

specified torque.
8 (0.8/69)

• Pour coolant.
CYLINDER HEAD ASSEMBLY AND GASKET
Removal steps
1. Radiator hose upper
2. Heater hose
3. A/C Compressor drive
belt
4. Engine harness
5. Air intake duct
6. Injection pipe
7. Leak off pipe
8. PCV hose
9. Glow plug harness
10. Oil level gauge guide
tube
11. Oil cooler water pipe
12. A/C Compressor
Assembly
13. Vacuum actuator hose
14. Front exhaust pipe
15. By-pass hose
17. Rocker arm shaft
18. Push rod
19. Cylinder head
Assembly
20. Cylinder head gasket
Installation steps
To install, follow the
removal steps in the
reverse order.
6A1-37-1.tif
REMOVAL
Preparation:
• Drain coolant from the radiator and engine.
1. Radiator Hose Upper
• Disconnect upper radiator hose from engine side.
2. Heater Hose
• Disconnect heater hose from heater pipe.
3. A/C Compressor Drive Belt
• Loosen idler lock nut.
• Loosen adjust bolt and remove drive belt.
4. Engine Harness
• Disconnect harness connectors from units on
thermostat housing.
5. Air Intake Duct
• Remove the clip and air intake duct.
6A1-38-1.tif
6. Injection Pipe
• Remove flare nut injection pump side.
• Remove flare nut injection nozzle side and remove
injection pipe.
NOTE:
Plug the injection nozzle holder and the delivery
holder to prevent the entry of foreign matters into
them.
7. Leak Off Pipe
• Remove the leak off pipe side of leak off hose.
8. PCV Hose
• Remove the PCV hose from air intake pipe.
6A1-38-2.tif
9. Glow Plug Harness

• Remove the guide tube from cylinder head.
6A1-39-1.tif

• Remove the pipe fixing bolt of cylinder head rear side.
• Remove the oil cooler water pipe fixing nut from inlet
manifold.
6A1-39-2.tif
12. A/C Compressor Assembly (A/C Model)

• Remove the clutch harness connector.
• Remove the A/C compressor fixing bolts and
temporally tighten the A/C compressor to chassis
frame side use the wire.
6A1-39-3.tif
13. Vacuum Actuator Hose (Exhaust Brake Model)

• Remove the vacuum hoses from vacuum actuator.
6A1-39-4.tif
14. Front Exhaust Pipe

• Remove the exhaust pipe fixing bolts from exhaust
manifold.
• Remove the exhaust pipe stay bolt.
15. By-pass Hose

6A1-40-1.tif
17. Rocker Arm Shaft

• Loosen the rocker arm shaft bracket bolts a little at a
time in the numerical order shown in the illustration.
NOTE:
Failure to loosen the rocker arm shaft bracket bolts a
little at a time in numerical order will adversely effect
the rocker arm shaft.
18. Push Rod
6A1-40-2.tif

• Loosen the cylinder head bolts a little at a time in the
numerical order shown in the illustration.
NOTE:
Failure to loosen the cylinder head bolts a little at a
time in numerical order will adversely effect the
cylinder head lower surface.
20. Cylinder Head gasket
• Remove the cylinder head gasket and dowel.
6A1-40-3.tif
INSTALLATION
20. Cylinder Head Gasket
Cylinder head gasket is determined by the piston head
projection from the cylinder body upper surface, in order to
improve engine performance.
Three types of gasket are provided by the difference of
thickness. Select the adequate one out of three grades of
gasket, according to the following procedure.
Before measurement, clear off carbon from the piston
6A1-41-1.tif
head and cylinder body surface and also clean the place
where a gasket was installed.

1) Use a dial indicator to measure the piston projection
amount.
2) Refer to the illustration for the piston head projection
measuring positions.
All measuring positions should be as close as possible
to the cylinder liner.
3) Measure the points !"#$ and obtain two
differences !-" and #-$ on each cylinder.
Calculate the average value of the piston head
6A1-41-2.tif
projection on each cylinder.
4) Obtain the maximum value in the four cylinders.
5) Determine the gasket grade required to the maximum
value described above in accordance with the
following table.
4JB1/4JB1T/4JB1TC Cylinder Head Gasket Thickness

mm (in)
Gasket Grade Mark Piston Gasket Thickness
Projection (Reference)
0.758 - 0.813 1.60
A
(0.030 - 0.032) (0.0630)
0.813 - 0.859 1.65
B
(0.032 - 0.034) (0.0650)
6A1-41-3.tif 0.859 - 0.914 1.70
C
(0.034 - 0.036) (0.0670)
NOTE:
projection must not exceed 1.0 mm(0.039 in).
4JG2 Cylinder Head Gasket Thickness mm (in)

Piston Gasket Thickness
Gasket Grade Mark
Projection (Reference)
0.658 - 0.713 1.60
A
(0.026 - 0.028) (0.0630)
0.713 - 0.759 1.65
B
(0.028 - 0.030) (0.0650)
0.759 - 0.814 1.70
C
6A1-42-1.tif
(0.030 - 0.032) (0.0670)
NOTE:
projection must not exceed 1.0 mm (0.039 in).

1) Install the dowel in cylinder block.
2) Install the cylinder head gasket with top mark up.
3) Clean up cylinder head lower surface and cylinder
body upper surface.
4) Install the cylinder head as softly.
5) Apply engine oil to screw and seat of cylinder head
bolts.
6) Tighten the cylinder head bolts to the specified torque
6A1-42-2.tif
in three steps following the numerical order shown in
the illustration.
Cylinder Head bolts Torque N∙m (kg∙m/lb∙ft)
1st Step 2nd Step 3rd Step
49 (5.0/36) 60 - 75° 60 - 75°
18. Push Rod

• Apply engine oil to push rod and in to the cylinder
head.
17. Rocker Arm shaft

1) Loosen all adjusting screws.
2) Position the rocker arm shaft with the large oil hole
6A1-42-3.tif
3) Tighten the rocker arm shaft bracket bolts to the

specified torque in the numerical order shown in the
illustration.
Rocker Arm Shaft Bracket Bolt Torque N∙m (kg∙m/lb∙ft)
54 (5.5/40)
• Valve clearance adjustment.
6A1-43-1.tif

Above works refer to “ROCKER ARM SHAFT
spring.
head cover.
• The gasket must be perfectly smooth with no loose
areas.
• Tighten the cylinder head cover nuts to the specified
torque in the numerical order shown in the illustration.
Cylinder Head Cover Torque N∙m (kg∙m/lb∙in)
6A1-44-1.tif
13 (1.3/113)
15. By-Pass Hose

• Install the pipe to manifold and tighten bolts and nuts
W/Exhaust Brake Manifold Nut Torque N∙m (kg∙m/lb∙ft)
37 (3.8/27)
WO/Exhaust Brake
Manifold Nut Torque N∙m (kg∙m/lb∙ft)
6A1-44-2.tif
40 (4.1/30)
Pipe Stay Bolts Torque N∙m (kg∙m/lb∙ft)

40 (4.1/30)
13. Vacuum Actuator Hose (Exhaust Brake Model)

• Install the vacuum hose to the vacuum actuator.
6A1-44-3.tif

• Install the A/C compressor fixing bolts and tighten
bolts to the specified torque.
Compressor Bolts Torque N∙m (kg∙m/lb∙ft)
37 (3.8/27)
6A1-44-4.tif

• Install the water pipe bolt and tighten bolt to the
specified torque.
Water Pipe Nut Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
Pipe Bracket Bolt Torque N∙m (kg∙m/lb∙ft)

40 (4.1/30)
6A1-45-1.tif

• Install the guide tube bolt and tighten bolt to the
specified torque.
Guide Tube Bolt Torque N∙m(kg∙m/lb∙ft)
19 (1.9/14)
6A1-45-2.tif
8. PCV Hose
7. Leak Off Pipe
• Mount using a new copper washer.
6A1-45-3.tif
6. Injection Pipe
• Install the flare nut to injection pump side.
• Install the flare nut to injection nozzle side.
• Tighten the flare nut to the specified torque.
Flare Nut torque N∙m (kg∙m/lb∙ft)
29 (3.0/22)
• Fit pipe clip in specified torque.
6A1-45-4.tif
5. Air Intake Duct

4. Engine Harness
• Connect the thermo-sensor harness and thermo-meter
unit harness.
6A1-46-1.tif

Check drive belts for wear or damage, and replace with
new ones as necessary. Check belts for tension, and
adjust as necessary.
• Check drive belts tension.
• Push the middle of belts with a force of 10kg and
check each bolt for deflection.
• Standard deflection
mm (in)
6A1-46-2.tif Initial tension
AC generator & fan pulley drive belt
A/C compressor drive belt 8 - 12 (0.31 - 0.47)
P/S pump drive belt
TENSION ADJUSTMENT
P/S oil pump and A/C compressor pulley belt
• With P/S pump lock bolt loose, adjust belt tension with
adjust belt.
Cooling fan pulley belt
• With AC Generator mounting and lock bolts loose,
adjust belt tension with adjuster's adjust bolt.
6A1-46-3.tif
Torque Standard N∙m (kg∙m/lb∙ft)

AC generator fixing bolt 40 (4.1/30)
Adjust plate fixing bolt 19 (1.9/14)
Adjust plate lock bolt 19 (1.9/14)
6A1-46-4.tif
2. Heater Hose
• Connect the heater hose them tighten clip securely.
1. Radiator Hose Upper
• Connect the radiator hose them tighten clip securely.
• Pour coolant
OIL PAN
Removal steps
2. Engine mount bolts
4. Oil pan Assembly
Installation steps
6A1-48-1.tif
REMOVAL
Preparation:
• Lift up car.
• Drain engine oil.
NOTE
Install drain plug with new gasket.
N∙m(kg∙m/lb∙ft)
44 (4.5/33)

• Remove oil hose ! from oil pan.
6A1-48-2.tif
2. Engine Mount Bolts

• Remove the engine mount bolts right & left side.
6A1-49-1.tif

• Remove the exhaust pipe bracket.
side.
6A1-49-2.tif
4. Oil Pan Assembly

• Raising the engine about 50mm.
• Remove the oil pan from cylinder block.
INSTALLATION
4. Oil Pan Assembly
to the No.5 bearing cap arches, the grooves, and the
timing gear case arches at the positions shown in the
illustration.
6A1-50-1.tif
• Fit the gasket rear lipped portion into the No.5 groove.
• Be absolutely sure that the lipped portion in fitted
snugly in to the groove.
• Install the oil pan to the cylinder body.
Oil Pan Bolt Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6A1-50-2.tif
3. Stiffener and Space Rubber

• Install the space rubber.
• Install the stiffener left side and right side tighten bolt
Engine body Side N∙m (kg∙m/lb∙ft)
37 (3.8/27)
Clutch Housing Side N∙m (kg∙m/lb∙ft)

78 (8.0/58)
• Install exhaust pipe bracket.

• Install the mount bolts and tighten to the specified
torque.
Mount Bolt Torque N∙m (kg∙m/lb∙ft)
40 (4.1/30)
• Install the oil hose to oil pan.

• Pour engine oil
OIL PUMP ASSEMBLY
Removal steps
2. Engine mount bolts
4. Oil pan Assembly
Installation steps
6A1-51-1.tif
REMOVAL
Preparation:
• Lift up car.
NOTE
Install drain plug with new washer.
N∙m(kg∙m/lb∙ft)
44 (4.5/33)

• Remove the oil hose ! from oil pan.
6A1-51-2.tif

• Remove the engine mount bolts right & left side.
6A1-52-1.tif

• Remove the exhaust pipe bracket.
side.
6A1-52-2.tif
4. Oil Pan Assembly

• Raise the engine about 50mm.
• Remove the oil pan from cylinder block.
• Remove the oil pump from cylinder block.
INSTALLATION
• Prepare a solution of 80% engine oil and 20%
molybdenum disulfide.
• Apply and ample coat of the solution to the teeth of the
oil pump pinion.
• Apply engine oil to oil pipe O-ring and insert the O-ring
in O-ring hold on cylinder block.
• Install oil pump asm with oil pipe in cylinder block and
19 (1.9/14)
• Tighten sleeve nut to the specified torque.

6A1-53-1.tif N∙m (kg∙m/lb∙ft)
25 (2.5/18)
4. Oil Pan Assembly

Above works refer to “OIL PAN” Section in this manual.
PISTON, PISTON RING AND CONNECTING ROD
6A1-45-1.tif
REMOVAL
Preparation:
• Drain coolant
• Drain engine oil
NOTE
• Install drain plug with new washer.
44 (4.5/33)

1) Radiator hose upper
2) Heater hose
3) A/C compressor drive belt
4) Engine harness
5) Air intake duct
6) Injection pipe
7) Leak off pipe
8) PCV hose
9) Glow plug harness
10) Oil level gauge guide tube
11) Oil cooler water pipe (Oil Cooler Model)
12) A/C compressor assembly (A/C Model)
13) Vacuum actuator hose (Exhaust Brake Model)
14) Front exhaust pipe
15) By-pass hose
16) Cylinder head cover
17) Rocker arm shaft
18) Push rod
19) Cylinder head assembly
20) Cylinder head gasket
Above works refer to “CYLINDER HEAD ASSEMBLY
AND GASKET” Section in this manual.
2. Oil Pan Assembly
1) Vacuum pump oil hose
2) Engine mount bolt
3) Stiffener and spacer rubber
4) Oil pan
Above works refer to “OIL PAN” Section in this
manual.
• Remove the relief valve and oil pipe.
6A1-55-1.tif

• If the connecting rod lower bearings are to be
reinstalled, mark their fitting positions by tagging each
bearing with the cylinder number from which it was
removed.
6A1-55-2.tif
6. Piston and Connecting Rod Assembly

1) Remove carbon deposits from the upper portion of the
and connecting rod.
6A1-56-1.tif
2) Move the piston to the top of the cylinder and tap it

with a hammer grip or similar object from the
connecting rod lower side to drive it out.
6A1-56-2.tif
3) If the connecting rod upper bearings are to be

removed.
6A1-56-3.tif

Use a piston ring replacer to remove the piston rings.
Piston Ring Replacer
Do not attempt to use some other tool to remove the
piston rings. Piston ring stretching will result in
reduced piston ring tension.
6A1-56-4.tif
5) Use a pair of pliers to remove the piston pin snap

rings.
6A1-56-5.tif
6) Tap the piston pin out with a hammer and a brass bar.
If the pistons and piston pins are to be reinstalled,
mark their installation positions by tagging each piston
and piston pin with the cylinder number from which it
was removed.
6A1-57-1.tif
INSTALLATION
1) Try to insert the piston pin into the piston pin hole with
Select piston and connecting rod combinations so that
the weight variation of the different assemblies is held
within the specified limits.
g(oz)
Variance in weight Less than
after assembly 3(0.1058)

3) Use a pair of pliers to install the piston pin snap ring to
the piston.
NOTE:
6A1-57-2.tif
do not change the piston/piston pin combination.
4) Install the piston to the connecting rod.

The piston head front mark ! and the connecting rod
"ISUZU" casting mark " must be facing the same
direction.
6A1-57-3.tif
5) Apply a coat of engine oil to the piston pin and the

piston pin hole.
Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
6A1-58-1.tif
6) Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
Check that the connecting rod moves smoothly on the
piston pin.
6A1-58-2.tif
7) Install the piston rings with the piston ring expander.

mark facing up.
Discrimination mark is painted as shown in the
illustration.
6A1-58-3.tif
8) Use a piston ring replacer to install the three piston

rings.
Piston Ring Replacer
Install the piston rings in the numerical order shown in
the illustration.
! Oil ring
" 2nd compression ring
# 1st compression ring
6A1-58-4.tif
NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
6A1-58-5.tif
9) Apply engine oil to the piston ring surfaces.

10) Check that the piston rings rotate smoothly in the
piston ring grooves.
11) Position the piston ring gaps as shown in the
illustration.
6A1-59-1.tif
12) Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting
rod bearing fitting surface.
13) Apply a coat of engine oil to the upper bearing
surfaces.
Apply a coat of engine oil the cylinder wall.
6A1-59-2.tif
14) Position the piston head front mark so that it is facing

Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0(J-8037)
15) Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
6A1-59-3.tif

1) Position the bearing cap front mark so that it is facing
2) Install the connecting rod bearing caps.
Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
6A1-59-4.tif
3) Apply a coat of engine oil to the threads and setting

faces of each connecting rod cap bolt.
4) Tighten the connecting rod bearing cap bolts to the
specified torque in two steps using the Angular
Tightening Method.
Connecting Rod Bearing Cap Bolt Torque N∙m (kg∙m/lb∙ft)
1st Step 2nd Step
29 (3.0/22) 45° - 60°
6A1-60-1.tif NOTE

1) Install the piston cooling oil pipe to the cylinder body.
2) Tighten the oil pipe bolts and relief valve to the
specified torque.
Oil Pipe Bolt Torque N∙m (kg∙m/lb∙ft)
! M8x1.25 19 (1.9/14)
" M6x1.00 8 (0.8/69)
6A1-60-2.tif
Oil Pressure Regulating Valve Torque N∙m (kg∙m/lb∙ft)

# M6x1.5 29 (3.0/22)
NOTE:
Check that there is no interference between the piston
and the oiling jet pipe by slowly rotating the
crankshaft.

2. Oil Pan Assembly

1) Apply the recommended liquid gasket or its equivalent
to the No.5 bearing cap arches, the grooves, and the
timing gear case arches at the positions shown in the
illustration.
2) Fit the gasket rear lipped portion into the No.5 groove.
Be absolutely sure that the lipped portion is fitted
snugly into the groove.
3) Install the oil pan to the cylinder body.
Oil Pan Bolts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6A1-60-1.tif
4) Install the space rubber and stiffener (right & left side)
then tighten bolts to the specified torque.
Engine Body Side Stiffener Bolts Torque N∙m (kg∙m/lb∙ft)
37 (3.8/27)
Clutch Housing Side Stiffener Bolts TorqueN∙m (kg∙m/lb∙ft)

78 (8.0/58)
5) Install the exhaust pipe bracket.

6A1-60-2.tif
6) Install the support rubber and tighten nuts to the

specified torque.
Support Rubber Nut Torque N∙m (kg∙m/lb∙ft)
40 (4.1/30)
6A1-60-3.tif
7) Install the vacuum pump oil hose ! to oil pan.
6A1-60-4.tif
1. Cylinder Head ASM

3) Push rod
4) Rocker arm shaft
5) Valve clearance adjustment
7) By-pass hoses
9) Vacuum actuator hose (Exhaust Brake Model)
14) PCV hose
15) Leak off pipe
16) Injection pipe
17) Air intake duct
18) Engine harness
19) A/C compressor drive belt (With A/C Model)
20) Heater hose
CAMSHAFT AND TAPPET
Removal steps
1. Transmission and clutch
Assembly
2. Engine Assembly
gasket
4. Timing gear
(Gear drive model)
4a. Timing belt
(Belt drive model)
5. Oil pan
6. Oil pump
7. Camshaft and tappets
Installation steps
6A1-63-1.tif
REMOVAL
Preparation:
• Drain coolant.
NOTE
Install drain plug with new washer.
Drain Plug Torque N∙m (kg∙m/lb∙ft)
83 (8.5/61)
1. Transmission and Clutch Assembly

1) Transmission
2) Clutch
2. Engine Assembly
1) Radiator assembly
2) Intake air duct
3) Heater hose
4) Engine control cable
6) Fuel hose
7) Oil pressure switch harness
9) Power steering pump & bracket assembly (Power
steering Model)
10) Actuator vacuum hose (Exh. Brake Model)
11) Vacuum pump hose (Exh. Brake Model)
13) Support rubber
14) Engine assembly
Above works refer to “ENGINE ASSEMBLY” Section in
this manual.

1) Injection pipe
2) Leak off pipe
3) PCV hose
7) By-pass hose
9) Rocker arm shaft
10) Push rod

1) Cooling fan assembly
2) Crankshaft damper pulley
3) Noise shield cover
4) Noise cover spacer
5) Timing gear case cover
6) Camshaft timing gear
Above works refer to “TIMING GEAR (Gear Type)”
4a. Timing Belt (Belt Drive Model)

3) Timing pulley upper cover
4) Timing pulley lower cover
5) Flange: camshaft pulley
6) Flange: injection pump pulley
7) Timing belt
Above works refer to “TIMING BELT (Belt Type)”
8) Camshaft timing pulley
• Use a dial indicator to measure the camshaft end play.
This must be done before removing the oil pump.
the camshaft and/or the driven gear must be replaced.
Camshaft End Play mm(in)
Standard Limit
0.08 (0.003) 0.20 (0.008)
6A1-65-1.tif
• Install the stopper bolt ! to the timing pulley to

prevent the pulley from turning.
• Loosen the center bolt.
6A1-65-2.tif
• Use the timing pulley puller " to remove the pulley.

6A1-65-3.tif
• Remove the center bolt and remove the timing pulley

with pulley center.
6A1-66-1.tif
• Remove the oil seal retainer.
6A1-66-2.tif
5. Oil Pan Assembly

• Disconnect vacuum pump oil hose ! from oil pan.
6A1-66-3.tif
• Remove the stiffener and space rubber from oil pan

both side.
• Remove the oil pan bolts and remove oil pan from
cylinder body.
6A1-66-4.tif

• Remove the oil pump assembly from cylinder body.
6A1-66-5.tif
7. Camshaft and Tappets

• Remove the camshaft from cylinder body.
• Take care not to damage the camshaft bearings.
6A1-67-1.tif
• Take out the tappets from cylinder body.
6A1-67-2.tif
INSTALLATION
7. Camshaft and Tappets
• Apply a coat of engine oil to the tappet and the cylinder
body tappet insert holes.
• Locate the position mark applied at disassembly (if the
NOTE:
The tappet must be installed before the camshaft.
• Apply a coat of engine oil to the camshaft and the
camshaft bearings.
• Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
6A1-68-1.tif

• Prepare a solution of 80% engine oil and 20%
molybdenum disulfide.
• Apply and ample coat of the solution to the teeth of the
oil pump pinion.
• Apply engine oil to oil pipe O-ring and insert the O-ring
in O-ring hold on cylinder block.
• Install oil pump asm with oil pipe in cylinder block and
Oil Pump Bolt Torque N∙m (kg∙m/lb∙ft)
6A1-68-2.tif
19 (1.9/14)
• Tighten sleeve nut to the specified torque.

