Isuzu 4H6H - Mecha - en

ENGINE MECHANICAL (4HK1, 6HK1) 1A-1
ENGINE
ENGINE MECHANICAL (4HK1, 6HK1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1, 6HK1) . . . . . . . . 1A-3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-81
Precautions on Service Work . . . . . . . . . . . . . . . 1A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-87
Main Data and Specifications. . . . . . . . . . . . . . 1A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-93
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 1A-14 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-100
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Piston, Connecting Rod . . . . . . . . . . . . . . . . . .1A-102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-16 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-102
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-102
Inlet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .1A-103
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-111
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-113
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-24 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-113
Turbocharger and Exhaust Manifold . . . . . . . . . . 1A-25 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-25 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-27 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-32 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-118
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-118
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-121
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-51 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-123
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . .1A-125
Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-53 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-125
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-125
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-127
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-54 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-132
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-56 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-132
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-57 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . .1A-133
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-58 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-133
Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-133
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-59 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-60 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-137
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-61 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-138
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-63 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-138
Fixing torque . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-65 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-138
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-65 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .1A-140
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-66 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-140
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-68 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-140
Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-145
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-69 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-149
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-69 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-149
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-70 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .1A-151
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-71 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-151
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-151
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-152
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-153
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Lubrication System . . . . . . . . . . . . . . . . . . . . . .1A-156
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-78 Precautions on Service Work . . . . . . . . . . . . .1A-156
1A-2 ENGINE MECHANICAL (4HK1, 6HK1)
Function Check . . . . . . . . . . . . . . . . . . . . . . . 1A-157
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-158
Oil Port Cover ASM. . . . . . . . . . . . . . . . . . . . . . 1A-159
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-161
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-161
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-163
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-163
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 1A-177
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-177
ISUZU DIESEL ENGINE (4HK1, 6HK1)

Precautions on Service Work Matters that require attention in specifically dealing
with this engine.
Matters that require attention in terms of
maintenance Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
To prevent damage to the engine and ensure reliability
are made with extreme precision. For this reason, they
of its performance, pay attention to the following in
are highly sensitive to foreign matter and if it gets in, it
maintaining the engine: When taking down the engine
can lead to an accident on the road, for instance; thus,
on the ground, do not make the bearing surface of the
make sure that foreign matter will be prevented from
oil pan touch directly the ground. Use a wood frame, for
getting in.
example, to support the engine with the engine foot and
When servicing the fuel system, every precaution must
the flywheel housing.
be taken to prevent the entry of foreign material into the
Because there is only a small clearance between the
system.
oil pan and the oil pump strainer, it can damage the
oil pan and the oil strainer. • Before beginning the service procedure, wash the
fuel line and the surrounding area.
• When the air duct or air cleaner is removed, cover
the air intake opening to prevent foreign matter • Perform the service procedures with clean hands.
from getting into the cylinder. If it gets into it, it can Do not wear work gloves.
considerably damage the cylinder and others while • Immediately after removing the fuel hose and/or
the engine is operating. fuel pipe, carefully tape vinyl bags over the
• When maintaining the engine, never fail to remove exposed ends of the hose or pipe.
the battery ground cable. If not, it may damage the • If parts are to be replaced (fuel hose, fuel pipe,
wire harness or electrical parts. If you need etc.) do not open the new part packaging until
electricity on for the purpose of inspection, for installation.
instance, watch out for short circuits and others.
• Apply engine oil to the sliding contact surfaces of Work procedure
the engine before reassembling it. This ensures • The fuel opening must be quickly sealed when
adequate lubrication when the engine is first removing the fuel pipe, injection pipe, fuel injector,
started. fuel supply pump, and common rail.
• When valve train parts, pistons, piston rings, • The eyebolts and gasket must be stored in a clean
connecting rods, connecting rod bearings or parts box with a lid to prevent adhesion of foreign
crankshaft journal bearings are removed, put them matter.
in order and keep them. • Fuel leakage could cause fires. Therefore, after
• When installing them, put them back to the same finishing the work, wipe off the fuel that has leaked
location as they were removed. out and make sure there is no fuel leakage after
• Gaskets, oil seals, O-rings, etc. must be replaced starting the engine.
with new ones when the engine is reassembled.
• As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust may be
clung to them. Then, apply the designated liquid
gasket to each place anew before assembly.
• Surfaces covered with liquid gasket must be
assembled within 7 minutes of gasket application.
If more than 7 minutes have elapsed, remove the
existing liquid gasket and apply new liquid gasket.
• When assembling or installing parts, fasten them
with the specified tightening torque so that they
may be installed properly.
How to read the model
4HK1
Name
1. Cast The Engine Model 2. Stamp An Engine Number
6HK1
WSHK0001
Name
1. Stamp An Engine Number
Explanations on functions and operation Cylinder liner