Sleeve Nut Torque N∙m (kg∙m/lb∙ft)
25 (2.5/18)
5. Oil Pan Assembly

Above works refer to “OIL PAN” Section in this manual.
4a. Timing Belt

7) Timing belt
4. Timing Gear (Gear Type)


10) Push rod
9) Rocker arm shaft
7) By-pass hose
6) Oil cooler water pipe (Oil cooler Model)
3) PCV hose
2) Fuel leak off pipe
1) Injection pipe
2. Engine Assembly
14) Engine assembly
13) Support rubber
11) Vacuum pump hose
10) Actuator vacuum hose
9) Power steering pump & bracket assembly (With Power
Steering Model)
6) Fuel hose
3) Heater hose
2) Intake air duct

2) Clutch
1) Transmission
this manual.
• Pour coolant
• Pour engine oil
CRANKSHAFT FRONT OIL SEAL (Gear Drive Type)
Removal steps
1. Fan shroud
2. Power steering pump drive belt
3. AC generator drive belt
4. Cooling fan Assembly
6. Front oil seal
Installation steps
To install, follow the removal steps
in the reverse order.
6A1-71-1.tif
REMOVAL
Preparation:
• Drain coolant.
1. Fan Shroud
2. Power Steering Pump Drive Belt
• Loosen power steering pump mounting bolt and adjust
6. Front Oil Seal

• Use a plastic hammer and a screwdriver to top around
the oil seal to free it from the gear case cover.
Take care not to damage the oil seal fitting surfaces.
6A1-72-1.tif
INSTALLATION
6. Front Oil Seal
• Use the installer to install the front oil seal ! to the
gear case cover ".
Oil Seal Installer: 5-8840-2061-0
Note the oil seal installation depth # shown in the
illustration.
Depth # = 1 mm (0.039 in.)
6A1-72-2.tif

Tighten the crankshaft damper pulley bolt to the specified
torque.
NOTE:
pulley.
Pulley Boss Bolt Torque N∙m (kg∙m/lb∙ft)
206 (21/152)
6A1-72-3.tif

specified torque.
8 (0.8/69)

• Refer to Drive Belt Adjustment in this section.
• Install power steering pump drive belt and adjust belt
tension.
• Refer to “Drive Belt Adjustment” in this section.
1. Fan Shroud
• Pour coolant
CRANKSHAFT FRONT OIL SEAL (Belt Drive Type)
6A1-73-1.tif
REMOVAL
Preparation:
• Drain coolant.
2. Fan Shroud
11. Timing Belt
Above works refer to “TIMING BELT (Belt Type)” Section
in this manual.
12. Crankshaft Pulley Center

• Remove the pulley center by using special tool.
Remover: 5-8840-0161-0
13. Crankshaft Timing Pulley
14. Front Oil Seal
• Remove the oil seal by using special tool.
Front oil seal remover: 5-8840-2362-0
NOTE:
Take care not to damage sealing surface of front plate
6A1-74-1.tif
INSTALLATION
14. Front Oil Seal
• Install the oil seal by using special tool.
Installer: Front oil seal: 5-8840-2361-0
1) With the sleeve attached to the oil seal, put it in the
2) With the edge portion of the oil seal attached securely
to the crankshaft, tighten it with the center bolt until the
6A1-74-2.tif
4) After pressing in the seal, check the measurement of
the oil seal.
Standard mm (in)
0.6 - 1.2 (0.024 - 0.047)
NOTE:
• Install the oil seal after assembling the timing
pulley housing.
• The lip portion of the oil seal is applied with oil.
• Take note of the press-in direction of the oil seal.
13. Crankshaft Timing Pulley
12. Crankshaft Pulley Center

• Install the timing pulley center and tighten bolt to the
specified torque.
Pulley Center Bolt Torque N∙m (kg∙m/lb∙ft)
206 (21/152)
6A1-74-3.tif
11. Timing Belt

3. Power Steering Pump Drive Belt (P/S pump Model)
2. Fan Shroud
Above works refer to “TIMING BELT (Belt Type)” Section
in this manual.
CRANKSHAFT REAR OIL SEAL (Gear & Belt Drive Type)
Removal steps
1. Transmission and clutch Assembly
2. Flywheel
3. Rear oil seal
Installation steps
To install, follow the removal steps in the
reverse order.
6A1-76-1.tif
REMOVAL
Preparation:
• Raise vehicle and support with suitable safely.
1) Transmission
! Transmission
• Reference mark the flange yoke to the parking brake
drum.
• Disconnect the propeller shaft at flange yoke.
• Put aside the propeller shaft and tie it to the frame so
that it does not interface with servicing work.
6A1-76-2.tif
" Parking Brake Cable

• Move the joint cover.
• Disconnect the joint bolt.
• Remove the clip then disconnect the cable from the
bracket.
6A1-76-3.tif
# Wiring Connector
• Disconnect the wiring connectors from the car speed
sensor, the neutral switch and the back-up light switch.
$ Shift Cable and Select Cable
• Disconnect the shift cable and select cable on the
transmission side.
6A1-77-1.tif
% Clutch Slave Cylinder

• Remove the clutch pipe fixing clips and the clip
bracket (Right hand drive models only).
6A1-77-2.tif
• Remove the slave cylinder assembly with the flexible

hose attached, and then tie it to the frame so that it
does not interface with servicing work.
6A1-77-3.tif
& Exhaust Brake Assembly

' Front Exhaust Pipe
6A1-77-4.tif
( Transmission Assembly
NOTE:
The exhaust pipe bracket, the gear control bracket
and the clips are sometimes installed in the wrong
position or direction confusedly. To prevent incorrect
installation of these parts, put a correct installation
mark on them.
• Support the transmission with mission jack.
CAUTION:
To prevent the falling of the transmission, tie it firmly
to the jack with a chain or belt.
Do not allow transmission to hang unsupported from
clutch. Damage to the clutch assembly will result.
6A1-78-1.tif
• Remove the nuts of the transmission mounting bracket

on the crossmember side.
• Engine and transmission angles may need to be
adjusted for removal.
• Hold the rear section of the engine by the jack or hoist.
CAUTION:
When lifting the engine by the jack, use wood blockes
to prevent any possible damage to the oil pan.
• Remove transmission fastening bolts.
• Pull out the transmission assembly rearward.
) Mounting Bracket
2) Clutch
• Raise vehicle and support with suitable safety stands.
CAUTION:
Do not let clutch fluid remain on a painted surface,
Wash it off immediately.
! Pressure Plate Assembly

" Driven Plate Assembly
• Use the pilot aligner to prevent the driven plate
assembly from falling free.
Pilot Aligner: 5-5825-3001-0
• Mark the flywheel and pressure plate lug for alignment
when installing.
• Loosen the pressure plate assembly fixing bolts.
2. Flywheel
6A1-79-1.tif
3. Rear Oil Seal

• Rear oil seal Remove: 5-8840-2360-0
NOTE:
Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
6A1-79-2.tif
INSTALLATION
3. Rear Oil Seal
• Use the oil seal installer the oil seal to the cylinder
body.
Rear oil seal Install: 5-8840-2359-0
NOTE:
6A1-80-1.tif
adapter.
3) Insert the sleeve into the adapter portion, and tighten it
in with the bolt (M12x1.75L=70) until the adapter
section hits the sleeve.
4) Remove the adapter and the sleeve.
the oil seal.
Standard mm (in)
12.2 - 12.8 (0.48 - 0.50)
2. Flywheel
1st Step 2nd Step
59 (6.0/43) 60° - 90°
6A1-80-2.tif
2) Clutch

• Apply multi-purpose with MOS2 type grease to the
driven plate hub spline.
• Use the pilot aligner to install the driven plate
assembly.
6A1-80-3.tif

• Tighten pressure plate assembly fixing bolts in
numerical order.
Pressure Plate Fixing Bolt Torque N∙m (kg∙m/lb∙ft)
18 (1.8/13)
• Remove the pilot aligner.
NOTE:
6A1-81-1.tif
In case a new pressure plate assembly is mounted,
after tightening a pressure plate at the specified
torque, be sure to remove the wiring for protection of
a diaphragm spring.
1) Transmission
) Mounting Bracket
Mounting Bracket Nuts Torque N∙m (kg∙m/lb∙ft)
69 (7.0/51)
CAUTION:
To prevent the falling of the transmission, tie it
securely to the jack with a chain or belt.
• Shift transmission into high gear.
• Align transmission with engine slope.
• Turn output parking brake drum to aid clutch spring
engagement.
6A1-81-2.tif
Clutch Housing to Flywheel

Hosing Bolts Torque N∙m (kg∙m/lb∙ft)
M10 : 46 (4.7/34)
M12 : 91 (9.3/67)
• Raise engine and transmission up into rear

transmission mount.
Engine Rear Mounting Nuts
and Bolts Torque N∙m (kg∙m/lb∙ft)
M10 : 40 (4.1/30)
M12 : 69 (7.0/51)
6A1-81-3.tif

Front Exhaust Pipe Bolts Torque N∙m (kg∙m/lb∙ft)
37 (3.8/27)

Exhaust Brake Bolts Torque N∙m (kg∙m/lb∙ft)
17 (1.8/12)

Slave Cylinder Bolts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
• Perform slave cylinder adjustment before installation

of the return spring.
a) Loosen the lock nut of the push rod.
b) Turn the adjust nut until it reaches the shift fork.
c) Back off the adjust nut 1.5 turns. (shift fork free
play Approximately 2 mm/0.1 in).
d) Tighten the lock nut.
Push Rod Lock Nut Torque N∙m (kg∙m/lb∙ft)
16 (1.6/12)

# Wiring Connector
• Color of Connector
Back-up Light Switch: Brown
Neutral Switch: Gray
! Propeller Shaft
• Line up reference mark.
Propeller Shaft Nuts Torque N∙m (kg∙m/lb∙ft)
66 (6.7/48)

FLYWHEEL AND PILOT BEARING
Removal steps
2. Pilot bearing
3. Flywheel
Installation steps
To install, follow the removal steps in the
reverse order.
6A1-83-1.tif
REMOVAL
Preparation:
1) Transmission
2) Clutch
this manual.
2. Pilot Bearing
• Remove pilot bearing using remover.
Pilot Bearing Puller: 5-8840-2000-0
Sliding hammer: 5-8840-0019-0
3. Flywheel
• Set the flywheel stopper.
• Loosen flywheel fixing bolts then remove the flywheel.
6A1-83-2.tif
INSTALLATION
3. Flywheel
1st Step 2nd Step
6A1-84-1.tif
59 (6.0/43) 60° - 90°
2. Pilot Bearing
• Install the pilot bearing using installer.
Pilot bearing Installer: 5-8522-0024-0
6A1-84-2.tif

2) Clutch
1) Transmission
this manual.
CRANKSHAFT AND MAIN BEARINGS
10a
Removal steps
2. Engine Assembly
gasket
4. Timing gear (Gear drive model)
4a. Timing belt (Belt drive model)
5. Oil pan Assembly
Assembly
9. Front oil seal
10a. Timing pulley housing
11. Water pump Assembly
12. Flywheel and rear plate
8 13. Rear oil seal
14. Crankshaft and main bearing
Installation steps
the reverse order.
6A1-85-1.tif
REMOVAL
Preparation:
1) Transmission
2) Clutch
this manual.
2. Engine Assembly
2) Intake air duct
3) Heater hose
6) Fuel hose
8) A/C compressor assembly
9) Power steering pump bracket assembly (Power
Steering Model)
10) Actuator vacuum hose (Exh. Brake Model)
11) Vacuum pump hose (Exh. Brake Model)
13) Support rubber
14) Engine assembly
this manual.
1) Injection pipe
2) Leak off pipe
3) PCV hose
7) By-pass hose
9) Rocker arm shaft
10) Push rod

6) Oil pipe
7) Idle gear
8) Idle gear “B" and shaft
9) Injection pump
11) Crankshaft gear
• Use the crankshaft timing gear remover ! to remove
the crankshaft gear ".
Crankshaft Timing Gear Remover: 5-8840-2057-0
6A1-87-1.tif

7) Timing belt
8) Crankshaft timing pulley center
• Use the fixing wrench to prevent the crankshaft from
turning.
Fixing Wrench: 5-8840-0161-0
• Remove the timing pulley center from the crankshaft.
6A1-87-2.tif
9) Crankshaft timing pulley

• Block the crankshaft with a piece of hard wood.
• Use the crankshaft timing pulley puller to remove the
timing pulley.
Crankshaft Timing Pulley Puller: 5-8840-2035-0
6A1-88-1.tif
10) Injection pump timing pulley

11) Injection pump
Above works refer to “CYLINDER BLOCK
5. Oil Pan Assembly
Above works refer to “CAMSHAFT AND TAPPET” Section
in this manual.
• Remove the oil pipe from cylinder block.
6A1-88-2.tif

• If the connecting rod lower bearings are to be
removed.
6A1-88-3.tif
• Remove carbon deposits from the upper portion of the

and connecting rod.
Move the piston to the top of the cylinder and tap it
with a hammer grip or similar object from the
connecting rod lower side to drive it out.
6A1-88-4.tif
• If the connecting rod upper bearings are to be

removed.
6A1-89-1.tif

Front Oil Seal Remover: 5-8840-2362-0
6A1-89-2.tif

11. Water Pump Assembly
12. Flywheel and Cylinder Body Rear Plate
• Set the flywheel stopper.
• Loosen the flywheel fixing bolts then remove the
flywheel.
• Remove the cylinder block rear plate.
13. Rear Oil Seal (Gear and Belt Drive Model)
Rear Oil Seal Remover: 5-8840-2360-0
NOTE:
Take care not to damage sealing surface of front plate
6A1-89-3.tif
14. Crankshaft and Main Bearing

1) Remove the main bearing caps and thrust washer.
2) Remover the crankshaft with care.
3) Remove the crankshaft upper bearing.
6A1-89-4.tif
INSTALLATION
14. Crankshaft and Main Bearings
• The crankshaft upper bearings have an oil hole and an
oil groove. The lower bearings do not…
• Install main bearings in the cylinder body and main
bearing cap respectively.
• Apply new engine oil to upper and lower main
bearings.
• Make sure that main bearing are in correct position.
6A1-90-1.tif
• Carefully wipe any foreign material from the upper

bearing.
• Install the main bearings to the cylinder body and the
main bearing caps.
NOTE:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.
• Be sure that they are positioned correctly.
• Apply new engine oil to the upper and lower main
bearing faces.
6A1-90-2.tif
• Carefully mount the crankshaft.

• Apply engine oil to the thrust washer.
• Install thrust washer on No.3 journal.
Oil grooves in thrust washer must face the crankshaft.
6A1-90-3.tif

to the No.5 crankshaft bearing cap cylinder body fitting
surfaces at points and shown in the illustration.
NOTE:
Be sure that the bearing cap fitting surface is
completely free of oil before applying the liquid
gasket.
Do not allow the liquid gasket to obstruct the cylinder
thread holes and bearings.
6A1-90-4.tif
• Install the bearing caps with the bearing cap head

arrow mark facing the front of the engine.
• Apply engine oil to the front of the engine.
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
167 (17.0/123)
6A1-91-1.tif NOTE:

Use the oil seal installer to install the oil seal to the cylinder
body.
Rear Oil Seal Installer: 5-8840-2361-0
NOTE:
6A1-91-2.tif
adapter.
3) Insert the slave into the adapter portion, and tighten it
in with the bolt (M12x1.75L=70) until the adapter
section hits the slave.
4) Remove the adapter and the slave.
the oil seal.
Standard mm (in)
12.2 - 12.8 (0.48 - 0.50)
12. Flywheel and Cylinder Body Rear Plate

• Align the rear plate with the cylinder body knock pins.
• Tighten the rear plate to the specified torque.
Rear Plate Bolts Torque N∙m (kg∙m/lb∙ft)
82 (8.4/61)
6A1-92-3.tif
• Block the crankshaft with a piece of hard wood to

prevent the flywheel form turning.
• Apply a coat of engine oil to the threads of the flywheel
bolts.
• Align the flywheel with the crankshaft dowel pin.
1st Step 2nd Step
6A1-92-1.tif
59 (6.0/43) 60° - 90°

• Fit the O-ring to the water pump body.
• Remove the water pump assembly and tighten bolts to
Water Pump Bolt Torque N∙m (kg∙m/lb∙in)
20 (2.0/14)
6A1-92-2.tif

• Install the timing pulley housing the cylinder body.
Take care not to twist the front oil seal.
• Tighten the timing pulley housing together with the
timing pulley housing gasket to the specified torque.
Timing Pulley Housing Bolt Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
• Cut away the flash from the gasket.

6A1-92-3.tif

• Install the timing gear housing the cylinder body.
• Tighten the timing gear housing together with the
timing gear housing gasket to the specified torque.
Timing Gear Housing Bolt Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
• Cut away the flash from the gasket.

Front Oil Seal Installer: 5-8840-2361-0
Notes:
1) With the oil seal attached to the sleeve, put it in the
6A1-92-4.tif
2) With the edge of the oil seal attached securely to the

crankshaft, tighten it with the center bolt until the
4) After pressing in the oil seal, check the measurement
of the oil seal.
Standard mm (in)
0.6 - 1.2 (0.024 - 0.047)
Above works refer to “PISTON” Section in this manual.
5. Oil Pan Assembly
Above works refer to “OIL PUMP AND OIL PAN” Section
in this manual.
Above works refer to “CAMSHAFT AND TAPPET”
11) Injection pump
10) Injection pump timing pulley
Above works refer to “CYLINDER BLOCK
9) Crankshaft timing pulley
• Use the crankshaft timing pulley installer to install the
timing pulley.
• The timing pulley flange must be facing the cylinder
body.
Crankshaft Timing Pulley Installer: 5-8522-0020-0
6A1-93-1.tif
8) Crankshaft timing pulley center

• Install the crankshaft pulley center.
• Use the fixing wrench to prevent the crankshaft from
turning.
Fixing Wrench: 5-8840-0161-0
• Tighten the crankshaft pulley center bolt to the
specified torque.
Crankshaft Pulley Center Bolt Torque N∙m (kg∙m/lb∙ft)
206 (21/152)
6A1-93-2.tif
7) Timing belt

Above works refer to “TIMING GEAR (Belt Type)”
11) Crankshaft gear
• Install the crankshaft gear.
• Use the crankshaft gear installer ! to install the
crankshaft gear ".
• The crankshaft gear timing mark ("X-X") must be
facing outward.
6A1-94-1.tif

9) Injection pump
8) Idler gear "B" and shaft
7) Idle gear
6) Timing gear oil pipe

10) Push rod
9) Rocker arm shaft assembly
7) By-pass hose
4) Glow plug harness connector
3) PCV hose
2) Fuel leak off pipe
1) Injection pipe
2. Engine Assembly
13) Support rubber
11) Vacuum pump hose
10) Actuator vacuum hose (Exhaust Brake Model)
9) Power steering pump & bracket assembly (Power
Steering Model)
6) Fuel hose
3) Heater hose
2) Intake air duct
this manual.

2) Clutch
1) Transmission
this manual.
ENGINE ASSEMBLY
Removal steps
2. Radiator Assembly
3. Intake air duct
4. Heater hose
5. Engine control cable
6. Glow plug harness
7. Fuel hose
8. Oil pressure switch harness
9. A/C Compressor Assembly.
(A/C model)
10. Power steering pump & bracket
Assembly
(Power steering model)
11. Actuator vacuum hose
(Exhaust brake model)
12. Vacuum pump hose
13. Front exhaust pipe
14. Support rubber
15. Engine Assembly
Installation steps
the reverse order.
6A1-96-1.tif
REMOVAL
Preparation:
• Disconnect Battery Ground Cable
• Drain Coolant

• Raise vehicle and support with suitable safely.
1) Transmission
! Propeller Shaft
• Reference mark the flange yoke to the parking brake
drum.
• Disconnect the propeller shaft at flange yoke.
• Put aside the propeller shaft and tie it to the frame so
that it does not interface with servicing work.
6A1-97-1.tif

• Move the joint cover.
• Disconnect the joint bolt.
• Remove the clip then disconnect the cable from the
bracket.
6A1-97-2.tif
# Wiring Connector
• Disconnect the wiring connectors from the car speed
sensor, the neutral switch and the back-up light switch.
• Disconnect the shift cable and select cable on the
transmission side.
6A1-97-3.tif

• Remove the clutch pipe fixing clips and the clip
bracket (Right hand drive models only).
6A1-98-1.tif
• Remove the slave cylinder assembly with the flexible

hose attached, and then tie it to the frame so that it
does not interface with servicing work.
6A1-98-2.tif

6A1-98-3.tif
NOTE:
The exhaust pipe bracket, the gear control bracket
and the clips are sometimes installed in the wrong
position or direction confusedly. To prevent incorrect
installation of these parts, put a correct installation
mark on them.
CAUTION:
To prevent the falling of the transmission, tie it firmly
to the jack with a chain or belt.
Do not allow transmission to hang unsupported from
clutch. Damage to the clutch assembly will result.
6A1-98-4.tif
• Remove the nuts of the transmission mounting bracket

on the crossmember side.
• Engine and transmission angles may need to be
adjusted for removal.
• Hold the rear section of the engine by the jack or hoist.
CAUTION:
When lifting the engine by the jack, use wood blocks
to prevent any possible damage to the oil pan.
• Remove transmission fastening bolts.
• Pull out the transmission assembly rearward.
) Mounting Bracket
2) Clutch
• Raise vehicle and support with suitable safety stands.
CAUTION:
Do not let clutch fluid remain on a painted surface,
Wash it off immediately.
• Use the pilot aligner to prevent the driven plate
assembly from falling free.
• Mark the flywheel and pressure plate lug for alignment
when installing.
• Loosen the pressure plate assembly fixing bolts.
6A1-99-1.tif
1) Remove the radiator hose upper and lower.
2) Remove the reservoir tank hose
3) Remove the cushion rubbers on both sides.
4) Remove the radiator stay.
6A1-100-1.tif
3. Intake Air Duct

4. Heater Hose
5. Engine Control Cable
• Loosen the locking nut at the bracket and disconnect
accelerator cable from injection pump control lever.
7. Fuel Hose
• Remove the fuel inlet hose and fuel return hose.
8. Oil Pressure Switch Harness
6A1-100-2.tif
9. A/C Compressor Assembly

• Loosen the idler pulley lock nut.
• Loosen the adjust bolt then remove the drive belt.
6A1-100-3.tif
• Disconnect magnetic clutch harness connector.

temporally tighten the A/C compressor to chassis
6A1-100-4.tif
10. Power Steering Pump & Bracket Assembly (Power

Steering Model)
1) Loosen the idler pulley lock nut.
2) Loosen the adjust bolt then remove the drive belt.
3) Remove the pipe bracket fixing bolt and clip.
4) Remove the power steering pump fixing bolts pump to
chassis frame side use the wire.
6A1-101-1.tif
11. Actuator Vacuum Hose (Exh. Brake Model)

• Disconnect the vacuum hose from actuator side.
6A1-101-2.tif
12. Vacuum Pump Hose (Exh. Brake Model)

• Disconnect the vacuum hose from vacuum tank side
and magnetic valve side.
6A1-101-3.tif

• Remove the exhaust pipe fixing bolts from exhaust
manifold.
• Remove the exhaust pipe stay bolt.
• Remover the fixing nuts from front pipe.
6A1-101-4.tif
14. Support Rubber

1) Right Hand
6A1-101-5.tif
2) Left Hand
15. Engine Assembly
1) Lift engine carefully by using hoist.
2) Lift front part of engine higher than rear part of it.
3) Take out engine assembly taking care not to damage
full pipes, brake pipes and etc.
6A1-102-1.tif
INSTALLATION
15. Engine Assembly
• Position engine mountings by using hoist.
14. Support Rubber
• After all fixing bolts (left:two bolts, right:two bolts) were
inserted to every holes, and engine asm and tighten
fixing bolts to the specified torque.
40 (4.1/30)
6A1-103-1.tif

• Connect the exhaust pipe and tighten nut to the
specified torque.
Exhaust Pipe Nut Torque N∙m (kg∙m/lb∙ft)
69 (7.0/51)
• Install the exhaust pipe stay and tighten bolt nut to the
specified torque.
Stay Bolt Nut Torque N∙m (kg∙m/lb∙ft)
6A1-103-2.tif
40 (4.1/30)
12. Vacuum Pump Hose (Exh. Brake Model)

• Connect the vacuum hose to vacuum tank side and
magnetic valve side.
6A1-103-3.tif
11. Actuator Vacuum Hose (Exh. Brake Model)

• Connect the vacuum hose to actuator.
6A1-103-4.tif
10. Power Steering Pump & Bracket Assembly (Power

Steering Model)
• Install the power steering pump and pipe bracket then
tighten bolts to the specified torque.
Pump Bolts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
Pipe Bracket Bolts Torque N∙m (kg∙m/lb∙ft)

19 (1.9/14)
6A1-104-1.tif
Clip Bolt Torque N∙m (kg∙m/lb∙in)

10 (1.0/87)
• Install Power Steering pump drive belt and adjust belt

tension.
Check drive belts for wear or damage, and replace
with new ones as necessary.
Check belts for tension, and adjust as necessary.
mm (in)
6A1-104-2.tif Initial tension
P/S pump drive belt 8 - 12 (0.31 - 0.47)
• P/S pump lock bolt loose, adjust belt tension with

adjust belt.
Idler Lock Nut Torque N∙m (kg∙m/lb∙ft)
27 (2.8/20)
6A1-104-3.tif

• Install the A/C compressor fixing bolts and tighten
bolts to the specified torque.
Compressor Fixing Bolts Torque N∙m (kg∙m/lb∙ft)
37 (3.8/27)
• Connect the magnetic clutch harness connector.
6A1-104-4.tif

tension.
with new ones as necessary. Check belts for tension,
and adjust as necessary.
mm (in)
6A1-105-1.tif
Initial tension
A/C compressor drive belt 8 - 12(0.31 - 0.47)
• A/C compressor pulley lock bolt loose, adjust belt

tension with adjuster's adjust bolt.
Idler Lock Nut Torque N∙m (kg∙m/lb∙ft)
27 (2.8/20)
8. Oil Pressure Switch Harness

• Connect the oil pressure switch harness connector.
7. Fuel Hose
• Connect the fuel feed hose and return hose then
tighten clip securely.
• Install the harness connector then tighten bolt
securely.
5. Engine Control Cable
1) Install the control wire to the engine control lever.
2) Hold accelerator lever in the fully closed position and
stretch the control cable in the direction indicated by
the arrow to remove any slack.
3) Tighten the accelerator cable bracket bolt.
6A1-105-2.tif
4. Heater Hose
• Connect the heater hose then tighten clip securely.
3. Intake Air Duct
• Connect the air duct then tighten clip securely.
6A1-106-1.tif
1) Install the cushion rubber on both sides.
2) Install the radiator stay
3) Connect the radiator hose upper and lower.
4) Connect the reservoir tank hose.
6A1-106-2.tif

2) Clutch
• Apply multi-purpose with MOS2 type grease to the
driven plate hub spline.
• Use the pilot aligner to install the driven plate
assembly.
6A1-106-3.tif

• Tighten pressure plate assembly fixing bolts in
numerical order.
Pressure Plate Fixing Bolt Torque N∙m (kg∙m/lb∙ft)
18 (1.8/13)
• Remove the pilot aligner.
NOTE:
6A1-106-4.tif
In case a new pressure plate assembly is mounted,
after tightening a pressure plate at the specified
torque, be sure to remove the wiring for protection of
a diaphragm spring.
1) Transmission
) Mounting Bracket
Mounting Bracket Nuts Torque N∙m (kg∙m/lb∙ft)
69 (7.0/51)
CAUTION:
To prevent the falling of the transmission, tie it
securely to the jack with a chain or belt.
• Shift transmission into high gear.
• Align transmission with engine slope.
• Turn output parking brake drum to aid clutch spring
engagement.
6A1-107-1.tif
Clutch Housing to Flywheel

Housing Bolts Torque N∙m (kg∙m/lb∙ft)
M10 : 46(4.7/34)
M12 : 91(9.3/67)
• Raise engine and transmission up into rear

transmission mount.
Engine Rear Mounting Nuts
and Bolts Torque N∙m (kg∙m/lb∙ft)
M10 : 40(4.1/30)
M12 : 69(7.0/51)
6A1-107-2.tif

Front Exhaust Pipe Bolts Torque N∙m (kg∙m/lb∙ft)
37 (3.8/27)

Exhaust Brake Bolts Torque N∙m (kg∙m/lb∙ft)
1 7(1.8/12)

Slave Cylinder Bolts Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
• Perform slave cylinder adjustment before installation

of the return spring.
a) Loosen the lock nut of the push rod.
b) Turn the adjust nut until it reaches the shift fork.
c) Back off the adjust nut 1.5 turns. (shift fork free
play Approximately 2 mm/0.1 in).
d) Tighten the lock nut.
Push Rod Lock Nut Torque N∙m (kg∙m/lb∙ft)
16 (1.6/12)

# Wiring Connector
• Color of Connector
Back-up Light Switch: Brown
Neutral Switch: Gray
! Propeller Shaft
• Line up reference mark.
Propeller Shaft Nuts Torque N∙m (kg∙m/lb∙ft)
66 (6.7/48)
• Connect the battery ground cable

• Pour coolant
• Start the engine and check coolant leakage
HOME
ENGINE COOLING 6B - 1
SECTION 6B
ENGINE COOLING
CONTENTS
PAGE
General Description......................................................................................................... 6B - 1
On-Vehicle Service .......................................................................................................... 6B - 6
Water Pump.................................................................................................................. 6B - 6
Thermostat ................................................................................................................... 6B -10
Radiator ........................................................................................................................ 6B -12
Drive Belt Adjustment ................................................................................................. 6B -15
GENERAL DESCRIPTION
6B-1-1.tif
6B - 2 ENGINE COOLING
The cooling system is a pressurized coolant forced circulation

type which consists of water pump, thermostat cooling fan,
radiator and other components. The circulating coolant cools
the lubricating oil in the oil filter and turbocharger.
WATER PUMP
The coolant pump is a centrifugal impeller type and is driven by
V type drive belt.
The water pump is not disassembled type.
6B-2-1.tif
THERMOSTAT
The thermostat is a wax pellet type with a juggle valve and is
installed in the thermostat housing.
6B-2-2.tif
RADIATOR
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of coolant, the radiator is adjusted
through a valve fitted to the upper tank to a pressure range of
2
93 - 123 kPa (0.95 - 1.25 kg/cm ). The cap fitted to the cylinder
head thermostat housing has only a water supply function.
6B-2-3.tif
Engine coolant change procedure

1. To change engine coolant, make sure that the engine is
cool.
WARNING:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor or
boiling water. To open the radiator cap, put a piece of
thick cloth on the cap and loosen the cap slowly to
reduce the pressure when the coolant has become
cooler.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE:
For best result it is suggested that the engine cooling
system be flushed at least once a year. It is advisable
to flush the interior of the cooling system including the
radiator before using anti-freeze (ethylene-glycol
based).
Replace damaged rubber hoses as the engine anti-
freeze coolant is liable to leak out even minor cracks.
Isuzu recommends to use Isuzu genuine anti-freeze
(ethylene-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
CAUTION:
A failure to correctly fill the engine cooling system in
changing or topping up coolant may sometimes cause
the coolant to overflow from the filler neck even before
the engine and radiator are completely full.
If the engine runs under this condition, shortage of
coolant may possibly result in engine overheating. To
avoid such trouble, the following precautions should
be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck using
a filling hose which is smaller in outside diameter of the
filler neck.
Otherwise air between the filler neck and the filling hose
will block entry, preventing the system from completely
filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over this
maximum rate may force air inside the engine and radiator.
And also, the coolant overflow will increase, making it
difficult to determine, whether or not the system is
completely full.
5. After filling the system to the full, pull out the filling hose
and check to see if air trapped in the system is dislodged
and the coolant level goes down. Should the coolant level
go down, repeat topping-up until there is no more drop in
the coolant level.
6. After directly filling the radiator, fill the reservoir to the
maximum level.
7. Install and tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and reopen
radiator cap. If the water level is lower, replenish.
WARNING:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor or
boiling water. To open the radiator cap, put a piece of
thick cloth on the cap and loosen the cap slowly to
reduce the pressure when the coolant has become
cooler.
8. After tightening radiator cap, warm up the engine at about
2,000 rpm.
Set heater adjustment to the highest temperature position,
and let the coolant circulate also into heater water system.
9. Check to see the thermostat has opened through the
needle position of water thermometer, conduct a
5 minutes idling again and stop the engine.
10. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system and
reservoir tank hose for leakage.
11. Fill the coolant into the reservoir tank up to “MAX” line.
ANTI-FREEZE SOLUTION
• Relation between Mixing ratio and Freezing point
Freezing temperature of the engine coolant varies with
the ratio of anti-freeze solution in water.
Proper mixing ratio can be determined by referring to
the chart. Supplemental inhibitors or additives claiming
to increase cooling capability that have not been
specifically approved by Isuzu are not recommended
for addition to the cooling system.
6B-4-1.tif
• Calculation of mixing ratio
Mixing ratio
Anti-freeze solution (Lit/qt.)
=
Anti-freeze solution (Lit/qt.) + Water (Lit/qt.)
Note: Anti-freeze solution + Water = 10 lit

Total cooling system capacity.
In case of 6.8 lit total cooling system capacity
Anti-freeze
Mixing Water:
solution:
ratio (%) lit. (imp. qt/U.S. qt)
lit. (imp. qt./U.S. qt)
0 0 0 10 (8.80/10.57)
5 0.5 (0.44/0.53) 9.5 (8.36/10.04)
10 1.0 (0.88/1.06) 9.0 (7.92/9.51)
15 1.5 (1.32/1.59) 8.5 (7.48/8.98)
20 2.0 (1.76/2.11) 8.0 (7.04/8.45)
25 2.5 (2.20/2.64) 7.5 (6.60/7.93)
30 3.0 (2.64/3.17) 7.0 (6.16/7.40)
35 3.5 (3.08/3.70) 6.5 (5.72/6.87)
40 4.0 (3.52/4.23) 6.0 (5.28/6.34)
45 4.5 (3.96/4.76) 5.5 (4.84/5.81)
50 5.0 (4.40/5.28) 5.0 (4.40/5.28)
• Mixing ratio
Check the specific gravity of engine coolant in the
cooling system in temperature ranges from 0° to 50°C
using a suction type hydrometer, then determine the
mixing ratio of the coolant by referring to the table at
left.
6B-4-2.tif
ON-VEHICLE SERVICE
WATER PUMP
Removal steps
1. Fan shoroud
3. Power steering pump drive
belt
4. A/C compressor drive belt
7. Timing pulley upper cover
8. Timing pulley lower cover
9. Water pump Assembly
Installation steps
6B-5-1.tif
REMOVAL
Preparation:
• Drain coolant
1. Fan Shroud
• Remove the reservoir tank hose, bypass hose and fan
guide.
• Remove lock nut and take out cooling fan assembly.
• Loosen the idler pulley lock nut and loosen adjust bolt,
and remove the drive belt.
6B-5-2.tif

• Loosen A/C compressor idler pulley lock nut and
adjust bolt and remove the drive belt.
6B-5-3.tif

6B-6-1.tif
6B-6-2.tif

• Remove the O-ring
6B-6-3.tif
INSPECTION
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump
assembly must be replaced.
• Cracks in the coolant pump body
• Coolant leakage from the seal unit
• Play or abnormal noise in the bearing
• Cracks or corrosion in the impeller
INSTALLATION
• Set O-ring in water pump body groove.
• Install water pump assembly, and tighten to specified
torque.
Pump Fixing Bolt Torque N∙m (Kg∙m/lb∙ft)
20 (2.0/14)
6B-7-1.tif 8. Timing Pulley Lower Cover

• Install timing pulley lower cover, and tighten to
specified torque.
Cover Fixing Bolts Torque N∙m (Kg∙m/lb∙in)
8 (0.8/69)

• Install timing upper cover, and tighten to specified
torque.
Cover Fixing Bolts Torque N∙m (Kg∙m/lb∙in)
8 (0.8/69)

• Install crankshaft damper pulley, and tighten to
specified torque.
Pulley Bolt Torque N∙m (Kg∙m/lb∙in)
19 (1.9/14)

• Install the drive belts and adjust belt
with new ones as necessary. Check belts for tension,
and adjust as necessary.
• Push the middle of belts with a force of 98 N
(10 kg/22 lb) and check each bolt for deflection.
6B-7-2.tif • Standard deflection
mm (in)
Initial tension
AC Generator drive belt
8 – 12
A/C compressor drive belt
(0.31-0.47)
Power Steering drive belt
6B-7-3.tif
Generator Fixing Belt Torque N∙m (Kg∙m/lb∙ft)

40 (4.1/30)
Adjust Plate Fixing Belt Torque N∙m (Kg∙m/lb∙ft)

19 (1.9/14)
A/C Idler Pulley Lock Nut Torque N∙m (Kg∙m/lb∙ft)

27 (2.8/20)
6B-8-1.tif
P/S Idler Pulley Lock Nut Torque N∙m (Kg∙m/lb∙ft)
27 (2.8/20)

• Mount fan pulley and cooling fan assembly on the
water pump and tighten to the specified torque.
Fan Pulley Nut Torque N∙m (Kg∙m/lb∙in)
8 (0.8/69)
1. Fan Shroud
• Install the fan shroud and reservoir tank hose and
bypass hose.
• Pour coolant.
6B-8-2.tif
THERMOSTAT
6B-9-1.tif
REMOVAL
Preparation:
1. Switch Harness
2. Outlet Pipe
• Remove mounting bolt and remove outlet pipe
together with radiator hose.
3. Gasket
4. Thermostat
INSPECTION
Submerge the thermostat assembly in the water.
Place wooden blocks on the bottom of the water container.
Not to directly heat the thermostat.
Gradually increase the water temperature. Stir the water so
that the entire water is same temperature.
• Make sure that primary valve begins to open at the
specified temperature.
Valve Opening Temperature °C (°F)
6B-9-2.tif
82 (180)
• Make sure that secondary valve opens fully at the

specified temperature.
Valve Full Open Temperature °C (°F)
95 (203)
Make necessary repair and parts replacement if extreme wear

or damage is found during inspection.
INSTALLATION
4. Thermostat
3. Gasket
2. Outlet Pipe
• Connect outlet pipe and tighten bolts to the specified
torque.
N∙m (Kg∙m/lb∙ft)
19 (1.9/14)
6B-10-1.tif
1. Switch Harness
• Install switch harness.
• Install battery ground cable.
• Pour coolant.
RADIATOR
6B-11-1.tif
REMOVAL
Preparation:
• Loosen drain plug to drain coolant.
1. Reservoir Tank Hose & Bypass Hose
• Disconnect the hose from radiator.
2. Radiator Hose
• Disconnect lower hose and upper hose from the
engine.
3. Air Intake Duct
4. Radiator Stay
5. Condenser
• Remove the condenser from radiator and temporarily
tighten the condenser to cab body front side, use the
wire.
6. Cushion Rubber
• Remove cushion rubbers on both sides of the bottom.
• Remove upward the radiator assembly with hose,
taking care not to damage the radiator core by fan
blade.
INSPECTION
Radiator Valve
• Apply air pressure from filler neck using radiator cap
tester and check the opening pressure of radiator
valve. If the valve opening pressure is out of the
standard value range, replace with a new radiator
valve.
2
Radiator valve opening pressure kPa (kg/cm /psi)
93 - 123 (0.95 - 1.25/13.5 - 17.8)
• Remove the radiator valve and check a negative

pressure valve as the center of the valve seat side. If
the negative pressure valve does not work smoothly,
clean or replace the radiator valve.
Radiator valve fixing torque N∙m (kg∙m/lb ft)
6 (0.6/4)
• Conduct cooling system leakage check after

reinstalling the radiator valve.
Radiator Core
• Deformed radiator fins could reduce radiation effects,
resulting in overheat. Straighten the fins. In such a
case, take care not to damage the fin roots.
• Remove dust and other foreign materials.
Flushing the Radiator

• Wash the inside of radiator and the coolant passage
with water and neutral detergent. Remove all scales
and rust.
Checking for Coolant Leakage

• Clog up the reserver tank hose carefully and check the
cooling system for leakage with a radiator cap tester
2
by applying an air pressure of 147 kPa (1.5 kg/cm /21
psi) from filler neck to inside the radiator.
• As the radiator upper tank is provided with a valve, the
pressure fails to rise higher than the valve opening
pressure unless the hose is clogged up.
6B-12-1.tif
INSTALLATION
• Install the radiator
6. Cushion Rubber
• Install cushion rubbers on both sides of radiator
bottom.
• Install radiator assembly with hose, taking care not to
damage the radiator core by a fan blade.
5. Condenser
4. Radiator Stay
3. Air Intake Duct
6B-13-1.tif
• Connect the Duct and tighten clip securely.
2. Radiator Hose
• Connect inlet hose and outlet hose to the engine.
• Pour coolant
• Pour coolant up to filler neck of radiator, and up to
MAX mark of reservoir tank.
1. Reservoir Tank Hose & Bypass Hose
• Start engine to warm up, and check for coolant level.
DRIVE BELT ADJUSTMENT
6B-14-1.tif
INSPECTION
Check drive belts for wear or damage, and replace with
new ones as necessary. Check belts for tension, and
adjust as necessary.
• Check drive belts tension.
• Push the middle of belts with a force of 98 N
(10 kg/22 lb) and check each bolt for deflection.
6B-14-2.tif
mm (in)
Tension at readjustment
AC generator & fan pulley
drive belt
8 ~ 12 (0.31 ~ 0.47)
A/C compressor drive belt
P/S pump drive belt
6B-14-3.tif
TENSION ADJUSTMENT
1. Cooling Fan Pulley Belt
• With AC Generator mounting and lock bolts loose,
adjust belt tension with adjuster's adjust bolt.
Tighten bolt to the specified torque
Generator Fixing Bolt Torque N∙m (Kg∙m/lb∙ft)
40 (4.1/30)
Adjust Plate Fixing Bolt Torque N∙m (Kg∙m/lb∙ft)