The cylinder liner is selected to match an internal
Electronic engine control
diameter of a bore of the cylinder block and built, which
With the control unit, the range from injection to air
is imprinted on the left side of the cylinder.
intake/exhaust, including fuel injection quantity,
injection timing, intake air restriction, EGR, and idling Piston
rpm, is controlled. The piston is aluminum-alloy and an autothermatic
piston with a strut cast, while the combustion chamber
Cylinder block
is a round reentrant type.
The cylinder block is cast-iron with the center distance
of each bore being equal and is of the highly rigid, Cylinder head
symmetrical structure with the crankshaft center being The cylinder head is cast-iron and there are 4 valves
the center. The bearing cap is of the ladder frame per cylinder. The angular tightening method of the
structure and tightened up under the plastic range cylinder head bolt further increases reliability and
rotation angle method. durability.
Crankshaft • Rotate the crankshaft to make the No.1 cylinder
Tuftriding is given, while on the No. 1 balance weight meet the compression top dead center (TDC).
imprinted is the grade of each journal diameter. 4HK1
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Common rail-type electronic control injection
system
The common rail-type electronic control injection
system is composed of a fuel supply pump that sets the
target pressure of high-pressure fuel and supply it, a
common rail that measures such high-pressure fuel
and a fuel injector that turns it into a fine spray and
injects it. Each is controlled via ECM based upon
various signals, while injection timing or fuel injection 6HK1
quantity is controlled under every possible driving
condition.
Fuel injector
The fuel injector is a 7-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the
fuel injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injectors according to ID code data in
memory. At the replacement of fuel injectors, ID code
data should be stored in ECM.
Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system !"#$$%&
The preheating system consists the ECM, the glow • Insert a 0.4 mm thickness gauge into a clearance
relay, glow plugs and the glow indicator lamp. The between the rocker arm and the bridge to check it
preheating system is operated when the engine coolant and adjust it if needed.
temperature is low, and make the engine easy to start.
Valve clearance mm (in)
Lubrication system
It is an oil filter with full-flow bypass, which uses a Intake valve 0.4 (0.016)
water-cool oil cooler and oil jet to cool the piston. Exhaust valve 0.4 (0.016)
Function check Caution:

Inspection/adjustment of valve clearance Adjust while being cold.
1. Inspection of valve clearance 2. Adjustment of valve clearance
• Remove the cylinder head cover.
Caution:
• Remove the fuel injector harness ASM. Adjust valve clearance carefully so that the bridge may
• Loosen the terminal nuts alternately to remove. become level (hit the end of the 2 valve axes).
• Remove the leak off pipe.
a. Completely loosen all of the bridge and rocker • With a thickness gauge kept inserted, tighten
arm adjusting nuts and adjusting screws an adjusting screw of the bridge lightly and
(4HK1: 8 nuts and 8 screws, 6HK1: 12 nuts and make sure that the tip of the adjusting screw
12 screws). touches the end of valve axis and the
b. Place a 0.4 mm thickness gauge between the movement of the thickness gauge has become
No. 1 cylinder rocker arm end and the bridge tight.
cap. • Then, check if the end of the valve axis on the
c. Tighten the rocker arm adjusting screw until the opposite side is unstable or hits diagonally. If
thickness gauge is snug (not tight) between the so, loosen the bridge adjusting screw a little so
rocker arm end and the bridge cap. that the end of the valves on both sides may
touch properly.
d. Tighten the rocker arm lock nut.
Valve bridge clearance: r 0.1 mm (0.0039 in) or
e. Tighten the bridge adjusting screw until the less
bridge contacts the valve head.
• After making an adjustment so that the end of
f. Tighten the bridge lock nut. the valves on both sides may touch properly,
g. Check that the thickness gauge is still held tighten up an adjusting screw nut of the bridge
snugly between the rocker arm end and the with a flathead screwdriver so that the bridge
bridge cap. If it is too tight, slightly loosen the adjusting screw may not rotate.
bridge adjusting screw and lock nut to restore Tightening torque: 22 Nm (16 lb ft)
snugness.
h. Remove the thickness gauge. Caution:
i. Repeat Steps 2 through 5 for the remaining If the adjusting screw of the bridge is poorly adjusted,
cylinders. the bridge would tilt and be pushed down and seized,
which may damage the bridge guide, for example.
Tightening torque: 22 Nm (16 lb ft) Thus, adjust it accurately.
Tightening torque:
Name
1. Rocker Arm Rocker arm adjustment screw 22 Nm (16 lb ft)
2. Bridge Cap nut
3. Bridge Bridge adjustment screw nut 22 Nm (16 lb ft)
Adjustment table (4HK1)
Cylinder No. 1 2 3 4
Valve arrangement IN EX IN EX IN EX IN EX
No. 1 cylinder
{ { { {
Compression top dead center position
No. 4 cylinder
u u u u
Adjustment table (6HK1)