19 (1.9/14)
2. P/S Oil Pump and A/C Compressor Pulley Belt

• With P/S pump lock bolt loose, adjust belt tension with
adjust belt.
Tighten lock nut to the specified torque.
Lock Nut Torque N∙m (Kg∙m/lb∙ft)
27 (2.8/20)
HOME
ENGINE FUEL 6C - 1
SECTION 6C
ENGINE FUEL
CONTENTS
PAGE
General Description....................................................................................................... 6C - 2
On-Vehicle Service ........................................................................................................ 6C - 7
Fuel Filter Assembly.................................................................................................. 6C - 7
Fuel Filter Cartrige..................................................................................................... 6C - 8
Injection nozzle.......................................................................................................... 6C - 9
Injection Pump Assembly (Gear Drive Type) .......................................................... 6C - 26
Injection Pump Assembly (Belt Drive Type)............................................................ 6C - 31
Injection Timing Adjustment..................................................................................... 6C - 41
Adjustment of Idling Speed ...................................................................................... 6C - 42
Injection Pump Data .................................................................................................. 6C - 43
Injection Volume and Governor Performance Diagram ......................................... 6C - 45
Fuel Tank.................................................................................................................... 6C - 55
Fuel Gauge Unit ......................................................................................................... 6C - 57
Accelerator Control ....................................................................................................... 6C - 58
Accelerator Control Cable ........................................................................................ 6C - 58
Accelerator Pedal ...................................................................................................... 6C - 60
Idling Control Cable .................................................................................................. 6C - 62
Air Cleaner Element .................................................................................................. 6C - 64
6C - 2 ENGINE FUEL
GENERAL DESCRIPTION
When working on the fuel system, there are Clean and inspect "O" rings. Replace where
several things to keep in mind: required.
• Any time the fuel system is being worked on, • Always relieve the line pressure before
disconnect the negative battery cable except servicing any fuel system components.
for those tests where battery voltage is • Do not attempt repairs on the fuel system until
required. you have read the instructions and checked
• Always keep a dry chemical (Class B) fire the pictures relating to that repairs.
extinguisher near the work area.
• Replace all pipes with the same pipe and
fittings that were removed.
ENGINE FUEL 6C - 3
FUEL FLOW
6C-2-1.tif
The fuel system consists of the fuel tank, the water Fuel, fed by the injection pump plunger, is delivered to
separator, the fuel filter, the injection pump, and the the injection nozzle in the measured volume at the
injection nozzle. optimum timing for efficient engine operation.
The fuel from the fuel tank passes through the water
separator and the fuel filter where water particles and
other foreign material are removed from the fuel.
6C - 4 ENGINE FUEL
INJECTION PUMP
6C-3-1.tif
6C-3-2.tif
A Bosch Distributor Type Injection Pump is used. A The injection pump is compact, light weight, and
single reciprocating/revolving plunger delivers the fuel provides reliable high-speed operation.
uniformly to the injection nozzles, regardless of the An aneroid compensator is available as an option for
number of cylinders. vehicles to be operated at high altitudes. It adjusts the
The governor, the injection timer, and the feed pump fuel and air mixing ratio.
are all contained in the injection pump housing.
ENGINE FUEL 6C - 5
FUEL FILTER AND WATER SEPARATOR
6C-4-1.tif 6C-4-2.tif
A cartridge type fuel filter and a water separator are The water separator has an internal float. When the
used along with the VE type injection pump. float reaches the specified level, a warning light
As the inside of the injection pump is lubricated by the comes on to remind you to drain the water from the
fuel which it is pumping, the fuel must be perfectly water separator.
clean. The fuel filter and the water separator remove A diaphragm type priming pump is installed at the top
water particles and other foreign material from the fuel of the water separator. It is used during the water
before it reaches the injection pump. draining and the air bleeding procedures.
6C - 6 ENGINE FUEL
INJECTION NOZZLE
6C-5-1.tif
For 4J Series diesel engines, there are two types 4JB1-TC Engine
available: Direct injection engine (4JB1/4JB1T) and The two-spring nozzle holder has been developed to
Indirect injection engine (4JG2). Accordingly, the reduce NOx (Nitrogen Oxides) and particulates from
injection nozzles to be used are different depending on direct injection diesel engine exhaust.
the type of the engine and the combustion chamber.
The injection nozzle sprays pressurized fuel from the
injection pump into the combustion chamber through
the injection nozzle orifices.
4JB1 engines employ a hole type nozzle with four
injection orifices. The nozzle is made up of the nozzle
body and the needle valve assembly.
Pressurized fuel from the injection pump is sprayed by
the injection nozzle into the combustion chamber
through the nozzle body orifices.
ENGINE FUEL 6C - 7
ON-VEHICLE SERVICE
FUEL FILTER ASSEMBLY
6C-6-1.tif
REMOVAL
Preparation
1. Fuel Filler Cap
2. Fuel Hose
• Disconnect fuel hose from filter body.
Plug the hose ends to prevent fuel spillage.
• Remove the fixing bolts on fuel filter bracket.
INSTALLATION
• Install the fuel filter bracket then tighten fixing bolt.
2. Fuel Hose
• Connect hoses to filter body.
1. Fuel Filler Cap
• Feed fuel to the injection pump by means of the
priming, and bleed the fuel system.
6C - 8 ENGINE FUEL
FUEL FILTER CARTRIDGE

REMOVAL
• Remove the cartridge using a filter wrench.
Filter wrench: 5-8840-0253-0 (J-22700)
INSTALLATION
• Clean the cartridge mounting surface of filter body so
that the cartridge can be securely.
Apply engine oil thinly to new cartridge O-ring.
• To facilitate bleeding, fill the new cartridge with light oil.
• Tighten the cartridge until O-ring comes in contact with
the sealing, taking care not to spill the light oil.
• Retighten 1/3~ 2/3 using a filter wrench.
6C-7-1.tif
Filter wrench: 5-8840-0253-0 (J-22700)
Bleeding
• Operate priming pump to send the air in the fuel
• Loosen injection pump bleeding plug, and operate the
priming pump until no bubble is made.
• Tighten the bleeding plug.
• Start the engine, and if it is not started in 10 seconds
or less, repeat the bleeding steps.
• Make sure of no fuel leakage, and tighten the priming
pump.
6C-7-2.tif
Draining
• When the water in the sedimentor reaches the
specified volume, warning light is actuated.
In this case, follow the draining steps below.
• Set a vinyl hose over the drain plug.
• Loosen the drain plug.
• To drain the water, operate the priming pump several
times.
• After draining, tighten the drain plug.
• Operate the priming pump several times to check for
fuel leakage.
• Check and see the warning light is off.
ENGINE FUEL 6C - 9
INJECTION NOZZLE
Removal steps
1. Injection pipe
2. Leak off pipe or hose
3. Injection nozzle
Installation steps
the reverse order.
6C-8-1.tif
REMOVAL
Preparation:
1. Injection Pipe
• Loosen the flare nut on the injection pump side.
• Loosen the flare nut on the injection nozzle side,
disconnect and put aside the pipe.
2. Leak off Pipe or Hose
3. Injection Nozzle
INSPECTION
• Set the nozzle in a nozzle tester.
Check there is no fuel leak in the nozzle seal when a
2
fuel pressure of kg/cm is applied.
If there is leak, replace.
6C - 10 ENGINE FUEL
DISASSEMBLY (4JG2 Engine)

• Grip nozzle holder with a vise, loosen retaining nut and
disassemble.
• Loosen holder nut and remove the nozzle.
6C-9-1.tif
CAUTION
• Be careful not to damage the needle valve.
• Remove spacer, positioning pin, and push rod.
• Remove spring and adjusting shim.
6C-9-2.tif
CAUTION
• Wash all the parts removed and arrange them on a
cylinder basis, care should be taken not to miss any
parts.
• Soak the nozzle assembly in a parts receptacle filled
with light oil.
• Care should be taken not to miss shim, if used.
6C-9-3.tif
INSPECTION (4JG2 Engine)

Nozzle
• Soak the nozzle removed in clean light oil, wash
nozzle body and needle valve separately, and check
and see that the needle valve slide smoothly in the
nozzle body.
6C-9-4.tif
6C-9-5.tif
ENGINE FUEL 6C - 11
CAUTION
• If the needle valve does not slide smoothly repair or
replace with a new nozzle assembly.
Nozzle lapping procedure
• Apply thinly a compound (Chrome oxide kneaded with
an animal oil) to the seat of needle valve and lap.
6C-10-1.tif
CAUTION
• Excess compound may cause worn needle valve, and
be sure to wash out the compound after lapping.
Nozzle body & needle
• Check nozzle body and end for seizure.
If significantly seized, replace as a nozzle assembly
basis. Also replace as a nozzle assembly basis, if
needle valve end is deformed or seized.
6C-10-2.tif
CAUTION
• If either nozzle body or needle valve is faulty, replace
with a new nozzle assembly.
6C-10-3.tif
REASSEMBLY (4JG2 Engine)

To reassemble, follow the removal steps in the reverse order,
noting the following point.
CAUTION
• Be careful to fit spacer because positioning pins are
set off.
6C-10-4.tif
6C - 12 ENGINE FUEL
• Install retaining nut and tighten nut to the specified

torque.
39 (4.0/32)
6C-11-1.tif
ADJUSTMENT OF INJECTION OPENING

PRESSURE (4JG2 Engine)
• Set nozzle holder assembly on a nozzle tester.
• Apply hydraulic pressure by operating tester handle,
and make sure fuel cam be injected under the
following pressure.
2
Kpa (Kg/cm /psi)
14,710 (150/2,133)
6C-11-2.tif
CAUTION
• If not injected under the specified pressure, adjust with
adjusting shim.
Ref. Types are available in the 1.0 mm - 1.75 mm
thickness range (on a 0.01 mm basis).
• Unless extremely deformed spray in seen, there is no
problem.
CAUTION
• The spray condition, when judged with a nozzle tester,
is deemed as normal so long as the spray form is not
excessively deformed.
6C-11-3.tif
Oil tight test (4JG2 Engine)

1) After completion of the adjustment of injection
pressure, wipe off light oil at the tip of the nozzle with
waste.
2
2) With pressure 1,961 Kpa (20 kg/cm /284 psi) less than
the specified injection pressure applied, check to see if
an oil drop trickles off the tip of the nozzle within 10
seconds after application of pressure. (There is no
problem with the nozzle when oil gathers at the tip, but
6C-11-4.tif
does not drop off.)
3) When an oil drop trickles, clean the nozzle thoroughly.
Then reassemble it to check for any dropping of oil.
When oil still drops, change it with a new one.
ENGINE FUEL 6C - 13
INSTALLATION (4JG2 Engine)

CAUTION
• Nozzle and assembling should be as illustrated.
• Use new heat shield and new corrugated washer.
6C-12-1.tif
3. Injection Nozzle (4JG2 only)

• Lightly tighten the holder nut to suck extent that the
nozzle holder can turn one word and one word.
• Set positioning confirmation drilled hole (φ2) within a
nozzle turning angle of ±5° against the cylinder head-
side positioning boss.
• Apply a wrench as illustrated and tighten the holder nut
to the specified torque using a special tool.
CAUTION
040LX016.tif • After tightening the holder nut, make sure that the
drilled hole makes ±5° or smaller with the cylinder
head-side positioning boss.
• When mounting leak off pipe, injection nozzle and
pipe, clean then with air so that dust may not
enter.
Nozzle Fixing Torque N∙m (Kg∙m/lb∙ft)

64 (6.5/47)
Wrench: nozzle holder 5-8840-0259-0

6C-12-3.tif
2. Leak Off Pipe

• Mount using a new copper washer
• Tighten nut to the specified torque.
Pipe Nut Torque N∙m (Kg∙m/lb∙ft)
29 (3.0/22)
1. Injection Pipe
• Connect injection pipe to nozzle holder.
• Tighten the injection pump side.
Sleeve Nut Torque N∙m (Kg∙m/lb∙ft)
29 (3.0/22)
• Fit pipe clip in specified position.

6C - 14 ENGINE FUEL
4-1 Injection Nozzle (Two spring nozzle holder)

(4JB1-TC only)
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
DISASSEMBLY
1. Retaining nut
2. Nozzle & pin
3. Spacer & pin
4. Lift piece
5. Spring seat
6. Push rod
7. Shim (Second nozzle opening pressure adjustment)
8. Second spring
9. Collar
10. Spring seat
11. First spring
12. Shim (First nozzle opening pressure adjustment)
14. Eye bolt
15. Gasket
080LX002.tif
(1) Before disassembly remove carbon deposit from

nozzle and nozzle holder using a wire brush and wash
the outside nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush
during cleaning it.
(2) Disassemble the nozzle holder assembly to numerical
order.
ENGINE FUEL 6C - 15
REASSEMBLY AND OPENING

PRESSURE ADJUSTMENT (4JB1-TC
only)
2. Shim (First opening pressure adjustment)
3. First spring
4. Spring seat
5. Collar
6. Second spring
7. Push rod
8. Shim (Second opening pressure adjustment)
9. Spring seat
10. Lift piece
11. Spacer & pin
12. Nozzle & pin
13. Retaining nut
14. Gasket
15. Eye bolt
080LX003.tif The nozzle holder is adjusted as the components are

reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in light oil
to completely remove any dirt or foreign matter.
REASSEMBLY AND ADJUSTMENT PROCEDURE

1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.
2 Full needle valve lift confirmation Confirm the full needle valve lift in accordance with the
closed method.
3 Pre-lift confirmation Confirm pre-lift in accordance with the closed method.
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
4 Second nozzle opening pressure Confirm the second nozzle opening pressure in accordance
confirmation with the closed method.
5 Second nozzle opening pressure Adjust the second nozzle opening pressure using the shim.
adjustment
6 Confirm the condition of the fuel spray with the nozzle and
Final inspection nozzle holder assembled.
6C - 16 ENGINE FUEL
First nozzle opening pressure adjustment

1. Claim the nozzle holder in a vise.
040MV015.tif
2. Install the shim, first spring and spring seat in the

nozzle holder.
040MV016.tif
3. Install the collar, second spring, shim, spring seat and

pushrod in the nozzle holder.
040MV017.tif
4. Install the pins, lift piece and spacer in the nozzle

holder.
040MV018.tif
5. Install the pins in the spacer.

6. Install the nozzle on the spacer.
040MV019.tif
ENGINE FUEL 6C - 17
7. Hand-tighten the adjustment retaining nut together

with the gasket to the nozzle holder.
Retaining nut: 5-8677-7140-0
Gasket: 5-8677-7139-0
040MV010.tif
8. Tighten the adjustment retaining nut to the specified

torque.
Torque: 29 - 39 N∙m (3.0 - 4.0 kg∙m)
040MV014-1.tif
9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.
CAUTION:
Use a micrometer to measure shim thickness.
040MV030.tif
• First nozzle opening pressure adjusting shims

Parts No. Thickness (mm)
1-1534-9042-0 0.40
1-1534-9043-0 0.50
1-1534-9044-0 0.52
1-1534-9045-0 0.54
1-1534-9046-0 0.56
040LX010.tif
1-1534-9047-0 0.58
1-1534-9048-0 0.60
1-1534-9049-0 0.70
6C - 18 ENGINE FUEL
Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining
nut.
Gasket: 8-9722-7602-0
Plug: 5-8677-7141-0
040MV013.tif
2. Position the nozzle holder with the nozzle facing down

and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 5-8677-7142-0
040MV012.tif
3. Install the nut on the dial gauge holder.

Nut: 5-8677-7143-0
040MV011.tif
4. Install the pin to the dial gauge.
Note:
The lengths of the pins do not include the
threaded portions.
Pin (liter=100 mm): 5-8677-7144-0
Dial gauge: 1-8531-7015-0
040MV029.tif
ENGINE FUEL 6C - 19
5. Secure the dial gauge to the nozzle holder using the

nut so that the pin contacts the tip of the first spring
seat.
CAUTION:
• Secure the dial gauge so that a stroke of 2 mm can
be measured.
• Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)
040MV009.tif
6. Set the nozzle holder to the nozzle tester and put

needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.
040MV030.tif
8. Operate the nozzle tester and increase the in-line

2
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that
the nozzle’s needle valve moves through its full lift.
Record full lift ‘L’. (Read dial gauge)
Note:
The above operation is used to determine whether
the nozzle seat is worn and whether the nozzle
assembly is in good condition.
040MV008.tif
6C - 20 ENGINE FUEL
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV007.tif
040MV006.tif
2. Read the needle valve lift ‘liter’ from the dial gauge
indication (once the needle valve has descended when
the second spring has stopped operating). Refer to the
pre-lift measuring point for ‘liter’.
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure +approx 1
2
MPa (10 kg/cm ).
Note:
This point can be found while the pressure is
decreasing.
040MV025-1.tif
3. Confirm that pre-lift ‘liter’ is as specified.

Pre-lift mm
0.04
040MV005.tif
4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit.
Service kit:
8-9720-3470-1
040MV031.tif
ENGINE FUEL 6C - 21
Second nozzle opening pressure confirmation

1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
2
kg/cm ) so that the nozzle’s needle valve moves
through its full lift.
040MV030.tif
2. Release the nozzle tester handle so that in-line

pressure decreases.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV022.tif
3. Then, read the pressure gauge indication (second

nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift (usually
pre-lift liter + 0.05 mm).
040MV024.tif
040MV026.tif
6C - 22 ENGINE FUEL
Second nozzle opening pressure adjustment

If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and
replace the shim until the pressure is as specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
• Use a micrometer to measure shim thickness.
040MV017.tif
• Second nozzle opening pressure adjusting shims

Part No. Thickness (mm)
8-9711-6034-0 0.40
8-9711-6035-0 0.50
8-9711-6037-0 0.52
8-9711-6039-0 0.54
8-9711-6041-0 0.56
8-9711-6043-0 0.58
8-9711-6044-0 0.59
040LX009.tif
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.tif
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-tighten
the retaining nut. Then, tighten the original retaining
nut to the specified torque.
Torque: 59 - 79 N∙m (6.0 - 8.0 kg∙m)
040MV014-1.tif
4. Set the nozzle holder to the nozzle tester and check

first nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.
040MV030.tif
ENGINE FUEL 6C - 23
DISASSEMBLY (4JBI/4JB1T Engine)

1. Retaining Nut
2. Injection Nozzle
1) Remove the nozzle assemblies from the nozzle
holders.
Tag the nozzle assemblies and the nozzle holders to
ensure that they are reinstalled in their original
positions.
The nozzle assembly and nozzle holder combinations
must not be interchanged.
2) Immerse the injection nozzle in a tool tray filled with
clean diesel oil to protect them from dust.
3. Spacer
4. Spring Seat
5. Spring
6. Adjusting Shim
7. Nozzle Holder
6C-22-1.tif
6C-22-2.tif
INSPECTION AND REPAIR (4JB1/4JB1 T

Engine)
during inspection.
Inspection Nozzle Needle Inspection

1. Remove the needle from the nozzle body.
2. Carefully wash the nozzle needle and the nozzle body
in clean diesel fuel.
3. Check that the nozzle needle moves smoothly inside
the injection nozzle body.
If the nozzle needle does not move smoothly, it must
be repaired (See "Nozzle Lapping Procedure" belows).
6C-22-3.tif
6C - 24 ENGINE FUEL
Nozzle Lapping Procedure

1. Lap the nozzle needle ! and the nozzle body " by
applying a compound of oxidized chrome and animal
oil #.
NOTE:
Do not apply an excessive amount of the oxidized
chrome and animal oil compound to the injection
needle valve seat area. Applying too much compound
will cause the injection nozzle needle and the injection
nozzle body cavity to wear excessively.
6C-23-1.tif
2. Carefully wash the needle valve and the nozzle body in
clean diesel fuel after lapping.
Nozzle Body and Needle Valve Inspection

Check the nozzle body and the needle valve for damage
and deformation.
The nozzle and body assembly must be replaced if either
of these two conditions are discovered during inspection.
6C-23-2.tif
Reassembly
7. Nozzle Holder
6. Adjusting Shim
5. Spring
4. Spring Seat
3. Spacer
2. Injection Nozzle
1. Retaining Nut
Tighten the retaining nut to the specified torque.
34 (3.5/25)
6C-23-3.tif
ENGINE FUEL 6C - 25
Injection Nozzle Adjustment

1) Attach the injection nozzle holder to the injection
nozzle tester.
2) Apply pressure to the nozzle tester to check that the
2
kPa (kg/cm /psi)
18,142 (185/2630)

6C-24-1.tif pressure, install or remove the appropriate number of
Adjusting Shim Availability mm (in)

Range 0.50 - 1.50 (0.02 - 0.06)
Increment 0.025 (0.001)
Total No. of Shims 40
Removing or installing one shim will increase of decrease

the nozzle opening pressure approximately 369.46 kPa
2
(3.77 kg/cm /53.6 psi).
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE WILL SPRAY
OUT UNDER GREAT PRESSURE. IT CAN EASILY
PUNCTURE A PRESON'S SKIN. KEEP YOUR HANDS
AWAY FROM THE INJECTION NOZZLE TESTER AT ALL
THE TIMES.
INSTALLATION (4JB1/4JB1T Engine)

3. Injection Nozzle
1) Install the injection nozzle gasket ! and the O-ring "
to the injection nozzle holder #.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2) Apply engine oil to the cylinder head nozzle holder
hole.
3) Install the nozzle holder together with the nozzle holder
bracket $ to the cylinder head.
6C-24-2.tif
37 (3.8/27)
2. Leak Off Hose

1. Injection Pipe
6C-24-3.tif
6C - 26 ENGINE FUEL
INJECTION PUMP ASM (4JB1/4JB1T, 4JG2 Gear Drive Type)
6C-25-1.tif
REMOVAL
Preparation:
• Drain coolant.
2. Fan Shroud
• Loosen Power Steering pump mounting bolt and
• Loosen A/C compressor idler pulley lock nut, adjust
bolt and remove the drive belt.
ENGINE FUEL 6C - 27

• Loosen AC generator mounting bolt (under side) and
8. Air Intake Duct
6C-26-1.tif
9. Injection Pump Control Cable

• Removal the control cable bracket bolt and remove the
control lever side.
10. Fuel Hose
• Disconnect the fuel feed hose and fuel return hose.
11. CSD (Cold Starting Device) Water Hose
• Disconnect the water hose from injection pump side.
6C-26-2.tif
12. Injection Pump Harness

• Remove the tachometer sensor (with tachometer)
CSD solenoid, fuel cut solenoid.
13. Injection Pipe
• Release pipe clip.
• Remove the flare nut on the pump side.
• Remove the flare nut on the injection nozzle side, and
remove the injection pipe.
6C-26-3.tif CAUTION
• Be sure to plug the injection nozzle holder and delivery
holder to prevent the entry of foreign matter.

• Remove pump mounting nut
• Loosen injection pump rear bracket adjuster lock bolt.
• Remove the mounting bolt on the engine side, and pull
out the pump from the engine.
NOTE:
Plug the injection pump delivery holder parts with the
shipping caps (or the equivalent) to prevent the entry
6C-26-4.tif
of foreign materials.
6C - 28 ENGINE FUEL
INSTALLATION
1. Timing gear case a camshaft timing gear side c
injection pump timing gear side check holde cover.
2. Turn the crankshaft clockwise to see the TDC mark of
the crank pulley to the pointer, and then bring the No.
1 cylinder to the TDC on the compression stroke.
6C-27-1.tif
3. Look in through the check hole on the crankshaft

timing gear side and check to see if the “O” mark on
the timing gear is in line with the pointer of the check
hole.
4. In the condition above with the injection pump gear
mark “O” set to the pointer of the check hole, install
the injection pump assembly.
• Install the injection pump fixing bolts and tighten them
Pump Bolts Torque N∙m (Kg∙m/lb∙ft)
6C-27-2.tif
15 (1.5/11)
13. Injection Pipe

• Connect the pump side and nozzle side of the pipe,
and tighten securely.
• Install clip where it was.
29 (3.0/22)

• Mount engine harness and connect it to switches.
6C-27-3.tif
11. CSD Water Hose

• Connect the water hose and tighten clip securely.
6C-27-4.tif
ENGINE FUEL 6C - 29
10. Fuel Hose

• Connect the fuel feed hose and fuel return hose.
• Connect the leak off hose.
1) Install the control wire to the engine control lever.
2) Hold the accelerator lever in the fully closed position
and stretch the control cable in the direction indicated
by the arrow to remove any slack.
6C-28-1.tif 8. Air Intake Duct

6C-28-2.tif

• Install AC generator drive belt and adjust belt tension.
• Depress the drive belt mid-portion with a 98 N (10
kg/22 lb) force.
8 (0.31) - 10 (0.39)

torque.
6C-28-3.tif
Generator Fixing Bolt N∙m (Kg∙m/lb∙ft)

40 (4.1/30)
Adjust Plate Fixing Bolt N∙m (Kg∙m/lb∙ft)

19 (1.9/14)
6C-28-4.tif
6C - 30 ENGINE FUEL

tension.
• Depress the drive belt mid-portion with a 98N (10
kg/22 lb) force.
8 (0.31) - 10 (0.39)
• Tighten the idler lock nut to the specified torque

27 (2.8/20)

• Install P.S pump drive belt and adjust belt tension.
• Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.
8 (0.31) - 10 (0.39)

27 (2.8/20)
2. Fan Shroud
N∙m (Kg∙m/lb∙in)
8 (0.8/69)
6C-29-1.tif • Connect battery ground cable.

• Pour coolant.
ENGINE FUEL 6C - 31
INJECTION PUMP ASSEMBLY (4JG2 Belt Drive Type)
Removal steps
2. Fan shroud
3. Power steering pump drive belt
4. A/C compressor drive belt
6. Power steering pump & bracket
Assembly
8. Timing pulley upper cover
9. Timing pulley lower cover
10. Flange; Camshaft pulley
11. Timing belt
12. Injection pump timing pulley
13. Air intake duct
14. Injection pump control cable
15. Fuel hose
16. CSD water hose
17. Injection pump hearness
18. Injection pipe
19. Injection pump Assembly
Installation steps
6C-30-1.tif
REMOVAL
Preparation:
• Drain coolant
2. Fan Shroud
6C-30-2.tif • Removal reservoir tank hose and fan shroud.
• Loosen power steering pump idle pulley lock nut and
6C - 32 ENGINE FUEL

• Loosen A/C compressor idler pulley lock nut, adjust
6C-31-1.tif

• Loosen AC generator mounting bolt (under side) and
6C-31-2.tif
6. Power Steering Pump & Bracket Assembly (P/S Model)

• Loosen power steering oil pipe bracket and clip.
• Remove P/S pump bracket assembly and hang the
P/S pump bracket assembly.
6C-31-3.tif
7. Crankshaft Dumper Pulley
6C-31-4.tif
ENGINE FUEL 6C - 33

6C-32-1.tif
6C-32-2.tif
11. Timing Belt

• Prepare a fixing bolt (M8 x 40, P=1.25)
• Turn crankshaft timing pulley in the normal direct
pulley side mark to timing pulley housing side mark.
• Make sure that the camshaft pulley and injection
timing pulley fixing bolt holes are set to each other.
Then Fit in a fixing bolt and lightly tighten.
• No. 1 cylinder should be at top dead center.
If the fixing bolt holes are not set (No. 4 cylinder is at
top dead center) give another turn.
6C-32-3.tif
• Remove tensioner and timing belt.
WARNING
• If crankshaft and camshaft and turned with timing
belt being not mounted, piston and valve will
interfere with each other. Therefore, the shafts
must not be turned.
6C-32-4.tif
6C - 34 ENGINE FUEL
12. Injection Pump Timing Pulley

• Install the stopper bolt ! to the timing pulley to
prevent it from turning.
6C-33-1.tif
• Use the timing pulley puller " to remove the injection

pump timing pulley.
6C-33-2.tif
13. Air Intake Duct

• Remove the control cable bracket bolt and remove the
control lever side.
15. Fuel Hose
• Disconnect the fuel feed hose and fuel return hose.
6C-33-3.tif
16. CSD Water Hose

18. Injection Pipe
• Remove the pump bracket bolt engine side.
• Remove the adjust lock bolt.
• Remove the injection pump fixing bolt and take out
injection pump.
ENGINE FUEL 6C - 35
INSTALLATION
• Put the timing pulley housing side and injection pump
side setting marks together, and temporarily tighten.
• After adjusting injection timing retighten.
• Mount rear bracket on cylinder block and tighten to the
specified torque.
6C-34-1.tif 19 (1.9/14)
• Install adjust lock bolt and lightly tighten.

• After adjusting injection timing, retighten.
18. Injection Pipe

• Connect the pump side and nozzle side of the pipe,
and tighten securely.
• Install clip where it was.
29 (3.0/22)

• Mount engine harness and connect it to switches.
6C-34-2.tif
16. CSD Water Hose

• Connect the water hose and tighten clip securely.
6C-34-3.tif
15. Fuel Hose

• Connect the fuel feed hose and fuel return hose.
• Connect the rear off hose.

1) Install the Control wire to the engine control lever.
2) Hold the accelerator lever ! in the fully closed
position and stretch the control cable " in the
direction indicated by the arrow to remove any slack.
6C-34-4.tif
6C - 36 ENGINE FUEL
13. Air Intake Duct

• Connect the air intake duct and tighten clip securely.
12. Injection Pump Timing Pulley

• Align the timing pulley with the pump shaft key.
• Install the stopper bolt to the timing pulley.
This will prevent the timing pulley from moving.
• Tighten the timing pulley nut to the specified torque.
Injection Pump Timing Pulley Nut Torque N∙m (Kg∙m/lb∙ft)

64 (6.5/47)
6C-35-1.tif
• Remove the stopper bolt from the injection timing
pulley.
11. Timing Belt

• When removing the belt, make sure the marks on the
bolt fixed camshaft, injection pulley and crankshaft
timing pulley are set to each other.
CAUTION
• Do not turn crankshaft because otherwise piston and
valve will interfere with each other.
6C-35-2.tif
CAUTION
• For accurate mounting, be sure to mount the belt in
the direction that letters on the belt are readable.
6C-35-3.tif
ENGINE FUEL 6C - 37
• Mount new timing belt on pulleys in the following steps.

Crankshaft timing pulley ! camshaft
Timing pulley." Idle pulley # Injection
Pump pulley $ tensioner %
• Set the belt on crankshaft timing pulley and hold with
one hand.
• Stretch and pass the belt round each pulley with the
other hand.
• After passing it round injection pump pulley,
6C-36-1.tif install tensioner while taking care not to slacken the
belt.
CAUTION
• On completion of belt passing, make sure that the
setting mark on crankshaft timing pulley is set.
• If not set, reset the mark and repeat the belt passing.
• Remove tension adjust, lever mounting bolt, and
loosen the fulcrum bolt to such extent that the lever is
movable.
• Hung a spring balance from the end hole of tension
adjust lever, and with the balance pulled down with 88
6C-36-2.tif
N (9Kg/20 lb)., loosen once the, tensioner mounting
bolt and there retighten it.
• Turn the crankshaft by 45° counterclockwise to shift
belt slackness on the tensioner.
• Again hand the spring balance from the end hole of
tension adjust lever and pull it down with the specified
force. Under this condition, loosen tensioner mounting
bolt to absorb belt slackness and retighten is to
specified torque.
Belt Tension N (Kg/lb)

6C-36-3.tif
98 ~ 118 (10 ~ 12/22 ~ 26)
Bolt Torque N∙m (Kg∙m/lb∙ft)

76 (7.8/56)
• Fix the tension adjust lever.
6C-36-4.tif
6C - 38 ENGINE FUEL
CAUTION
• In case where the timing belt has been replaced with
the actuation of warning light, put off the light with
change over switch on the reverse side of meter.
• Refer to Chassis Electrical in Seetion 8 .
• Tighten the tension adjusting lever nut and bolt.
6C-37-1.tif

• Install the timing pulley flange ! to the camshaft ".
• Tighten the timing pulley flange bolts to the specified
torque.
N∙m (Kg∙m/lb ft)
19 (1.9/14)

• Install timing pulley lower cover and tighten bolt to the
6C-37-2.tif specified torque.
N∙m (Kg∙m/lb in)
8 (0.8/69)

• Install timing pulley upper cover and tighten bolt to the
specified torque.
8 (0.8/69)

• Install crankshaft damper pulley and tighten bolt to the
specified torque.
19 (1.9/14)
6. Power Steering Pump & Bracket Assembly (P/S Model)

• Install the pipe bracket, clip and tighten bolts to the
specified torque.
Pipe bracket bolts N∙m (Kg∙m/lb ft)
19 (1.9/14)
Pipe clip bolts N∙m (Kg∙m/lb ft)

10 (1.0/7)
6C-37-3.tif
ENGINE FUEL 6C - 39
• Install the Power Steering pump & bracket assembly.

10M bolts N∙m (Kg∙m/lb ft)
40 (4.1/30)
8M bolts N∙m (Kg∙m/lb ft)

19 (1.9/14)
Lock nut N∙m (Kg∙m/lb ft)

27 (2.8/20)

• Install AC generator drive belt and adjust belt tension.
• Depress the drive belt mid-portion with a 98N (10 kg/
22 lb) force.

8 (0.31) - 10 (0.39)

torque.
6C-38-1.tif
Generator fixing Bolt N∙m (Kg∙m/lb ft)

40 (4.1/30)
Adjust Plate Fixing Bolt N∙m (Kg∙m/lb ft)

19 (1.9/14)

tension.
6C-38-2.tif
kg/22lb) force.

8 (0.31) - 10 (0.39)

27 (2.8/20)
6C - 40 ENGINE FUEL

• Install power steering pump drive belt and adjust belt
tension.
kg/22 lb) force.
8 (0.31) - 10 (0.39)

27 (2.8/20)
2. Fan Shroud
8 (0.8/69)
6C-39-1.tif • Connect battery ground cable.

• Pour coolant.
ENGINE FUEL 6C - 41

• Set No. 1 cylinder to top dead center.
• Remove injection pump distributor head plug.
• Cancel wax CSD with the handle of a screw driver.
• Fit a dial gauge and set lift to 2 mm.
Measuring device: 5-8840-0145-0

• Set crankshaft damper pulley top dead center mark
about 45° before top dead center from the pointer.
6C-40-1.tif
• Set dial gauge in the "0" position.
• Turn the crankshaft a little right wise and left wise and
see if the pointer is stable in the "0" position.
• Turn the crankshaft in the normal direction and read
the measuring device's indication at as follows.
4JB1 BTDC 14°, BTDC 12° (’91/
542A)
4JB1T BTDC11°
4JB1TC BTDC4°
6C-40-2.tif 4JG2 (Belt Drive Type) ATDC 1° (’91/ 542A)
TDC 0° (’91/ 542B)
" (Gear Drive Type) ATDC 2° (’91/ 542A)
Measuring Device's Indication mm (in)

Standard 0.5 (0.0197)
• If it reads abnormal, loosen injection pump fixing nut

and pump bracket adjust bolt, make adjustment by
changing the pump mounting angle, and tighten the
nut and bolt to the specified torque where the dial
indicates the specified valve.
Pump fixing nut N∙m (Kg∙m/lb∙ft)
6C-40-3.tif
24 (2.4/17)
Adjust bolt N∙m (Kg∙m/lb∙ft)

19 (1.9/14)
• Remove the measuring device and tighten the

distributor head plug to the specified torque.
17 (1.7/12)
CAUTION
6C-40-4.tif
• When installing the distributor head plug, be sure to
use new copper washer.
• Connect injection pipe.
• Fit pipe clip where specified.
6C - 42 ENGINE FUEL
Adjustment of Idling Speed

1) Pull the parking brake and lock the wheels.
2) Set the transmission gear to the neutral position.
3) Start the engine and idle it until the water temperature
gets to 70 to 80°C (158 to176°F).
4) Turn back the idling control button, and remove the
control cable from the control lever (injection pump)
5) Set the engine tachometer.
6C-41-1.tif
6) Check the idling rotation.
When the idling rotation is outside the range of the
specified value, adjust it correctly.
Specified value (rpm) = 750 - 790 (4JB1)

700 - 740 (4JG2)
(1) Loosen the lock nut of the idling set bolt.

(2) Rotate the idling set bolt to set the idling rotation to the
specified value.
(3) Tighten the lock knut to lock the set bolt.
(4) Check the tension of the control cable, and remove
any slackening as required.
6C-41-2.tif
ENGINE FUEL 6C - 43
INJECTION PUMP DATA

TEST CONDITIONS
Items Conditions
Engine Type 4JB1(Gear) 4JG2(Belt) 4JB1(Gear) 4JG2(Gear) 4JB1TC 4JB1T
(For '91/542B) (For '91/542A) (For '91/542A)
Euro 2 Euro 1 Euro 1
Injection Nozzle
ZEXEL Part Number 105780-0000 105780-0000 105780-0060 105780-0060 105780-0060
Bosch Type Number DN12SD12T DN12SD12 DN00SD1510 
Injection Nozzle holder
ZEXEL Part Number 105780-2080 105780-2080 105780-2150 105780-2150 105780-2150
Bosch Type Number EF8511/9 EF8511/9   
Injection Nozzle MPa(kg/cm2/psi) 14.7 (150 / 2,133) 13.0(133 / 1,891)
Opening Pressure
Injection Line dimensions mm(in)
Inside Diameter 2 (0.079)
Outside Diameter 6 (0.236)
Length 840 (33.1) 450 (17.7)
Fuel delivery Pressure kPa(kg/cm2/psi) 20 (0.2 / 2.84)
Test Fuel SAE Standard Test Diesel Fuel (SAE967D)
ISO Standard Test Diesel Fuel (ISO4113)
Test Fuel Temperature °C (°F) 48 - 52 (118-126)
Identification Numbers 104746-1230 196000-1042 104742-1451 104746-1222 104746-6601 104746-6311
104746-1240 104742-1461
104746-1250 104742-1471 104746-1211 104766-6620 104746-6380
104746-1260 104742-1480 4JG2 (Belt) 104746-6670
104746-1270 104742-1490 (For +91/542A)
104746-1280
104746-1290
104746-1370
Note:
'91/542A ; Euro 1
'91/542B ; Euro 2
6C - 44 ENGINE FUEL

Use the data following the injection pump identification number
to adjust the injection volume.
F06LV002.tif
F06LV001.tif
F06LW002.tif
ENGINE FUEL 6C - 45
Engine ; 4JB1
Injection pump assembly No. ; 8943616830 (104741-6410)
8943616850 (104741-6430)
Adjustment specification of injection

volume
Average
Pump Uneven Oil
injection
rotation amplitude temperature Remarks
quantity 3
rpm mm /ST °C
mm3/ST
500 (38.6) 48±2
700 34.9±2.5 50±2
1000 42.1±1.0 4.0 50±2 Standard
1450 44.5±2.5 50±2
1800 47.6±3.0 60±2
2100 12.9±3.0 4.0 52±2
390 6.7±3.0 2.0 48±2
100 60 - 100 48±2
6C-44-1.tif
Adjustment specification of timer and

pump case pressure
Air pressure
Timer piston
Pump of pump
stroke mm
rotation kPa (kg/cm2) Standard
rpm Solenoid timer Solenoid timer
ON OFF ON OFF
700 Over 0.5 — — —
1300 — 1.4±0.4 — —
490±20
1600 — 3.9±2 — Standard
(5.0±0.2)
+ 0.4
1950 — 7.0 − 0.3 — —
6C-44-2.tif
Adjustment specification of aneroid

compensator
Air
Pump pressure Amount of Rate of
Altitude
rotation difference reduction reduction
m
rpm kPa mm3/ST %
(mmHg)
0 0 0 0
-5.9±3.3 Inflation Inflation
(500)
1000 (-44±3) point point
-21.9
2000 -4.6±1 -11±3
(-164)
6C-44-3.tif
6C - 46 ENGINE FUEL
Engine ; 4JB1
Injection pump identification No. ; 104746-1230, 1240, 1250, 1260, 1280, 1290, 1370
Injection volume adjustment

volume
Average
Pump Uneven Oil
injection
quantity 3
(rpm) (mm /ST) (°C)
(mm3/ST)
500 (38.6) 48±2
700 34.9±2.5 50±2
1000 42.1±1.0 4.0 50±2 Standard
1450 44.5±2.5 50±2
1800 47.6±3.0 50±2
2100 12.9±3.0 4.0 52±2
390 6.7±2.0 2.0 48±2
100 60 - 100 48±2
F06LV019.tif
Timer adjustment

pump case pressure
Timer At pressure
Pump piston of pump
rotation stroke (mm) (MPa (kg/cm2)) Standard
(rpm) Solenoid timer Solenoid timer
ON OFF ON OFF
700 Over 0.5 — — —
1300 — 1.4±0.4 — —
0.49±0.02
1600 — 3.9±2 — Standard
(5.0±0.2)
+ 0.4
1950 — 7.0 − 0.3 — —
F06LV020.tif

compensator (For 104746-1230,14746-
1280)
Pump Air pressure
Amount of Rate of
Altitude difference
rotation reduction reduction
(m) kPa
(rpm) (mm3/ST) (%)
(mmHg)
0 0 0 0
(500)
-21.9
2000 -4.6±1 -11±3 F06LV004.tif
(-164)
ENGINE FUEL 6C - 47
Engine ; 4JG2 (For ’91/542B) (Belt drive)

Injection pump assembly No. ; 897138-8422 (196000-1042)

volume
Average
Pump Uneven
injection
rotation amplitude Remarks
quantity
rpm mm3/ST
mm3/ST
100 78±12
350 64±6.0
500 52±3.0
720 55.9±3.4
1000 62.6±1.0 4.0
1250 60.9±3.5
1700 574±3.5 4.0
2100 13±5.0
2250 Below 5.0
F06LV005.tif 360 15.9±3.0 2.5
550 Below 3.0
F06LV006.tif
F06LV007.tif
F06LV004.tif
6C-46-3.tif F06LV008.tif
6C - 48 ENGINE FUEL
Engine ; 4JB1 (For ’91/542A) (Gear drive)

Injection pump identification No. ; 104742-1451, 1461, 1471

volume
Average
Pump Uneven Oil
injection
quantity 3
(mm3/ST)
500 (29.7±4.5) 48±2
1000 (46.4±3.5) 50±2
1150 47.6±1.0 3.5 50±2 Standard
1800 (55.5 +− 0.4
6.0 ) 50±2
2100 14.9±3.0 4.0 52±2 Standard
375 7.3±2.0 2.0 48±2 Standard
100 (60 - 100) 48±2
F06LV021.tif
Timer adjustment

pump case pressure
Timer At pressure
Pump piston of pump
rotation stroke (mm) (MPa (kg/cm2)) Remarks
ON OFF ON OFF
700 Over 0.5 — — —
1400 — 1.5±0.4 — —
0.53±0.02
1600 — 3.0±0.2 — Standard
(5.4±0.2)
+ 0.4
2100 — 5.7 − 0.3 — —
F06LV022.tif

compensator (For 104742-1471)
Pump Air pressure
Amount of Rate of
Altitude difference
rotation reduction reduction
(m) kPa
(rpm) (mm3/ST) (%)
(mmHg)
0 0 0 0
(500)
-21.9
2000 (-5.2±1.3) (-11±3)
(-164) F06LV004.tif
ENGINE FUEL 6C - 49
Engine ; 4JB1 (For ’91/542A) (Gear drive)

Injection pump identification No. ; 104742-1480, 1490
Injection volume adjustment Adjustment specification of injection

volume
Average
Pump Uneven Oil
injection
quantity
(rpm) (mm3/ST) (°C)
(mm3/ST)
500 (29.7±4.5) 48±2
1000 (46.4±3.5) 50±2
1150 47.6±1.0 3.5 50±2 Standard
1800 (55.5 +− 0.4
6.0 ) 50±2
2100 14.9±3.0 4.0 52±2 Standard
375 7.3±2.0 2.0 48±2 Standard
100 (60 - 100) 48±2
F06LV021.tif
Timer adjustment

pump case pressure
Pump Timer At pressure
rotation piston of pump Remarks
(rpm) stroke (mm) (MPa (kg/cm2))
1400 (1.5±0.4) —
0.53±0.02
1600 3.0±0.2 Standard
(5.4±0.2)
2100 5.7 +− 0.4
0.3
F06LV023.tif
F06LV004.tif
6C - 50 ENGINE FUEL
Engine ; 4JG2 (For ’91/542A) (Gear drive)

Injection pump identification No. ; 104746-1222

volume
Average
Pump Uneven Oil
injection
quantity 3
(mm3/ST)
500 (51.6) 48±2
1000 52.0±1.0 50±2 Standard
1440 (49.2) 3.5 50±2
1800 (51.0) 50±2
2100 19.6±3.0 5.5 52±2
360 13.2±2.0 2.0 48±2
100 (80 - 120) 48±2
F06LV024.tif
Timer adjustment
pump case pressure
+ 0.8
500 0.5 − 0.4
0.402±0.029
1000 3.1±0.2 Standard
(4.1±0.3)
1440 5.3±0.4
+ 0.4
1950 7.8 − 0.3
F06LV025.tif
Cold start device adjustment
F06LV026.tif
F06LV004.tif
ENGINE FUEL 6C - 51
Engine ; 4JG2 (For ’91/542A) (Belt drive)