Cylinder No. 1 2 3 4 5 6
Valve arrangement IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 cylinder
{ { { { { {
No. 6 cylinder
u u u u u u
• If the No. 1 cylinder is the compression TDC,

adjust a valve clearance with { mark given on
the table and if the No. 4 (4HK1) or No. 6
(6HK1) cylinder is the compression TDC, that
with u mark.
4HK1
6HK1
WSHK0002
4HK1
WSHK0003
• Attach the harness ASM to the fuel injector.

Tighten the harness bracket with the
designated torque. Name
1. Fuel Injector Harness Connector
Tightening torque: 48 Nm (35 lb ft)
6HK1
• Install the terminal nuts on the fuel injector.
Note:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
• Install the cylinder head cover.
Refer to the “Cylinder Head Cover”.
Compression pressure inspection
• Warm-up the engine.
1
• Remove a negative terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
WSHK0004
built on the lower head cover (no fuel will be
injected). Name
1. Fuel Injection Harness Connector
Caution:
When the harness connector is removed, ECM judges
• Install the negative terminal of the battery.
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory • Turn on the starter to emit foreign matter within the
of ECM. cylinders.
(For how to clear memory of ECM, refer to the Engine • Install an adapter and a gauge of a compression
Control System Section) gauge of the special tool.
Compression gauge: 5-8840-2675-0 (J-26999-12)

Compression gauge adapter
4HK1: EN-46722
6HK1: 5-8840-2622-0
• Turn on the starter to inspect compression
pressure.
4HK1
Compression pressure MPa (psi) / 200 rpm
Standard 2.84 – 3.24 (412 – 469)
Limit 1.96 (284)
Differences among
294 kPa (43)
the cylinders
6HK1
Compression pressure MPa (psi) / 200 rpm
Standard 3.24 (469)
Limit 2.26 (327)
Differences among
294 kPa (43)
the cylinders
• Measure each cylinder one by one.
Caution:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.
• Remove a negative terminal of the batteries.
• Install a harness connector for the fuel injector built
on the lower head cover.
• Install all the glow plugs.
• Install the negative terminal of the battery.
Main Data and Specifications
Item Engine model 4HK1

Type Diesel/4-cycle/water cooled-type, inline four-cylinder
OHC
Combustion chamber form Direct injection type
Cylinder liner type Dry type
Number of cylinders - cylinder bore u mm (in) 4-115 (4.53) u 125 (4.92)
strokes
Displacement cc (cu.in) 5193 (317)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3.23 (468)/200
Idle speed rpm 800
Valve clearance Intake 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold)
Ignition type Compressed ignition
Injection order 1-3-4-2
Lubricating system
Lubricating type Pressure type
Oil pump type Gear type
Volume of lubricating oil L (qts) 13.0 (13.7) — 20.5 (21.7)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in, water-cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax-type units
Thermostat valve-opening temperature qC (qF) 85 (185)
Volume of coolant L (qts) 14 (14.8) (incl. radiator)
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Injection nozzle type Multi-hole type
7-hole and I 0.16 mm (0.0063 in) inside diameter
Charging system
Generator type AC type
Power output V/A 24 - 50
Regulator type IC

Starting system
Starter type Reduction type
Power output V-kw 24 - 5.0
Preheat system type Glow plug
Glow plug standard voltage/electric current V/A 23 - 3.5

Type Diesel/4-cycle/water cooled-type, inline four-cylinder
OHC
Combustion chamber form Direct injection type
Cylinder liner type Dry type
Number of cylinders - cylinder bore u mm (in) 6-115 (4.53) u 125 (4.92)
strokes
Displacement cc (cu.in) 7790 (475)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3.04 (441)/200
Idle speed rpm For Hitachi products: 800, For JCB and Sumitomo
products: 900
Valve clearance Intake 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold)
Ignition type Compressed ignition
Injection order 1-5-3-6-2-4
Lubricating system
Lubricating type Pressure type
Oil pump type Gear type
Volume of lubricating oil L (qts) 28 (29.6) — 38 (40.2)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in, water-cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax-type units
Thermostat valve-opening temperature qC (qF) 82 (180)
Volume of coolant L (qts) 14.5 (15.3)
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type