Injection volume adjustment volume
Average
Pump Uneven Oil
injection
quantity 3
(mm3/ST)
500 (53.7) 48±2
1000 56.0±1.0 3.5 50±2 Standard
1440 (53.3) 50±2
1800 (54.3) 50±2
2100 19.6±3.0 5.5 52±2
360 13.2±2.0 2.0 48±2
100 (80 - 120) 48±2
F06LV027.tif
Timer adjustment
pump case pressure
+ 0.4
500 0.5 − 0.3
0.402±0.029
1000 3.1±0.2 Standard
(4.1±0.3)
1440 5.3±0.4
7.8 +− 0.4
0.8
1950
F06LV028.tif
Cold start device adjustment
F06LV004.tif
F06LV029.tif
6C - 52 ENGINE FUEL
Engine ; 4JB1T
Injection pump identification No. ; 104746-6311, 104746-6380

volume
Average Boost
Pump Uneven Oil
injection pressure
quantity (kPa
(mm3/ST) (kg/cm2))
500 (37.0±4.0) — 0 48±2
750 46.9±1.0 3.5 33.3 (0.34) 50±2 Standard
1150 (60.7±3.5) — 72.0 (0.73) 50±2
1250 61.6±1.0 5.0 72.0 (0.73) 50±2 Standard
1250 (54.7±3.5) — 0 50±2
1900 (65.6±4.0) — 72.0 (0.73) 50±2
2100 24.8±3.0 4.5 72.0 (0.73) 52±2 Standard
375 9.0±2.0 2.0 0 48±2 Standard
100 60 +− 400 — 0 48±2
F06LW001.tif
Timer adjustment

pump case pressure
Timer At pressure
Pump piston of pump Boost
stroke (mm) (MPa (kg/cm2)) Pressure
rotation Remarks
kPa
(kg/cm2)
ON OFF ON OFF
750 Over 0.5 — — — 72.0 (0.73)
1600 — 1.8±0.4 — — 72.0 (0.73)
618
1900 — 3.7±0.2 — 72.0 (0.73) Standard
(6.3±0.2)
F06LW003.tif + 0.4
2400 — 7.0 − 0.3 — — 72.0 (0.73)
F06LW004.tif
ENGINE FUEL 6C - 53
Engine ; 4JB1T

volume
Average Boost
Pump Uneven Oil
injection pressure
quantity (kPa
(mm3/ST) (kg/cm2))
500 (33.9±4.0) — 0 48±2
750 43.8±1.0 3.5 33.3 (0.34) 50±2 Standard
1150 (57.6±3.5) — 72.0 (0.73) 50±2
1250 58.5±1.0 5.0 72.0 (0.73) 50±2 Standard
1250 (51.6±3.5) — 0 50±2
1900 (62.5±4.0) — 72.0 (0.73) 50±2
2100 24.8±3.0 4.5 72.0 (0.73) 52±2 Standard
375 9.0±2.0 2.0 0 48±2 Standard
100 60 +− 400 — 0 48±2
F06LX014.tif
Timer adjustment

pump case pressure
Timer At pressure
Pump piston of pump Boost
stroke (mm) (MPa (kg/cm2)) Pressure
rotation Remarks
kPa
(kg/cm2)
ON OFF ON OFF
750 Over 0.5 — — — 72.0 (0.73)
1600 — 1.8±0.4 — — 72.0 (0.73)
618
1900 — 3.7±0.2 — 72.0 (0.73) Standard
(6.3±0.2)
7.0 +− 0.3
0.4
F06LW003.tif 2400 — — — 72.0 (0.73)
F06LW004.tif
6C - 54 ENGINE FUEL
Engine ; 4JB1TC

volume
Average Boost
Pump Uneven Oil
injection pressure
quantity (kPa
(mm3/ST) (kg/cm2))
500 60.5±1.0 5.0 0 48±2 Standard
800 67.4±1.0 5.5 52.0 (0.531) 50±2 Standard
800 76.8±1.0 6.0 80.0 (0.821) 50±2 Standard
1000 (83.8±6.5) 80.0 (0.821) 50±2
1250 (91.5±6.5) 80.0 (0.821) 50±2
1700 (105.7±6.5) 80.0 (0.821) 50±2
2075 34.0±3.0 7.0 80.0 (0.821) 52±2 Standard
375 13.9±2.0 2.0 0 48±2 Standard
100 60 +40
− 0 0 48±2
040LX001.tif
Timer adjustment

pump case pressure
Pump Timer Boost
At pressure
piston Pressure
rotation of pump Remarks
stroke (mm) kPa
(rpm) (MPa (kg/cm2))
(kg/cm2)
1020 Below 0.5 80.0 (0.82)
1350 1.8±0.2 471±29 (4.8±0.3) 80.0 (0.82) Standard
1500 (3.0±0.4) 80.0 (0.82)
+ 0.4
1800 4.5 − 0.3 80.0 (0.82)
040LX002.tif
Potentiometer adjustment
Average Boost
Pump Out-put
injection Pressure
speed voltage Remarks
quantity kPa
(r/min) (V)
(mm3/st) (kg/cm2)
1080 3.56±0.03 27.5±2.0 0 Standard
375 (0.93±0.45) 13.9±2.0 0 Standard
F06LW004.tif
ENGINE FUEL 6C - 55
FUEL TANK
6C-54-1.tif
REMOVAL
Preparation:
• Loosen fuel filler cap.
• Drain fuel from drain plug.
• After the drain fuel, tighten the drain plug to the
specified torque.
29 (3/22)
1. Evapo Fuel Hose

2. Fuel Feed Hose
3. Fuel Return Hose
• Plug the hose to prevent fuel from getting spilt, and tie
it to the frame with the plugged end up.
• Remove the connector of the fuel gauge.
5. Band
• Remove the nut of the fuel tank fixing band, and then
remove the band end on the frame side.
6C - 56 ENGINE FUEL
6. Fuel Tank
• Pull out the fuel tank to the outside.
Note:
When it is not possible to pull out the fuel tank,
remove the bracket and then draw out the fuel tank
downward.
INSTALLATION
6. Fuel Tank
Note:
When the bracket was removed to take off the fuel
tank, install the bracket to the frame and tighten it to
55 (5.6/41)
When mounting the fuel tank on the bracket, be sure

to place the packing section pasted on the fuel tank
securely on the bracket.
5. Band
• Tighten the band to the specified torque
12 (1.2/104)

• Connect the fuel gauge unit connector.
3. Fuel Return Hose
2. Fuel Feed Hose
• Set the hose to the pipe more than 25 mm (0.98 in)
deep.
1. Evapo Fuel Hose
• Fill the fuel to the fuel tank.
ENGINE FUEL 6C - 57
FUEL GAUGE UNIT
6C-56-1.tif
REMOVAL
Preparation: Disconnect Battery ground cable.
• Disconnect fuel gauge unit connector from fuel gauge
unit.
2. Fuel Gauge Unit
• Remove fuel gauge unit fixing screw and fuel gauge
unit.
NOTE:
• After removing fuel gauge unit, cover fuel tank with
waste to prevent any dust entering.
INSTALLATION
2. Fuel Gauge Unit
• Connect the wiring connector to the fuel gauge unit.
6C - 58 ENGINE FUEL
ACCELERATOR CONTROL
ACCELERATOR CONTROL CABLE
6C-57-1.tif
REMOVAL
1. Adjust Nut
• Loosen the adjust nut on the cable bracket mounted
on the inlet manifold.
2. Accelerator Control Wire (Injection Pump Side)
• Remove the control wire from injection pump control
lever.
3. Accelerator Control Wire (Accelerator Pedal Side)
• Remove the accelerator control wire from accelerator
pedal.
• Remove the cable clip from intake manifold duct.
• Remove the cable clip from chassis frame.
• Pull out the wire to the chassis side through the
grommet hole of the floor board, and remove the
control cable.
ENGINE FUEL 6C - 59
INSPECTION
Check the following items, and replace the control cable if
any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should be free of damage and
corrosion.
INSTALLATION
• Take care that the core wire of the cable does not get
damaged or kinked.
• Pull the cable through the grommet hole from under
the floor.
• Set the groove of the grommet securely into the floor
panel.
• Lower the cab.
3. Accelerator Control Wire (Accelerator pedal side)
• Connect the accelerator control wire to the accelerator
pedal.
• Check to see if the idling control knob is fully turned to
the left.
• Tilt up the cab.
6C-58-1.tif
2. Accelerator Control Wire (Injection pump side)

• Install the tip end of the wire to the engine control
lever.
1. Lock Bolt
• With the accelerator control lever attached to the
stopper bolt, pull the cable lightly toward the front of
the axis and fasten the cable bracket with the lock bolt.
• Check to see if the injection pump lever is at the idle
position (with the lever in touch with the stopper bolt).
6C-58-2.tif • Lower the cab.
• Check to see if the accelerator pedal play is in the
range of 5 ~ 10 mm above the pedal pad.
• Press down on the accelerator pedal fully, and check
to see if the engine rotates at the maximum speed with
lever return without fail to their original positions
respectively.
6C - 60 ENGINE FUEL
ACCELERATOR PEDAL
6C-59-1.tif
REMOVAL
1. Idle Switch Connector
• Remove control cable from Accelerator pedal bracket.
• Remove accelerator pedal assembly from brake pedal
bracket.
INSTALLATION
• Apply the sliding section with grease, and install it to
the brake pedal bracket.
• Install the cable to the lever of the accelerator pedal
bracket.
• After confirming that the idling control knob is fully
turned to the left, install the accelerator control cable.
1. Idle Switch Connector
6C-59-2.tif
ENGINE FUEL 6C - 61
Adjustment of the press-down amount of

the accelerator pedal
• After installing each cable, give a full stroke to the
accelerator pedal while pushing the accelerator pedal
pad by hand.
• Adjust the stopper bolt so that the clearance between
the pedal pad stopper bolt and the back of the pad
becomes 0 ~ 2 mm (0 ~0.079 in.), and tighten the lock
nut to the specified torque.
6C-60-1.tif
7.4 (0.75/65)
• Check to see if the accelerator pedal play is in the

range of 5 ~ 10 mm (0.2 ~ 0.4 in.) above the pedal
pad.
• Press down on the accelerator pedal fully, and check
to see if the engine rotates at the maximum speed with
lever return without fail to their original positions
respectively.
6C-60-2.tif
6C - 62 ENGINE FUEL
IDLING CONTROL CABLE
6C-61-1.tif
REMOVAL
• Loosen the idling control knob screw and remove the
knob from cable.
3. Wave Washer
INSTALLATION
4. Idling Control Cable.
• Install Control Cable to Accelerator pedal bracket.
3. Wave Washer
• Insert the idling control cable into the specified hole of
the instrument panel.
• Install the washer to the cable, and tighten it with the
nut.
ENGINE FUEL 6C - 63

• Insert the idling control knob into the cable, and tighten
the screw.
Inspection:
• With the idling control knob not in use, check to see if
the injection pump lever is at the idle position (with the
lever in contact with the stopper bolt).
• With the idling control knob turned fully to the right,
check to see if the engine idles up to 1,500 rpm or
more.
6C - 64 ENGINE FUEL
AIR CLEANER ELEMENT
6C-63-1.tif
REMOVAL
1. Cover Wing Nut
2. End Cover
3. Filter Wing Nut
Clean
• Wipe out the inside of the Air Cleaner assembly.
• Wipe off the Cover
Inspection
• The air filter with a light for fears rears or holes.
6C-63-2.tif
Cleaning Method
Dust Fouled Element
Rotate the element with your hand while applying compressed
air to the inside of the element. This will blow the dust free.
2
Compressed air pressure kPa (kg/cm /psi)
392 - 490 (4 - 5/57 - 71)
CAUTION
6C-63-3.tif
ENGINE FUEL 6C - 65

minutes.
6C-64-1.tif
3. Remove the element from the solution and rinse it well

with running water.
Water pressure must not exceed 274 Kpa
2
(2.8 kg/cm /40 psi).
6C-64-2.tif

NOTE:
Do not use compressed air or an open flame to dry the
element quickly. Damage to the element will result. It
will usually take two or three days for the element to
dry completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.
6C-64-3.tif
INSTALLATION
3. Filter Wing Nut
2. End Cover
1. Cover Wing Nut
6C - 66 ENGINE FUEL
MEMO
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HOME
ENGINE ELECTRICAL 6D1 – 1
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
PAGE
Battery ........................................................................................................................... 6D1
Starting System ............................................................................................................ 6D2
Charging System .......................................................................................................... 6D3
QOS-II Preheating System ........................................................................................... 6D6
QOS-III Preheating System .......................................................................................... 6D7
SECTION 6D1
BATTERY
CONTENTS
PAGE
General Description...................................................................................................... 6D1-2
Diagnosis....................................................................................................................... 6D1-2
On-Vehicle Service ....................................................................................................... 6D1-4
Battery Charging....................................................................................................... 6D1-4
Jump Starting ........................................................................................................... 6D1-5
Removal and Installation of Battery........................................................................ 6D1-7
Main Data and Specifications ...................................................................................... 6D1-7
6D1 – 2 ENGINE ELECTRICAL
GENERAL DESCRIPTION
There are six battery fluid caps at the top of the battery. 2. The battery protects itself against overcharging.
these are covered by a paper label. The battery will refuse to accept an excessive
The battery is completely sealed except for the six charge.
small vent holes at the side. these vent holes permit (A conventional battery will accept an excessive
the escape of small amounts of gas generated by the charge, resulting in gassing and loss of battery
battery. fluid.)
This type of battery has the following advantages over 3. The battery is much less vulnerable to self
conventional batteries. discharge than a conventional type battery.
1. There is no need to add water during the entire
service life of the battery.
DIAGNOSIS
1. VISUAL INSPECTION
Inspect the battery for obvious physical damage, such as a
cracked or broken case, which would permit electrolyte
loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary. If not, proceed to Step 2.
2. FLUID LEVEL CHECK

The fluid level should be between the upper level line and
lower level line on side of the battery.
a. CORRECT FLUID LEVEL - Charge the battery.
b. BELOW LOWER LEVEL - Replace battery.
3. VOLTAGE CHECK
(1) Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE – Battery
condition OK.
6D1-2-1.tif
b. VOLTAGE IS UNDER 12.4V - Go to procedure (2)
below.
(2) Determine fast charge amperage from specification
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage rate
no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE - Replace battery.
b. VOLTMETER IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE - Drop charging voltage to 15V
and charge for 10 - 15 hours.
c. VOLTAGE IS BETWEEN 12V AND 16V -
Continue charging at the same rate for an
additional 3-3.5 hours.
d. VOLTAGE IS BELOW 12V - Replace battery.
4. LOAD TEST
(1) Connect a voltmeter and a battery load tester across
the battery terminals.
(2) Apply 300 ampere load for 15 seconds to remove
surface charge from the battery.
Remove load.
(3) Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data and
Specifications in this section).
Read voltage after 15 seconds, then remove load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN FOLLOWING TABLE - The
battery is good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED -
Replace battery.
ESTIMATED TEMPERATURE
MINIMUM VOLTAGE
°F °C
70 21 9.6
60 16 9.5
50 10 9.4
40 4 9.3
30 -1 9.1
20 -7 8.9
10 -12 8.7
0 -18 8.5
The battery temperature must be estimated by feel and by the
temperature the battery has been exposed to for the
preceding few hours.
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during the charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot or
ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on battery
charging capacity.
5. The sealed battery used on this vehicle may be either
quick-charged or slow-charged in the same manner as
other batteries.
Whichever method you decide to use, be sure that you
completely charge the battery. Never partially charge
the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER) BATTERY
CAUTION:
Never push or tow the vehicle in an attempt to start it.
Serious damage to the emission system as well as
other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING:
Failure to carefully follow the jump starting procedure
could result in the following:
1. Serious personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles particularly.
Never expose the battery to an open flame or

electrical spark. Gas generated by the battery may
catch fire or explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with
fabrics or painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap
water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against
a short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE

1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector lever in the "PARK"
position.
If the vehicle is equipped with a manual transmission
place the shift lever in the "NEUTRAL" position.
Turn "OFF" the ignition.
Turn "OFF" all lights and any other accessory requiring
electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
completely clear, do not try to jump start.
3. Attach the other end of the same cable to the positive
terminal of the discharged battery.
Attach the end of one jumper cable to the positive
terminal of the booster battery.
Do not allow the vehicles to touch each other.
This will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the A/C compressor bracket
or the generator mounting bracket) of the vehicle with
the discharged battery.
This ground connection must be at least 450 mm (18
in) from the battery of the vehicle whose battery is
being charged.
WARNING:
Never attach the end of the jumper cable directly to
the negative terminal of the dead battery.
5. Start the engine of the vehicle with the good battery.

Make sure that all unnecessary electrical accessories
have been turned "OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.
REMOVAL AND INSTALLATION OF THE

BATTERY
REMOVAL
1. All switches should be in the "OFF" position.
2. Disconnect the battery ground cable.
3. Disconnect the battery positive cable.
4. Disconnect the battery cable.
CAUTION:
It is important that the battery ground cable be
6D1-7-1.tif disconnected first.
Disconnecting the battery positive cable first can
result in a short circuit.
INSTALLATION
To install the battery, follow the removal procedure in the
reverse order, noting the following points:
1. Make sure that the rod is hooked on the body side.

Model (JIS) 115E41R-MF 130E41R-MF 95D31R-MF 80D26R-MF
Voltage (V) 12 12 12 12
Cold-Cranking Performance (Amp) 651 799 622 582
Reserve Capacity (Min) 212 229 159 133
Load Test (Amp) 325 400 310 290
Fast Charge Maximum Amperage (Amp) 20 20 20 20
BCI Group No. - - 27 24
Overall Dimension L×W×H (mm) 410×178×213 410×178×213 - -
MEMO
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STARTING SYSTEM 6D2 – 1
SECTION 6D2
STARTING SYSTEM
CONTENTS
PAGE
General Description....................................................................................................... 6D2 - 1
On-Vehicle Service .................................................................................................... 6D2 - 3
Unit Repair...................................................................................................................... 6D2 - 5
GENERAL DESCRIPTION
STARTING CIRCUIT
The cranking system consists of a battery, starter, components are connected as shown in Figure. For
starter switch, starter relay, etc. and these main details of the starting circuit.
6D2-1-1.tif
STARTER
The starting system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts
of magnetic switch are closed, and the armature rotates.
At the same time, the plunger is attracted, and the pinion
is pushed forward by the shift lever to mesh with ring gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from ring gear,
and the armature stops rotation. When the engine speed
is higher than the pinion, the pinion idles, so that the
armature is not driven.
6D2 – 2 STARTING SYSTEM
STARTING CIRCUIT
6D2-2-1.tif
ON-VEHICLE SERVICE
6D2-3-1.tif
REMOVAL
Preparation
• Disconnect Battery Ground Cable.
1. "50" Terminal
2. "30" Terminal
3. Earth Cable Terminal
4. Starter Assembly
5. Spacer (4JB1, Except cold area)
6D2-3-2.tif
INSTALLATION
5. Spacer (4JB1, Except cold area)
4. Starter Assembly
• Tighten the fixing bolt and nut to the specified torque
Starter Bolts and Nuts Torque N∙m (Kg∙m/lb∙ft)
81 (8.3 / 60)
3. Earth Cable Terminal

• Connect the earth cable terminal.
2. "30" Terminal
• Connect the harness connector.
1. "50" Terminal
• Connect the battery cable terminal with starter switch
harness terminal, then tighten nut to the specified
torque.
Fixing Nut Torque N∙m (Kg∙m/lb∙in)
9 (0.9/78)
• Connect the battery cable.

UNIT REPAIR
6D2-5-1.tif
DISASSEMBLY
1. Lead Wire
Disconnect the lead wire from the magnetic switch.
6D2-5-2.tif
2. Through Bolt
Remove the through bolts from the yoke.
6D2-5-3.tif
3. Yoke Assembly
Separate the yoke from the solenoid switch.
4. Yoke Cover
6D2-6-1.tif
5. Brush and Brush Holder

Remove (pull out) the brushes and the brush holder from
the armature with a pair of long-nose pliers.
6. Armature
7. Drive Side Housing
6D2-6-2.tif
8. Overrunning Clutch
Remove the overrunning clutch from the housing.
6D2-7-1.tif
9. Return Spring
Remove the return spring from magnetic switch.
6D2-7-2.tif
10. Steel Ball

Remove the steel ball from the overrunning clutch.
6D2-7-3.tif
11. Idle Pinion

Remove the idle pinion from housing.
6D2-7-4.tif
12. Retainer
Remove the retainer from housing.
13. Roller
14. Magnetic Switch
6D2-7-5.tif

Make necessary correction or parts replacement if wear,
damage or any other abnormal condition are found
through inspection.
ARMATURE
Check the commutator for run-out and replace if the
amount of run-out exceeds the limit.
Run-out test mm (in.)
kw Standard Limit
2.2
0.02 (0.0008) 0.05 (0.0020)
2.0
6D2-8-1.tif
Check the mica segment for wear.

Depth of mica segment mm (in.)
kw Standard Limit
2.2
0.7 - 0.9 (0.028 - 0.035) 0.20 (0.008)
2.0
6D2-8-2.tif
Check the commutator outer diameter.

Commutator outer diameter mm (in.)
kw Standard Limit
2.2
35.00 (1.378) 34.00 (1.339)
2.0
6D2-8-3.tif
Armature short circuit test

Check the armature for short circuit by placing it on a
growler tester. Hold a piece of hacksaw blade against the
armature core while slowly rotating the armature. A short-
circuited armature will cause the blade to vibrate and to be
attracted by the core. If the hacksaw blade is attracted or
vibrates, the armature, is short circuited, and must be
replaced.
6D2-8-4.tif
Armature ground test

Touch one probe of a circuit tester to the commutator
segment and the other to the armature core. There
should be no continuity. If there is a continuity, the
armature is grounded. Replace the armature if it is
grounded.
6D2-9-1.tif
Armature continuity test

Connect the probes of a circuit tester across the 2
segments. There should be continuity at any test points.
Replace if it is open-circuited.
6D2-9-2.tif
YOKE
Field winding ground test
Using circuit tester, touch one probe to the field winding
end or brush and the other to the bare surface of yoke
body.
There should be no continuity. If the tester indicates a
continuity, the field coil is grounded and yoke assembly
should be replaced.
6D2-9-3.tif
Field winding continuity test

Using a circuit tester, touch one probe to the "C" terminal
lead wire and the other to the brush. There should be
continuity. Replace the yoke if it is open.
6D2-9-4.tif
BRUSH AND BRUSH HOLDER

Measure the brush length and replace if it is worn beyond
the service limit.
Brush length mm (in.)
kw Standard Limit
2.2 14.5 (0.57)
10 (0.39)
2.0 16 (0.63)
6D2-10-1.tif
Brush holder insulation test

Using a circuit tester, check the brush holder insulation.
Touch one probe to the holder plate and the other to the
positive brush holder. There should be no continuity.
6D2-10-2.tif
OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it damaged.
Rotate the pinion in direction of rotation (clockwise).
It should rotate smoothly. But in opposite direction, it
should be locked.
6D2-10-3.tif
BEARING
Check the bearings for wear and damage. If the bearings
are noisy during operation, they should be replaceds.
6D2-10-4.tif
REASSEMBLY
To install, follow the removal steps in the reverse order,
noting the following points:
• Magnetic Switch
• Idle Gear
• Clutch assembly
• Housing
1) Install the clutch asm to the magnetic switch.
2) Install the idle gear and housing.
Note:
Do not fail to assemble the steel ball and the spring
between the clutch and magnetic switch.
6D2-11-1.tif Assemble the roller to the idle gear in advance.
MAGNETIC SWITCH
Temporarily connect the solenoid switch between the
clutch and the housing and run the following tests.
Complete each test within three to five seconds.
1. Pull-in test
Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied
to the 50 terminal from the battery positive terminal, the
pinion should flutter.
6D2-12-1.tif
2. Hold-in test
Disconnect the lead at the M terminal. The pinion should
continue to flutter.
6D2-12-2.tif
3. Return test
Connect the battery negative terminal to the 50 terminal
and the body. Connect the battery positive terminal to the
M terminal. The pinion will flutter. When the lead to the
50 terminal is disconnected, the pinion should immediately
return to its stationary positions.
6D2-12-3.tif
4. Current value
• Make connections as shown in the illustration, and
measure the current value.
Standard = 120 A or less
Note:
For a battery, be sure to use one fully charged.
For lead wires, use thick ones since a large amount of
current flows through them.
6D2-12-4.tif
CHARGING SYSTEM 6D3 – 1
SECTION 6D3
CHARGING SYSTEM
CONTENTS
PAGE
Diagnosis........................................................................................................................ 6D3 - 4
On-Vehicle Service ........................................................................................................ 6D3 - 5
Unit Repair...................................................................................................................... 6D3 - 9
GENERAL DESCRIPTION
The charging system is the IC integral regulator The generator does not require particular maintenance
charging system and its main components are such as voltage adjustment. The rectifier connected to
connected as shown in Figure. the stators coil has nine diodes to transform A.C.
The regulator is a solid state type and it is mounted voltage into D.C. voltage. This D.C. voltage is
along with the brush holder assembly inside the connected to the output terminal of generator.
generator installed on the rear end cover.
6D3 – 2 CHARGING SYSTEM
Generator
6D3-2-1.tif
6D3-2-2.tif
CHARGING CIRCUIT
6D3-3-1.tif
DIAGNOSIS
GENERAL ON-VEHICLE INSPECTION
The operating condition of charging system is indicated by
the charge warning lamp. The warning lamp comes on
when the starter switch is turned on "ON" position. The
charging system operates normally if the lamp goes off
when the engine starts. If the warning lamp shows
abnormality or if undercharged or overcharged battery
condition is suspected, perform diagnosis by checking the
charging system as follows:
6D3-4-1.tif
1. Check visually the belt and wiring connector.

2. With the engine in stop status, turn the starter switch
to "ON" position and observe the warning lamp.
• If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal "L" on connector side.
• If lamp comes on:
Repair or replace the generator.
ON-VEHICLE SERVICE
GENERATOR
6D3-5-1.tif
REMOVAL
Preparation
• Loosen the idler pulley lock nut
• Loosen the adjust bolt and remove the drive belt.
• Disconnect the clutch harness connector.
temporarily tighten the A/C compressor to chassis
3. Harness Connector (A/C Model)

• Disconnect the "L", "S", "IG" terminal.
• Disconnect the "B" terminal.
4. Vacuum Hose (EXH. Brake Model)

• Remove the vacuum hose to vacuum tank and
exhaust actuator.
5. Oil Hose
• Remove the oil hose from oil pan.
• Remove the oil hose of vacuum pump side.
• Loosen the adjust plate fixing bolt.
• Remove the adjust bolt.
6D3-6-1.tif • Loosen the AC Generator fixing bolt then remove the
fan belt.
7. Power Steering Oil Pipe Bracket (P/S Model)

• Remove the oil pressure pipe bracket fixing bolt and
pipe clip bolt.
• Remove the oil suction pipe clip bolt.
8. AC Generator Fixing Bolts
9. AC Generator Assembly
6D3-6-2.tif
INSTALLATION
9. AC Generator Assembly
• Set the AC generator.
8. AC Generator Fixing Bolts
• Temporary install the AC generator fixing bolt.
7. Power Steering Oil Pipe Bracket (P/S Model)

• Install the oil pipe bracket and tighten bolts to the
specified torque.
Pipe Bracket Bolt torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
6D3-6-3.tif
• Install the suction pipe clip bolt and tighten bolt to the
specified torque.
Pipe Clip Bolt torque N∙m (kg∙m/lb∙in)
10 (1.0/87)
• Install the pressure pipe and suction pipe clip bolt,

then tighten bolt to the specified torque.
Pipe Clip Bolt Torque N∙m (kg∙m/lb∙in)
10 (1.0/87)

• Install the AC Generator drive belt and adjust belt
tension.
(10kg/22lb) force.
8 (0.31) - 10 (0.39)
• Install the fixing bolt and tighten bolt to the specified

6D3-7-1.tif torque.
Generator Fixing Bolt Torque N∙m (kg∙m/lb∙ft)

40 (4.1/30)
Adjust Plate Fixing Bolt Torque N∙m (kg∙m/lb∙ft)

19 (1.9/14)
6D3-7-2.tif
5. Oil Hose
• Install the oil hose ! to vacuum pump.
• Install the oil hose " to oil pan.
4. Vacuum Hose (EXH. Brake Model)

• Install the vacuum hose to vacuum tank and exhaust
actuator.
3. Harness Connector (A/C Model)

6D3-7-3.tif
• Connect the "L", "S", "IG" terminal and "B" terminal
connectors.
2. A/C compressor Assembly (A/C Model)

• Install the compressor assembly and tighten bolts to
Compressor Bolt Torque N∙m (kg∙m/lb∙ft)
19 (1.9/14)
• Connect the magnetic switch harness connector.
6D3-8-1.tif
1. A/C compressor Drive Belt (A/C Model)

tension.
• Depress the drive belt and mid-portion with a 98N (10
kg/ 22 lb) force.
8 (0.31) - 10 (0.39)

6D3-8-2.tif
Idle Pulley Lock Nut Torque N∙m (kg∙m/lb∙ft)

27 (2.8/20)
6D3-8-3.tif
UNIT REPAIR
6D3-9-1.tif
DISASSEMBLY
1. Vacuum Pump
• Dram fluid from discharged port.
• Remove the vacuum pump fixing bolts. Hold the
center plate and remove the vacuum pump
horizontally in direction in line with the rotor shaft.
2. Read Wire
3. Through Bolts
6D3-9-2.tif
4. Rotor and Front Cover Assembly

5. Stator and Rear Cover Assembly
• Insert a driver into the clearance between the front
cover and the stator core, and remove the assembly.
NOTE:
Take care not to damage the stator coil with the
driver. When the assembly will not come off, hold
down the rear cover and hit the end face of the shaft
gently with a plastic hammer to detach it.
6D3-9-3.tif
6. Rotor
• With the rotor gripped with a vise, remove the pulley
nut !, and then take off the pulley ", fan #, front
cover $ and the rotor %.
6D3-10-1.tif
7. Rear Bearing
8. Terminal Bolt and Nut
9. Rear Cover
• Remove the nuts fixing the B terminal and diode
holder.
Separate the stator and rear cover.
Note the position of insulation washers to ensure
reassembly into original position.
10. Stator
11. Diode
• Separate the diodes from the stator by melting away
6D3-10-2.tif solder on stator coil and diode.
When melting solder, hold the lead wire with long nose
pliers to prevent heat from being transferred to the
diodes.
12. IC Regulator Assembly

• Separate the IC regulator from the diode by melting
away solder on IC regulator holder plate and removing
the nut.
6D3-10-3.tif
13. Brush Holder

• Remove the serrated bolts and melt away solder on IC
regulator.
• Do not remove the serrated bolts unless the
replacement of brush or condenser.
To install, follow the removal steps in the reverse
order.

6D3-10-4.tif
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
ROTOR
1. Check the rotor slip ring surfaces for contamination and
roughness. If rough, polish with #500-600 sandpaper.
2. Measure the slip ring diameter, and replace if it
exceeds the limit.
mm (in)
Standard Limit
34.6 (1.36) 33.6 (1.32)
6D3-11-1.tif
3. Check for continuity between slip rings, and replace if

there is no continuity.
6D3-11-2.tif
4. Check for continuity between slip ring and rotor core or

slip ring and rotor shaft.
In case of continuity, replace the rotor assembly.
6D3-11-3.tif
Rear Ball Bearing

Check to see if the ball bearing rotates smoothly with no
noises.
When it does not rotate smoothly or any noises are heard,
replace it with a new one.
When installing the bearing, press it in with the stopper ring
turned to the spline side, while pushing the bearing inner ring.
Bearing press-in measurement: L mm (in)
Standard 41.8 - 42.0 (1.64 - 1.65)
6D3-11-4.tif
STATOR COIL
1. Check for continuity between respective phases.
In case of no continuity, replace the stator.
6D3-11-5.tif
2. Check for continuity across one of the stator coils and

stator core. If a continuity exists, replace the coil.
6D3-12-1.tif
DIODE
1. Check for continuity across the terminal (example:
across BAT and U). If a continuity exists, the diode is
in satisfactory condition. If no continuity exists the
diode is defective.
2. Make a test with the polarities reversed. If no
continuity exists, the diode is in satisfactory condition.
If a continuity exists at any point, the diode is defective
and should be replaced.
6D3-12-2.tif Auxiliary diodes are not provided with the terminal and
continuity test should be made across the terminals of
the conventional diodes.
- side diode check

Across terminals BAT (Positive side (+) diodes)
Tester pin Positive side Negative side
Positive side No continuity
U.V.W
Negative side Continuity
+ side diode check
Across terminals E (Negative side (+) diodes)
6D3-12-3.tif Tester pin Positive side Negative side
Positive side Continuity
U.V.W
Negative side No continuity
BRUSH
Measure length of brushes.
Brush length (L)
mm (in)
Standard Limit
20 (0.79) 6 (0.24)
Brushes are provided with a line which indicates the limit

of usage.
6D3-12-4.tif
IC REGULATOR
Measuring instruments is necessary.
Take the following measurements with the instruments
connected as shown in the illustration.
V1 Voltage at BAT1 V
Standard 10 - 13
V2 Voltage across F-E V

Standard Limit
2 or less 2 or more
Take measurement with `S' terminal disconnected.

V3 Measure the voltage at BAT1 - BAT2. V
6D3-13-1.tif
Standard 20 - 26
• Measurement the voltage across the E-F while varying

resistance gradually from zero using variable resistor.
Then check that voltage increases from 2V to 10 - 13.
If increase in voltage is interrupted at any point,
replace the regulator.
• V4 Measure the voltage across the intermediate tap on
variable resistor and `E' terminal without actuating the
variable resistor.
V
6D3-13-2.tif Standard voltage at 20°C (68°F) 14.0 - 14.9
If measured value deviates from the standard, replace

the regulator.
Check the following with the instrument connected as

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

replace the regulator.
VACUUM PUMP
Visual check
• Inspect the following parts for wear, damage or other
abnormal conditions.
Disassembly of Vacuum pump

• For the center plate, rotor and vane in the mentioned.
6D3-14-1.tif
Housing
• Measure the inside diameter of housing and place if it
exceed the standard.
mm (in)
57.0 - 57.1
Standard
(2.244 - 2.248)
Vane
Measure the length of vanes
6D3-14-2.tif
mm (in)
Standard 12.5 - 13.5 (0.492 - 0.531)
Check Valve
1. Apply a light pressure onto the "B" side of valve with a
screw driver and check that valve operates smoothly.
2
2. Apply compressed air 1 - 5 kg/cm onto "A" side of
valve and check if there is air leak.
6D3-14-3.tif
Reassembly of vacuum pump

1. Position the rotor, with the serrated boss turned up, on
the center plate and housing.
Align the holes in center plate and rotor.
2. Install vanes into slits in rotor.
The vanes should be installed with chamfered side
turned outward.
3. Install the O-ring and center plate
6D3-14-4.tif
REASSEMBLY
13. Brush Holder
12. IC Regulator Assembly
• Hold the brush in the holder as shown in the illustration
and solder the lead wire.
• Put the IC regulator on the brush holder and press the
bolt.
Bushing and connecting plate must be installed when
pressing the bolt.
6D3-15-1.tif
6D3-15-2.tif
11. Diode
• Connect the terminals by fixing the rivet at 1 and
soldering the terminal at 2.
6D3-15-3.tif
10. Stator
• When connecting stator coil leads and diode leads
using solder, use long-nose pliers and finish the work
as quickly as possible to prevent the heat from being
transferred to the diodes.
9. Rear Cover
8. Terminal Bolt and Nut
7. Rear Bearing
6D3-15-4.tif
6. Rotor
• Cover vice with copper plates, clamp the rotor with the
vice, and tighten nut to the specified torque.
Pulley Nut Torque N∙m (kg∙m/lb∙ft)
90 (9.2/67)
6D3-15-5.tif
5. Stator and Rear Cover Assembly

4. Rotor and Front Cover Assembly
3. Through Bolts
• Place guide bar through the holes in front cover and
rear cover flange for alignment, then install the through
bolts.
• Tighten the through bolts to the specified torque
Through Bolts Torque N∙m (kg∙m/lb∙in)
3.5 (0.36/31)
6D3-16-1.tif
2. Read wire
1. Vacuum Pump
• Install and mount the housing to the generator using 3
bolts.
• Pour engine oil (5 cc or so) in through the filler port,
then check that generator pulley can be turned
smoothly with hand.
• Tighten the pump fixing bolts to the specified torque.
Pump Fixing Bolts Torque N∙m (kg∙m/lb∙in)
3.5 (0.36/31)
6D3-16-2.tif
• Pour engine oil (5 cc or so) throuh the filler port, and

then check the pulley for smooth rotation.
UNIT REPAIR
6D3-17-1.tif
DISASSEMBLY
1. Removal of Through Bolts
Remove the three through bolts.
6D3-17-2.tif
2. Separation of Drive End Frame and Rear End Frame &

Stator
As illustrated, put a screw-driver into the notched part of
the drive end frame and separate the rear end frame and
stator from the drive end frame.
NOTE:
Be careful not to put in a screw-driver to excess so as
to prevent the stator coil from being scratched.
6D3-17-3.tif
3. Separation of Pulley, Fan, Drive End Frame, and Rotor

Fix the rotor in a lock vice, and after removing the lock nut
separate the pulley, fan, drive end frame, and rotor.
NOTE:
Be sure to fix the rotor through cloth in a vice.
6D3-18-1.tif
4. Removal of Bearing (on the Drive End Frame Side)

• Remove the ball bearing fixing screw.
6D3-18-2.tif
• As shows in the illustration, make the drive end frame

parallel to a block, and then push out the bearing with
a press through a jig.
6D3-18-3.tif
5. Separation of Rear End Frame and Rectifier & Stator

Remove the nuts M5 and M6, and separate the rectifier
and stator from the rear end frame.
6D3-18-4.tif
6. Separation of Rectifier and Stator

Disconnect the stator lead wire from the rectifier by means
of a soldering copper to separate the rectifier and stator
from each other.
NOTE:
Since the rectifier a low resistance to heat, the work
should be done quickly using radio pliers to absorb
heat.
6D3-18-5.tif
Tighten the lightly with 7. Removal of Bearing (on the Rear Side) [Only for
a vise with care not to
cause any damage.
Replace.]
Take out the bearing with a puller.
Insert it to see whether replacement is needed.
NOTE:
Conduct the bearing inspection mentioned below and
determine whether or not the bearing be replaced.
6D3-19-1.tif

NOTE:
Standard values and limits vary with alternators, and
therefore, maintenance standards for each part
should be followed.
1) Fan
Check to see whether it is deformed.
2) Bearing
Turn it by hand to check for smooth and noiseless
turning.
3) Stator
• Resistance between phases (neutral point and each
phase lead wire) should be 1Ω or less.
• Insulation resistance between the core and stator coil
6D3-19-2.tif
should be 0.1MΩ or more by a 500V megohmmeter.
NOTE:
If there is no continuity, the connection of lead wire
should be checked as the disconnected stator coil
cannot be considered.
4) Rotor
• Resistance between slip rings as shows in the
illustration, about 4Ω.
• Insulation resistance between slip ring and ball core:
0.1MΩ or more by 500V megohmmeter.
• Check slip rings for surface. If staind or rough, use
sand paper (#300 - #500).
6D3-19-3.tif
In this case, the slip ring can be used until its outer
diameter becomes 0.4mm shorter than the initial size.
6D3-20-1.tif
5) Rectifier
Conduct a rectifier continuity test using the KΩ range
of a circuit tester.
Specifically, change polarity between the rectifier and
holder fin, making sure that there continuity in either
one direction only. (There should not be continuity in
the other direction.)
NOTE:
It is impossible to judge a rectifier by the resistance in
the direction of easy flow. Because of diode’s
6D3-20-2.tif
characteristics, the current in the direction of easy
flow changes greatly depending on the power source
voltage.
Therefore, a tester’s indication varies depending on
its type and resistance range variation.
Accordingly, it must be regarded as a criterion that
there is a wide difference between the resistances
easy flow and the other direction.
Never use a 500V megohmmeter for such a continuity
test, since the rectifier may be damaged.
6) Brush
Measure the protruding length from the brush holder.
mm (in)
Standard Limit
12.5 (0.492) 5.5 (0.217)
6D3-20-3.tif
REASSEMBLY
Follow the same procedure as for disassembly in the

opposite order, paying special attention to the following
points:
• Brush
When fitting a new brush, be sure to see it so that the
free end of it is projecting 12.5mm (0.49 in) from the
holder.
6D3-21-1.tif
• Rotor
Be sure to fit it after brush is supported by the brush
holder.
Otherwise, the rotor cannot be fitted or the brush may
be broken.
6D3-21-2.tif
Output Characteristic
As alternator speed increases, the output gradually
increases as shows in the illustration.
In other words, when alternator speed exceeds a certain
limit to cause to enlarge output current, supply capacity will
further increase owing to the neutral point diodes.
6D3-21-3.tif
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QOSII PREHEATING SYSTEM 6D6 – 1
SECTION 6D6
QOSII PREHEATING SYSTEM
(4JB1/4JB1T/4JB1TC ONLY)
CONTENTS
PAGE
System Diagram............................................................................................................. 6D6 - 2
Inspection on QOS II system Operation ...................................................................... 6D6 - 3
QOSII System Troubleshooting.................................................................................... 6D6 - 4
GENERAL DESCRIPTION
QOS II preheating system features a quick-on glow With the employment of the thermoswitch, the glow
plug with thermometer control of the glowing time and time changes according to the engine coolant
the afterglow time function. temperature, thus allowing optimum starting conditions
The system consists of a controller, indicator lamp, to be obtained.
thermoswitch, relay, and glow plug ( 4 pcs).
6D6 – 2 QOSII PREHEATING SYSTEM
SYSTEM DIAGRAM
6D6-2-1.tif
QOS II Timing Chart
6D6-2-2.tif
Inspection on QOSII System Operation

THERMO SWITCH
The thermo switch is located on the water outlet pipe.
6D6-3-1.tif
Use a circuit tester to check the thermo switch for continuity.
OFF!ON : 7-13°C (44.6-55.4°F)

ON!OFF : Below 3°C (37.4°F)
10°C ON
OFF
3°C
6D6-3-2.tif
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Conventional model Approximately 1.5
Quick on start model Approximately 0.9
6D6-3-3.tif
QOSII SYSTEM TROUBLESHOOTING
6D6-4-1.tif
Problems when the water temperature of the engine is 0°C below.
Condition Cause Circuit

Glow plug relay will Bad connection of FLW between battery and starter. 3
not be lit.
Bad connection or disconnection of starter SW circuit
Bad connection or disconnection Malfunction of other
of Fuse No . 8 circuits occurred 2
simultaneously.
Bad starter awitch.
Bad connection of glow plug relay terminal. 1
Disconnection of glow plug relay excitation coil.
Disconnection of circuit between glow plug relay and timer. 6
Bad glow relay. (The main contact does not pass electricity.)
Bad connection of timer.
Bad timer.
Bad earth circuit of timer. 7
Bad thermoswitch. (It remains ON even in water temperature below 0°C.)
Earth short-circuiting of thermo SW. 7

Through glow plug Bad connection of FLW between battery and glow relay. 1
relay turns ON,
Bad connection or disconnection in preheating circuit of glow relay main contact
preheating is not
terminal connector.
done.
Bad connection between plug connector and preheating circuit 9
Glow plug relay Bad timer.
turns ON, but does
Bad timer. Short circuiting in circuit or earth between 5 terminal and glow relay. 6
not go OFF.
Bad glow relay.
Indication lamp is Bad timer.
not lit.
Burning-out of light bulb. 8
Note: Circuit No. in rectangle is shown in the previous pre-heating chart.
2) Problems when the time water temperature of the engine is 0°C or above.