Injection nozzle type Multi-hole type
7-hole and I0.16 mm (0.0063 in) inside diameter
Charging system
Generator type AC type
Power output V/A 24 - 120
Regulator type IC
Starting system
Starter type Reduction type
Power output V-kw 24 - 5.0
Preheat system type Glow plug
Glow plug standard voltage/electric current V/A 23 - 3.5
Special tool
Illustration Tool Number/Description
5-8840-26750-0
J-26999-12
Compression gauge
EN-46722
Compression gauge
adapter
(4HK1)
5-8840-2622-0
Compression gauge
adapter
(6HK1)
Cylinder Head Cover

Components
4HK1
Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
6HK1
WSHK0005
Name
2. Gasket 4. Gasket
Removal
1. Remove the head cover.
2. Remove the gasket.
4HK1 4HK1
Name Name
6HK1
6HK1
WSHK0006
WSHK0007
Name
1. Head Cover Name
1. Head Cover Case
3. Remove the fuel injector harness connector. 2. Fuel Injector Harness Connector
4. Remove the head cover case.
5. Remove the gasket.
Installation
1. Install the gasket on the lower cover.
2. Install the head cover case.
Tightening torque: 4HK1: 18 Nm (13 lb ft),
6HK1: 13 Nm (9.6 lb ft)
3. Install the fuel injector harness connector.
Caution: 4HK1
Push it in thoroughly until the claws of the lock raise.
4HK1
6HK1
Name
1. Head Cover Case
6HK1
WSHK0008
WSHK0007
Name
1. Head Cover Case
4. Install the gasket on the head cover.

5. Install the head cover and tighten up according to
the orders given on the figure.
6HK1: 13 Nm (9.6 lb ft)
Torque Specifications
4HK1
6HK1
N m{lb ft}
13 {9.6}
13 {9.6}
WSHK0009
Inlet Cover
Components
4HK1
Name
1. Case ASM 3. Inlet Pipe Gasket
2. Inlet Cover 4. Inlet Pipe
6HK1
!"#$$%&
Name
1. Case ASM 3. Inlet Pipe Gasket
2. Inlet Cover 4. Inlet Pipe
Removal 4HK1
1. Remove the common rail.
Refer to the “Common Rail” in the fuel system
section.
2. Remove the inlet pipe.
3. Remove the case ASM.
6HK1 Caution:
• Be careful not to forget to fasten the bolt indicated
with an arrow.
• Tighten up the stud part together with the common
rail.
!"#$$%&
4. Remove the inlet cover.
• On the place where the case ASM is to be installed
inside the inlet cover (arrowed) is a bolt. Be careful
not to forget to remove it.
* 4HK1 is shown for illustration.
• Peel the liquid gasket off carefully.
2. Install the case ASM.
• Apply the liquid gasket and mount within 7
minutes.

4HK1
Installation
1. Install the inlet cover.
• Apply the liquid gasket (ThreeBond 1207C or
equivalent) by using a bead diameter of 2.5 – 5.5
mm (0.1 – 0.2 in) along a groove of the inlet cover.
• Install within seven minutes after applying liquid

gasket.

6HK1
!"#$$%$
3. Install the gasket on the inlet pipe and tighten up
with the specified torque.
4. Install the common rail.
section.
4HK1
6HK1
N.m (lb ft)
20 (15) 39 (29)
24.5 (18)
!"#$$%&
Turbocharger and Exhaust Manifold

Components
4HK1
Name
1. Oil Feed Pipe 5. Turbo Charger ASM
2. Water Return Pipe 6. Exhaust Adapter
3. Exhaust Manifold 7. Oil Return Pipe
4. Water Feed Pipe
6HK1
4 3 2
WSHK0012
Name
1. Oil Feed Pipe 4. Exhaust Adapter
2. Exhaust Manifold 5. Oil Return Pipe
3. Turbo Charger ASM
Removal
1. Loosen the radiator drain cock to drain coolant.
(4HK1 only)
2. Remove the air intake duct from the turbocharger
and the air cleaner.
3. Remove the charge air pipe from the turbocharger
and the charge air cooler.
4. Disconnect the front exhaust pipe.
5. Remove the EGR pipe.
6. Remove the oil feed pipe.
7. Remove the oil return pipe.
8. Remove the water feed pipe. (4HK1 only)
• Remove the water return pipe. (4HK1 only) 6HK1
1 3 2
WSHK0013
Name Name
1. Water Return Pipe 1. Exhaust Manifold
2. Turbocharger
9. Remove the heat protector on the turbocharger. 3. Exhaust Adapter
10. Remove the exhaust adapter bolts.
11. Remove the four turbocharger clamping nuts.
12. Remove the turbocharger from the exhaust Inspection
manifold. • Inspection of exhaust manifold
13. Remove the exhaust manifold. Inspect the plane surface of the plane on which the
4HK1 manifold and the cylinder head are to be installed.
Manifold installation plane surface mm (in)