Indicator lamp is Bad timer
not lit
Burning-out of bulb. 8
Turn glow relay Bad thermoswitch or disconnection of thermo SW circuit. 4
ON. (Indicator will light up for 3.5 seconds.)
Bad timer.
Bad timer. Short-circuiting in circuit or earth between terminals 5 and glow relay.
Note: Circuit No. in rectangle is shown in the previous pre-heating chart.
3) Burning-out of glow plug

When only one line is burned out, it has no effect on the start up of the engine. Even if one line is burned
out, judging from the characteristics of the glow plug, the impressed voltage will change only slightly.
Therefore, no judgment can be made by normal testing while the glow plug is installed. In order to check
for disconnections and burn-outs, the glow plugs will have to be removed from the connectors and checked
one by one for continuity.
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QOSIII PREHEATING SYSTEM 6D7 – 1
SECTION 6D7
QOSIII PREHEATING SYSTEM
(4JG2 ONLY)
CONTENTS
PAGE
System Diagram............................................................................................................. 6D7 - 2
Inspection on QOS III system Operation ..................................................................... 6D7 - 5
GENERAL DESCRIPTION
QOS III preheating system features a quick-on glow With the employment of the thermoswitch, the glow
plug with thermometer control of the glowing time and time changes according to the engine coolant
the afterglow time function. temperature, thus allowing optimum starting conditions
to be obtained.
The system consists of a controller, indicator lamp,
thermosensor, vehicle speedsensor, dropping resistor, The afterglow time function is controlled by
relay (2 pcs), and temperature self-control type glow thermosensor, vehicle speed sensor, and the engine
plug (4 pcs) runstall sensor (charge relay).
6D7 – 2 QOSIII PREHEATING SYSTEM
SYSTEM DIAGRAM
6D7-2-1.tif
QOS II Timing Chart
6D7-2-2.tif
QOS III FLOW CHART
6D7-3-1.tif
QOS III BLOCK CHART
6D7-4-1.tif
Inspection on QOSIII System Operation

I Inspection on Quick Heating Operation
1. Disconnect thermo-sensor connection on the
thermostat housing.
6D7-5-1.tif
2. Connect the circuit tester between glow plug and

engine earth.
3. Inspect the following items with starter switch set to
ON position (but do not start the engine).
1) The glow indicator shall light for 1 ~ 6 sec.
2) The circuit tester shall indicate power supply voltage
for 9 ~ 13 sec.
• If above specifications are not satisfied, inspect wire
harness, glow relay and thermo-sensor. If satisfied,
inspect glow plug.
6D7-5-2.tif
II Inspection on Quick Heating Afterglow Operation

thermostat housing.
6D7-5-3.tif

engine earth.
3. Inspect the following item with start the engine.
1) The circuit tester shall indicate power supply voltage
for about 5 seconds.
• If above specification is not satisfied, inspect battery
voltage, engine earth, wire harness and starter switch
"st" signal to control unit.
If satisfied, inspect wiring harness, engine earth and
starter switch.
6D7-5-4.tif
III Inspection on Afterglow Operation

thermostat housing.
6D7-5-5.tif

engine earth.
3. Inspect the following items with start the engine.
1) The circuit tester shall indicate about 7 volts after 360
seconds of engine start.
• If above specifications are not satisfied, inspect battery
voltage, engine earth, wiring harness, glow plug,
dropping resistor, relay No. 2 and charge relay.
6D7-6-1.tif
THERMO SENSOR
Measure the resistance depending on the water
temperature as shown in the left figure. (Measuring range:
10°C ~ 50°C)
Temperature Current (mA) Resistance (KW)
20 ± 1 1.0 2.0 ~ 3.0
50 ± 1 1.0 0.68 ~ 1.0
6D7-6-2.tif
When installing the thermo sensor, apply sealant (Loctite

#262 or equivalent) to narrowed portion in the left figure to
prevent water leakage
Torque N∙m (kg∙m/lb∙in)
8 (0.8/69)
6D7-6-3.tif
GLOW PLUG
Inspect the resistance
Resistance at normal temperature Ω
0.8 ~ 1.0

23 (2.3/17)
6D7-6-4.tif
DROPPING RESISTOR
Inspect the resistance
Resistance of normal ambient temperature mΩ
225 ~ 255
6D7-7-1.tif
GLOW PLUG RELAY

Inspect the continuity
!-" No Continuity
If apply the battery voltage to terminal between # - $

!-" Continuity
6D7-7-2.tif
CHARGE RELAY
Inspect the continuity
"-$ Continuity
%-$ No Continuity
If apply the battery voltage to terminal between ! - #

"-$ No Continuity
6D7-7-3.tif
%-$ Continuity
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HOME
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 6E– 1
SECTION 6E
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
CONTENTS
PAGE
General Description........................................................................................................... 6E -2
EGR System Wiring Diagram............................................................................................ 6E -3
EGR System Operation ..................................................................................................... 6E -3
EGR System Check ........................................................................................................... 6E -4
Inspection........................................................................................................................... 6E -5
6E – 2 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL DESCRIPTION
D06LX001.tif
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.
The EGR valve are controlled by VSV, also VSV are controlled by EGR controller according to signals from RPM
sensor and Potentiometer.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.
EGR SYSTEM WIRING DIAGRAM
(above 40℃: OFF)

(below 30℃: ON)
826LX007.tif
1. CONNECTOR PIN ASSIGNMENT

No. CONNECTOR NAME
1 -
2 Battery (-) c/u GND
3 Thermo Switch
4 Battery (+)
5 -
6 -
7 rpm Signal (+)
8 rpm Signal (-)
9 Potentio Meter (+)
13-01.tif
10 Potentio Meter
11 Potentio Meter (-)
12 -
13 VSV
EGR SYSTEM OPERATION

1) On the input side of engine speed, there is provided a
hysteresis of 50 rpm on the speed rising side.
2) It does not work until 70 sec, pass after engine start.
3) It does not work while the water temperature switch is
on (30°C or lower).
4) While engine speed drops from 3,800 rpm or higher, it
does not work for 25 sec.
056LX016.tif
Exhaust Gas Recirculation (EGR) System Check

Step Action Value (s) Yes No
1 Check the EGR valve for looseness.
Is the EGR valve loose? - Go to Step 2 Go to Step 3
2 Tighten the EGR valve.
Is the action complete? - Verify repair -
3 1. Engine "OFF."
2. Ignition "ON."
3. Using test light to ground, check the EGR harness
between the EGR valve and ignition feed.
Does the test light illuminate? - Go to Step 5 Go to Step 4
4 Repair the EGR harness ignition feed.
Was the problem corrected? - Verify repair Go to Step 5
5 1. Remove the EGR valve.
2. Visually and physically inspect the EGR valve pintle,
valve passages and adapter for excessive deposits,
obstructions or any restrictions.
Does the EGR valve have excessive deposits,
obstructions or any restrictions? - Go to Step 6 Go to Step 7
6 Clean or replace EGR system components as necessary. -
Was the problem corrected? Verify repair Go to Step 7
7 1. Remove the EGR inlet and outlet pipes from the intake
and exhaust manifolds.
2. Visually and physically inspect manifold EGR ports and EGR system
EGR inlet and outlet pipes for blockage or restriction working
caused by excessive deposits or other damage. properly.
Do the manifold EGR ports or inlet and outlet pipes have No problem
excessive deposits, obstructions, or any restrictions? - Go to Step 8 found.
8 Clean or replace EGR system components as necessary.
Is the action complete? - Verify repair -
INSPECTION
Vacuum Switch Valve (VSV)
Check the resistance between the VSV connector terminals
using a circuit tester.
Cold Resistance: 37 - 44 (Ω) (for 12 volt)
Connect battery voltage between VSV connector terminals and
make sure of the continuity between the ports.
056LW026.tif
EGR Valve
With negative pressure applied to the diaphragm chamber,
make sure that the valve is smoothly actuated to make the
area between (1) and (2) ventilated.
Startup: About -18.66±2.67 Kpa (-140±20 mmHg)
Check to see if EGR valve is normally actuated under the
following conditions:
QWS off (After warming up)
Engine coolant temp: 80°C or higher
056LW009.tif
TOOL NO.
ILLUSTRATION
TOOL NAME
5-8840-0366-0
High Impedance
Multimeter
(Digital Voltmeter-
DVM)
6E-143-1.tif
5-8840-0279-0
Vacuum Pump with

Gauge
6E-143-3.tif
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HOME
ENGINE EXHAUST 6F – 1
SECTION 6F
ENGINE EXHAUST
CAUTION:
Exhaust system components must have enough of the floor pan and possible damage to the passenger
clearance from the underbody to prevent overheating compartment, insulation and trim materials.
CONTENTS
PAGE
General Description......................................................................................................... 6F - 2
Three Way Catalytic Converter ....................................................................................... 6F - 3
On-Vehicle Service ...................................................................................................... 6F - 4
Front Exhaust Pipe .......................................................................................................... 6F - 4
Exhaust Brake Unit.......................................................................................................... 6F - 5
Inspection..................................................................................................................... 6F - 5
6F – 2 ENGINE EXHAUST
GENERAL DESCRIPTION
Model ’91/542B (Euro 2)
501LX002.tif
General Export
501LX003.tif
When inspecting or replacing exhaust system components,

make sure there is adequate clearance from all points on the
underbody to prevent overheating of the floor pan and possible
damage to the passenger compartment insulation and trim
materials.
Check complete exhaust system and nearby body areas and
rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or
other deterioration which could permit exhaust fumes to seep
into the rear compartment or passenger compartment. Dust or
water in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should be
corrected immediately.
THREE WAY CATALYTIC CONVERTER

The three way catalytic converter is an emission control
device added to the exhaust system to reduce pollutants
from the exhaust gas stream.
CAUTION:
• The catalytic converter requires the use of unleaded
fuel only.
Periodic maintenance of the exhaust system is not

150LS001.tif required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete exhaust
system.
A dual bed monolith catalytic converter is used in
combination with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction)
converter contains platinum and rhodium which lowers the
levels of oxide of nitrogen (NOx) as well as hydrocarbons
(HC) and carbon monoxide (Co).
ON-VEHICLE SERVICE
Rattles and noise vibrations in the exhaust system are usually
caused by misalignment of parts. When aligning the system,
leave all bolts or nuts loose until all parts are properly aligned;
then tighten, working from front to rear.
1. Check connections for looseness or damage,
especially for exhaust gas leakage.
2. Check clamps and rubbers for weakness, cracks or
damage.
3. If any part of the converter heat shield is damaged or
dented to the extent that it contacts the catalyst, repair
or replace.
4. Check for dents or damage and for any holes or
cracks caused by corrosion.
FRONT EXHAUST PIPE
6F-6-1.tif
REMOVAL
Preparation:
• Battery ground cable
1. Exhaust manifold fixing nuts.
• Remove two fixing nuts from exhaust manifold and
front pipe.
2. Front exhaust pipe mounting bracket fixing bolt and
nut.
3. Front exhaust pipe fixing bolts and nuts.
• Remove two bolts fixed from front pipe and center
pipe.
4. Front exhaust pipe.
6F-6-2.tif • Take out the exhaust pipe to another side.
INSTALLATION
4. Front exhaust pipe.
3. Front exhaust pipe fixing bolts and nuts.
• Tighten the fixing nuts to the specified torque
50 (5.1/37)
2. Front exhaust pipe mounting bracket fixing bolt and nut.

• Tighten the fixing bolt to the specified torque
40 (4.1/30)
1. Exhaust manifold fixing nuts

• Tighten the fixing nuts to the specified torque
69 (7/51)
6F-7-1.tif

• After assembling each part, start the engine to check
for any leakage of gas at each connection.
Exhaust Brake Unit

INSPECTION
Operational inspection
• With the engine idling, operate the exhaust brake to
check for the sound of the valve hitting against the
stopper.
Unit inspection
• Check to see if the exhaust valve opens and closes
smoothly when the power chamber is
applied with a negative pressure (400 mmHg - 700
mmHg) by the vacuum pump.
6F-5-2.tif
• Check to see if the clearance between the valve and

the body is in the range of 0.1 mm - 0.2 mm (the
minimum of 0.1 mm) on an average of the points “A”
and “B” when the power chamber is applied with a
negative pressure (650 mmHg - 700 mmHg) by the
vacuum pump.
When the clearance is outside this range, adjust the
clearance with the adjust bolt.
6F-5-3.tif
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HOME
TURBOCHARGER 6G – 1
SECTION 6G
TURBOCHARGER
CONTENTS
PAGE
Turbocharger ................................................................................................................... 6G - 2
Main Data and Specifications ..................................................................................... 6G - 2
General Description......................................................................................................... 6G - 3
Identification of Unit.................................................................................................... 6G - 4
Turbocharger Servicing .............................................................................................. 6G - 4
Precautions .................................................................................................................. 6G - 4
Disassembly..................................................................................................................... 6G - 5
Inspection and Repair ..................................................................................................... 6G - 7
Reassembly...................................................................................................................... 6G - 9
IHI Service Net work ........................................................................................................ 6G -11
6G – 2 TURBOCHARGER
TURBOCHARGER
Model IHI RHF 4H | IHI RHB 5
Turbine type Mixed-flow | Radial-inflow
Compressor type Centrifugal
Maximum permissible speed rpm 180,000
Wastegate opening pressure kPa (mmHg) 109 ± 4.4 (815 ± 33) | 120 ± 4.8 (898 ± 36)
Weight N (kg/lb) 41 (4.2/9.3) | 45 (4.6/10.1)
IHI : Ishikawajima-Harima Heavy Industries., Ltd.
GENERAL DESCRIPTION
6G-3-1.tif
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings.
These parts are supported by the bearing housing.
The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing
air exhaust port.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger is indicated.
IDENTIFICATION OF UNIT
The turbocharger nameplate gives the date of
manufacture and other important information required to
identify the unit when service inquiries are made.
6G-4-1.tif
The turbocharger nameplate has the following information

stamped on it.
! Turbocharger Specification Number, Production Year
and Month
" Production Date, Serial Number
# ISUZU Parts Number
6G-4-2.tif
TURBOCHARGER SERVICING
1. Refer to TROUBLESHOOTING in this Manual to determine whether or not turbocharger repair or overhaul
is required.
2. The following procedures should also be performed (either with the turbocharger on the vehicle or removed
from the vehicle but not disassembled) to determine whether or not turbocharger repair or overhaul is
required.
* Visual checks
* Clearance measurements
* End play measurements
Refer to INSPECTION AND REPAIR
3. The turbocharger compressor and turbine housing may be removed from the center housing and rotating
assembly (CHRA) for further visual inspection.
Refer to DISASSEMBLY and REASSEMBLY.
PRECAUTIONS
Turbocharger servicing requires great care and expertise.
Faulty turbocharger servicing procedures can result in serious damage to pistons, valves, cylinder liners, and other
important engine parts.
ISUZU does not recommended the performance of any servicing procedure not specified described in this Manual.
Contact your nearest IHI service facility to have the turbocharger assembly repaired or overhauled.
The identification plate and assembly number will be required by the service facility.
A list of IHI Turbocharger Service Network locations is given at the end of this Section.
DISASSEMBLY
036LW001.tif
Disassembly Steps
1. Bolt 4. Compressor housing
2. Turbine housing 5. Center housing and rotating assembly
3. Bolt
Disassembly Steps
1. Bolt
Apply a setting mark across the center housing and
rotating assembly (1), the turbine housing (2), and the
compressor housing (3).
6G-6-1.tif
2. Turbine Housing
3. Bolt
4. Compressor Housing
5. Center Housing and Rotating Assembly
1) Loosen the bolts.
2) Disassembly the parts.
Handle the parts with extreme care.
Be particularly careful not to damage the turbine wheel
blades and the compressor wheel blades. Take care
6G-6-2.tif not to allow foreign material to enter the center
housing.
NOTE:
Disassembly and servicing of the center housing and
rotating assembly is not recommended.

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Minor servicing operations are described in this Section.
Contact the nearest IHI SERVICE FACILITY for major repairs
and maintenance.
Refer to “IHI SERVICE NETWORK” at the end of this Section.
Turbocharger pressure check

(1) Remove the waste gate control chamber connecting hose.
(2) Connect the pressure gauge.
(3) Start the engine and gradually increase the engine speed
(the vehicle must be stationary with no load applied to the
engine).
(4) Check to see that turbocharger pressure rises to
approximately 500 mmHg.
Pressure Gauge : 5-8840-0075-0
036HY00002.tif
Waste gate operation check

(1) Remove the hose between the waste gate control
chamber and the intake pipe.
(2) Connect the pressure gauge.
(3) Check to see that the rod begins to move when a pressure
of approximately 665 mmHg is applied to the waste gate,
control chamber.
NOTE:
Do not apply a pressure greater than 1467mmHg (196 kPa)
6G-7-2.tif
to the waste gate during this check.
(4) Check to see the pressure required to move the control

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

4JBIT (IHI RHB5) 898 ± 36 (120 ± 4.8)
4JBITC (IHI RHF4) 815 ± 33 (109 ± 4.4)
6G-7-3.tif
Important wheel shaft end play and bearing clearance

standards and limits are included below for your reference.
Wheel Shaft End Play

Use a dial indicator to measure the wheel shaft end play. Apply
a force of 1.2 kg (2.6 lb/11.8N) alternately to the compressor
wheel end and the turbine wheel end.
Wheel Shaft End Play mm (in)
Standard Limit
0.02 - 0.08
0.09 (0.0035)
(0.0008 - 0.0031)
6G-8-1.tif
6G-8-2.tif
Wheel Shaft and Bearing Clearance

Use a dial indicator to measure the wheel shaft and bearing
clearance.
Wheel Shaft and Bearing Clearance mm (in)
Standard Limit
0.07 - 0.12
0.16 (0.0063)
(0.0028 - 0.0047)
6G-8-3.tif
6G-8-4.tif
REASSEMBLY
036LW002.tif
Reassembly Steps
1. Center housing and rotating assembly 4. Turbine housing
2. Compressor housing 5. Bolt
3. Bolt
Reassembly Steps
1. Center Housing and Rotating Assembly
2. Compressor Housing
3. Bolt
1) Apply Threebond 1215 or equivalent to flange surface
of compressor housing shown in the illustration.
2) Align the setting marks (applied at disassembly) on the
center housing and rotating assembly and the
compressor housing.
6G-10-1.tif
Handle the parts with extreme care to avoid damaging
the compressor wheel blades.
3) Apply and anti-seizing agent (LOCTITE ANTISEIZE
LUBRICANT or the equivalent) to the new bolt
threads.
4) Install the new bolts to the compressor housing.
5) Tighten the bolts to the specified torque.
Compressor Housing Bolt Torque N∙m (kg∙m/lb∙ft)
4.7 (0.5/3.5)
6G-10-2.tif
4. Turbine Housing
5. Lock Plate and Bolt
1) Align the setting marks (applied at disassembly) on the
center housing and rotating assembly and the turbine
housing.
Handle the parts with extreme care to avoid damaging
the trubine shaft wheel blade.
2) Apply and anti-seizing agent (LOCTITE ANTISEIZE
LUBRICANT or the equivalent) to the bolt.
6G-10-3.tif
3) Tighten the bolt to the specified torque.
Turbine Housing Bolt Torque N∙m (kg∙m/lb∙ft)
28.0 (2.85/20.6)
4) Check that the rotating assembly turns smoothly.

IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger
Service Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s Republic of CHINA
Beijing, People’s Republic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN
TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT
LG4J-WE-9491



Issued by
Tokyo, Japan
First edition Jan., 1999 9001-12N-1

No. HGSTG-WE-661 PRINTED IN JAPAN
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WORKSHOP MANUAL

POWER TAKE OFF

International Service & Parts

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on the latest

This manual is applicable to 1994 year model and later vehicles.

SECTION NO. CONTENTS

POWER TAKE OFF

Idle gear Needle bearing

Oil pump (gear pump section)

PTO oil pump assembled point assembly drawing

PTO Rear ball bearing Bolt (oil pump to PTO)

HYDRAULIC CIRCUIT DIAGRAM

Check valve Flow control valve

Oil reserve tank

Check valve Flow control valve

Oil reserve tank

Check valve Flow control valve

Oil reserve tank

SYMBOL FOR HYDRAULIC CIRCUIT

Symbol Meaning of symbol Symbol Meaning of symbol

Check valve (swing check

Detent (position stop

Flow control valve

Hydraulic switching valve

Oil pump (unidirectional

Symptoms Due to Insufficient Hydraulic

Preparing for Hydraulic Operating Fluid Supply

How to Raise the Body (Cargo Deck)

(2) Set the shift lever to the "Neutral" position.

(3) Firmly actuate the parking brake and apply a scotch to

(5) When the clutch pedal is slowly returned, the body

Hydraulic Operating Fluid (Turbine Oil)

If the Dump Rise Operation is Disabled by

When hoist or crane equipment is provided

(1) Firmly actuate the parking brake and apply a scotch to

If neither hoist nor crane is provided

If the body (cargo deck) is kept being dropped and the

Oil tank Pipe

High-pressure hose Hoist cylinder

PTO with oil pump

Hydraulic operating Low-pressure hose

Test hose Hoist cylinder

Hydraulic Operating Fluid (Turbine Oil)

Hydraulic operating Low-pressure hose Work Procedure

Joint (low-pressure side): 5-8840-2439-0

(7) Raise the body (cargo deck) up to the most raised

Total Replacement of Hydraulic

Air Bleeding Procedure of Hydraulic

[Rear Dump Truck]

Principles Under Which Air iIs Released

Between "A" and "C"

[Three-Rotation Dump Truck]

CONTROL CABLE (FOR REAR DUMP TRUCK)

Cable stopper clip 6

Removal Steps Installation Steps

1. Lock Nut (Dump Lever Side)

3. Lock Nut (PTO Side)

Lock nut Special nut PTO

Cable connector groove

• Remove the cable holder from the control cable.

Cable holder Shift rod

Cable connector PTO