Standard 0.3 (0.01) or less
Limit 0.5 (0.02)
Caution:
If the plane surface exceeds the limit, replace it.
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter

• Check a crack in the exhaust manifold visually.
Carefully inspect he turbocharger for abrasion and/or
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.
Wheel shaft axial play

Use a dial gauge to measure the wheel axle shaft play
when a force of 12 N (2.6 lb) is alternately applied to
both sides of the compressor wheel.
4HK1
Axial play mm (in)
Standard 0.03 – 0.06 (0.0012 – 0.0024)
Limit 0.09 (0.0035)
6HK1
Axial play mm (in)
Standard 0.06 – 0.09 (0.0024 – 0.0036)
Name
Limit 0.11 (0.0043)
1. Oil Outlet
2. Oil Inlet
Installation
1. Put the gasket in to install the exhaust manifold.
• 4HK1: Tighten up with the 2 nuts and 6 bolts
according to the order given on the figure.

• 6HK1: Tighten up with the 12 nuts according to the
order given on the figure.

34 Nm (25 lb ft) for (7) only
Caution:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
manifold.
Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between
the wheel shaft and the bearing.
4HK1
Clearance mm (in)
Standard 0.056 – 0.127 (0.0022 – 0.0050)
Limit 0.14 (0.0055)
6HK1
Clearance mm (in)
Standard 0.10 – 0.17 (0.0039 – 0.0067)
Limit 0.205 (0.0081)
4HK1 4HK1
6HK1
Name
1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
6HK1
1 3 2
WSHK0014
2. Install the gasket and turbocharger to the exhaust

manifold. Tighten the nuts to the specified torque.

3. Tighten the adapter bolts (exhaust manifold side) WSHK0013
to the specified torque.
Name
Tightening torque: 32.4 Nm (24 lb ft) 1. Exhaust Manifold
2. Turbocharger
3. Exhaust Adapter
4. Install the water feed pipe to the turbocharger.

(4HK1 only)
• Tighten the joint bolts to the specified torque.

• Install the pipe bracket and tighten the bolts to the
specified torque.

4HK1 7. Install the turbocharger oil feed pipe to the top of
the turbocharger. Tighten the joint bolts to the
specified torque.
6HK1: 34.5 Nm (25 lb ft)
• Install the pipe bracket and tighten the bolts to the
specified torque.

8. Tighten the oil return pipe bolts to the specified
torque.
Tightening torque (Turbocharger side):
4HK1: 9 Nm (78 lb ft),
6HK1: 17.6 Nm (13 lb ft)
Tightening torque (Cylinder block):

4HK1: 22 Nm (15 lb ft),
6HK1: 17.6 Nm (13 lb ft)
Name
1. Water Feed Pipe
5. Install the water return pipe. Tighten the joint bolts

to the specified torque. (4HK1 only)

6. Install the water return pipe bracket. Tighten the
bolts to the specified torque. (4HK1 only)

• Install the rubber hose between the water return
pipe and the thermostat housing.
4HK1
Name
1. Oil Return Pipe
9. Install the air intake duct and tighten the bolts to

the specified torque.
Tightening torque: 10 Nm (87 lb in)

10. Install the charge air pipe in the turbo charger and
the charge air cooler.
Tightening torque:
Duct bolt 21 Nm (15 lb ft)
Duct clip 6 Nm (52 lb in)
11. Install the front exhaust pipe to the turbocharger
and tighten the nuts to the specified torque.
Name
1. Water Return Pipe Tightening torque: 67 Nm (49 lb ft)
12. Add cooling water to the radiator. (4HK1 only)

13. Install the EGR pipe.
• Put the gasket between both ends of the EGR pipe
and install to the specified torque.

14. Replenish the coolant. (4HK1 only)
4HK1
6HK1
N.m (lb ft)
17.6 (13) 34.5 (25)
23.5 (17) 50.5 (37) 32.4 (24)
17.6 (13)
!"#$$%&

Timing Gear Train

Components
4HK1
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Crankshaft Position Sensor
5. PTO Idle Gear Cover 11. Oil Pan
6. Flywheel 12. Fuel Supply Pump
6HK1
10
1
3
5 8
12
11
WSHK0017
Name
1. Idle Gear B Shaft 7. Rear Oil Seal
2. Idle Gear A 8. Flywheel Housing
3. Idle Gear B 9. Slinger
4. PTO Idle Gear 10. Idle Gear A Shaft
5. PTO Idle Gear Cover 11. PTO Idle Gear Shaft
6. Flywheel 12. Oil Pump
Removal
1. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
2. Remove the rocker arm shaft ASM.
Refer to “Rocker Arm Shaft ASM”.
3. Remove the camshaft ASM.
Refer to “Camshaft ASM”.
4. Remove the cylinder head ASM.
Refer to the “Cylinder Head”.
5. Remove the fuel supply pump ASM.
Refer to “Fuel Supply Pump” in the fuel system 6HK1
section.
!"#$$%&
7. Remove the flywheel.
* 4HK1 is shown for illustration. • Install the crankshaft stopper on the starter part of
6. Remove the crankshaft position sensor. the flywheel housing to stop the crankshaft from
• Remove the crankshaft position sensor before rotating.
remove flywheel.
Caution:
4HK1 Check if the stopper meshes with the ring gear without
fail and is installed properly.
Special tool
Crankshaft stopper: 5-8840-2230-0 (EN-47680)
• Loosen the fastening bolts of the flywheel little by

little according to the order given on the figure.
• After loosening all the bolts, remove the stopper to

remove the flywheel.
8. Remove the rear oil seal.

Refer to the “Crankshaft Rear Oil Seal”.
9. Use the slinger remover to remove the slinger.
Caution: • Never fail to remove the bolt(s) given on the figure.
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
8-9439-6858-0 (For 6HK1)

14. Remove the idle gear A.
15. Remove the idle gear A shaft. (6HK1)
16. Remove the oil pump. (6HK1)
17. Remove the idle gear B.
18. Remove the idle gear B shaft.
10. Remove the oil pan.

11. Remove the PTO idle gear cover.
12. Remove the PTO idle gear.
Inspection
* 4HK1 is shown for illustration. 1. Measurement of idle gear backlash
13. Remove the flywheel housing. • Apply a dial gauge on the teeth of the idle gear to
be measured and move the gear to right and left
lightly to read how much the dial gauge shook
(never fail to fix the gear).
• If the measurement exceeds the limit, replace the

idle gear.
Backlash of the timing gear mm (in)

Standard 0.10 – 0.17 (0.004 – 0.006)
Limit 0.30 (0.01)
• Measure backlash of the idle gear before removing

the idle gear A.
3. Outside diameter of idle gear shaft

• Use a micrometer to measure an external diameter
of each idle gear shaft.

shaft.
4HK1
2. Measurement of end clearance of the idle gear.
Outside diameter of idle gear shaft mm (in)
• Insert a thickness gauge between the idle gear and
the thrust collar to measure a clearance. Standard 29.959 – 29.980 (1.179 – 1.180)
Limit 29.80 (1.173)
• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
External diameter of the idle gear A shaft mm (in)
Axial play of idle gear mm (in) Standard 39.959 – 39.975 (1.573 – 1.574)
Standard 0.080 – 0.140 (0.003 – 0.006) Limit 39.80 (1.567)
Limit 0.20 (0.008)
• Measure an end clearance of the idle gear before

removing the idle gear B.
6HK1 6HK1
Outside diameter of idle gear shaft mm (in) Clearance between the idle gear and the mm (in)
shaft
Standard 29.959 – 29.980 (1.179 – 1.180)
Standard 0.020 – 0.062 (0.0007 – 0.0024)
Limit 29.9 (1.177)
Limit 0.200 (0.0079)
External diameter of the idle gear A shaft mm (in)
Clearance between the idle gear A and the mm (in)
Standard 49.950 – 49.975 (1.967 – 1.968)
shaft
Limit 49.9 (1.965)
Standard 0.025 – 0.075 (0.0010 – 0.0030)
Limit 0.200 (0.0079)
4. Clearance between the idle gear and the idle gear

shaft
• Measure an inside diameter of the idle gear
bushing to calculate a clearance between the idle Installation
gear and the idle gear shaft.
1. Install the idle gear B shaft.
• If the measurement exceeds the limit, replace • Tighten the idle gear B shaft to the specified
either the idle gear or the shaft. torque.
4HK1
Clearance between the idle gear and the mm (in) • After installation, apply engine oil to the shaft.
shaft
Standard 0.020 – 0.062 (0.0007 – 0.0024)
Limit 0.200 (0.0079)
Clearance between the idle gear A and the mm (in)

shaft
Standard 0.025 – 0.066 (0.0009 – 0.0026)
Limit 0.200 (0.0079)

Name
2. Install the idle gear B. 1. Crank Gear
• Install the idle gear B in the direction given on the 2. Idle Gear A
figure and tighten up the fastening bolts with the
specified torque. • Align the crankshaft gear (2) L mark and idle gear
A (1) 0 marks.
6HK1: 95 Nm (70 lb ft) • Tighten the installing bolt to the specified torque.
Name
1. Idle Gear
2. Thrust Collar
3. Bolt
3. Install the oil pump.

4. Install the idle gear A shaft. (6HK1)
5. Install the idling gear A.
• Rotate the crankshaft to make the No.1 cylinder
meet the compression top dead center (TDC).
Name
1. Idle Gear C 6. Crankshaft Gear
2. Camshaft Gear 7. Oil pump Drive Gear
3. Idle Gear B 8. Fuel Supply Pump Gear
4. PTO Gear 9. Idle Gear A
5. PTO Idle Gear
6. Install the flywheel housing. 4HK1

• Clean the rear side of the cylinder block. In
particular, remove overflow liquid gasket
thoroughly when the crankcase is installed.
• As the figure shows, apply the liquid gasket

(ThreeBond 1207B or equivalent) inside a hole of
the bolt (except the bolt holes indicated with an
arrow) evenly.
6HK1 • Align with the knock pin of the cylinder block and
install the flywheel housing.
Tightening torque of the flywheel housing (4HK1):

Nm (lb ft)
1 = 96 (71) 2 = 77 (57) 3 = 38 (28)
• Tighten up the Mark 3 from the cylinder block side.
!"#$$%&
4HK1
Tightening torque of the flywheel housing (6HK1):

Nm (lb ft)
1 = 96 (71) 2 = 86 (63) 3 = 119 (88)
4 = 53 (39) 5 = 73 (54) 6 = 26 (19)
6HK1
1
1 2
5
1
3
6
1
3
4
1
!"#$$%%
7. Install the PTO idle gear.
• Apply engine oil over the part where the gear of the
idle gear shaft is to be put together.
• Put the idle gear and the shaft together and install
it on the location given on the figure and tighten up
with the specified torque.
Tightening torque: 4HK1: 133 Nm (98 lb ft)

6HK1: 119 Nm (88 lb ft)
6HK1
8. Install the PTO idle gear cover.

• Install the O-ring on the cover and install it on the 9. Install the oil pan.
flywheel housing and tighten up the tightening • Apply the liquid gasket (ThreeBond 1207B or
bolts with the specified torque. equivalent) on a joint between the cylinder block,
the front cover and the flywheel housing with a
Tightening torque: 19 Nm (14 lb ft) beat diameter of 3 mm.
4HK1 • Install the oil pan within 7 minutes after applying

the liquid gasket.
4HK1
6HK1 6HK1
WSHK0042
• With the flywheel housing, the front cover and the

stud of the crankcase as a guide, put together the Name
gasket and put the oil pan on it. 1. Oil Pan
Then, put the rubber ASM on the oil pan and fix it 2. Gasket
by fastening bolts and nuts. Tightening
4HK1 4HK1
• After fastening the oil pan at the respective points
of (1), (2), (3), and (4), fasten other parts.

6HK1
• Fastening the oil pan from the part of A or B in
clock wise order.
• It tightens again by specified torque.
1
Tightening torque: 24.5 Nm (18 lb ft)
4
5
3
2
• After pressing in the slinger, make sure that the

distance between crankshaft end surface and the
slinger is A as specified.
4HK1
10. Install the rear slinger using installer, setting tool.

Special tool
4HK1
Oil seal installer kit: 5-8840-2703-0 (J-43282)
6HK1
Oil seal setting tool: 8-94396-856-0
• Install the slinger (1) to the end of adapter (2).
Install the adapter to the crankshaft (3).
• Install the slinger sleeve (4) to the adapter. Tighten
the center bolt (5) until the sleeve comes in contact
with the adapter stopper.
Distance (A): 17.3r0.3 mm (0.7r0.01 in)

Distance (B): 10.8r0.1 mm (0.7r0.01 in)
6HK1
•
• After pressing the oil seal, make sure that the

Distance (A): 17r0.3 mm (0.7r0.01 in) distance between crankshaft end surface and the
oil seal as specified.
Caution: 4HK1
Be sure to replace the slinger and oil seal as a set.
11. Install the rear oil seal using installer, setting tool.
Special tool
4HK1
6HK1
• Apply engine oil to the oil seal lip.
Caution:
Do not allow engine oil to come in contact with the
outside oil seal and felt ring.
• Insert the oil seal (1) into the adapter (2).
• Insert the oil seal sleeve (3) to the adapter.
• Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
6HK1 13. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
14. Remove the oil drain adapter.
15. Install the O-ring on the fuel supply pump and
make the slits with an arrow meet and with the stud
bolt as a guide, install the fuel supply pump
tentatively.
Caution:
• When removing the fuel supply pump, if the stud
bolt on the cylinder block side loosens, or the stud
bolt is replaced, apply the Loctite No. 262 on the
side where the stud bolt is to be buried before
assembly.
B
Distance (B): 7.5r0.15 mm (0.3r0.006 in)

12. Install the flywheel.
• Along with the knock pin of the crankshaft, install
the flywheel and tighten up with the specified
torque according to the order given on the figure.
Tightening torque:
1st step = 78 Nm (57 lb ft)
2nd step = 60q
3rd step = 60q

• Check if the alignment mark of the gear painted
white is at the location given on the figure when
viewed from the plug hole and tighten up with the
specified torque.
Nut tightening torque: 50 Nm (36 lb ft)
Bolt tightening torque: 76 Nm (56 lb ft)

• If the location of the teeth of the painted gear is not
in the right place, put it together all over again.
17. Install the cylinder head ASM.
18. Install the camshaft ASM.
19. Install the rocker arm shaft ASM.
20. Install the cylinder head cover.
Name
1. Plug Hole
2. Alignment Mark
16. Install the oil drain adapter ASM on the plug hole
and tighten with the specified torque.
• Apply engine oil over the O-ring nice and thin and
install it.
Name
1. Adapter
2. O-Ring
60 60
6 {4}
WSHK0065
Special Tool
5-8840-2230-0
EN-47680
Crankshaft stopper
1-8521-0027-0
Slinger remover
5-8840-2703-0
J-43282
Oil seal installer kit
8-94396-856-0
Oil seal setting tool
Rocker Arm Shaft ASM

Components

Name
1. Camshaft Bracket 5. Rocker Arm Bracket
2. Rocker Arm 6. Camshaft Bracket
3. Wave Washer 7. Rocker Arm Shaft
4. Rocker Arm
Removal
• Along with the camshaft bracket, remove the
rocker arm shaft ASM.
• Because the bolt(s) shown on the figure is are 6. Remove the camshaft bracket to take the shaft out.
designed to fix the rocker arm shaft, do not remove
it for now.
Name
Caution: 1. Camshaft Bracket
Pay full attention so as not to drop the bridge cap in the 2. Rocker Arm
gear case of the rear part of the cylinder head or the 3. Wave Washer
hole into which oil pours back in the front. 4. Rocker Arm
5. Rocker Arm Bracket
6. Camshaft Bracket
Disassembly 7. Rocker Arm Shaft
1. Remove the camshaft bracket.
2. Remove the rocker arm. 7. Check if the oil hole is clogged of the camshaft
bracket (on the rear side).
3. Remove the wave washer.
4. Remove the rocker arm.
5. Remove the rocker arm bracket.
• Disassemble according to the order (2) – (4)
thereafter.
8. Check if the rocker arm shaft is bent.

• Place the rocker arm shaft on a V block.
• Check if it is bent by rotating the shaft with a dial

gauge on the center of the shaft.
• As a result of measurement, if its bend is slight,

press it to rectify it (while cold).
• If the bend of the shaft exceeds the limit, replace 10. Inspect a clearance between the rocker arm and
the shaft. the rocker arm shaft.
• Use a cylinder gauge to measure an inside
diameter of the bushing of the rocker arm to
Bend of the rocker arm shaft mm (in)
measure a clearance between the external
Limit 0.3 (0.012) diameter of the shaft.

rocker arm and the shaft.
Clearance between the rocker arm and mm (in)

rocker arm shaft
Standard 0.010 – 0.056 (0.0004 – 0.0022)
Limit 0.2 (0.0079)
9. Check if the rocker arm shaft is worn.

• Use a micrometer to measure 8 places of the
vibrating part of the rocker arm.
• If the measurement falls is the limit or less, replace

the shaft.
External diameter of the rocker arm shaft mm (in)

Standard 22.0 (0.866) 11. Inspect a clearance between the roller of the
Limit 21.85 (0.860) rocker arm and the rocker arm pin.
a. Pass a string, for instance, through an opening
between the rocker arm and the roller, pull it in
the direction indicated with an arrow strongly
and measure the gap between the rocker arm
and the roller with the roller stuck out. Figure 1
b. After marking the measuring point, pull the
string out and measure the gap of the marked
place with the roller pushed deep into the end.
Figure 2
c. The gap between the measurement taken
under a. and that under b. will be a clearance
between the roller and the rocker arm pin. If it
exceeds the limit, replace the rocker arm.
Clearance between the roller and the mm (in)

rocker arm pin
Standard 0.068 – 0.099 (0.0026 – 0.0038)
Limit 0.2 (0.0079)
3. Install the wave washer between the rocker arm.

Reassembly 4. Install the rocker arm bracket.
• Pay attention to the direction in which the bracket
1. Install the camshaft bracket to one side of the
is put together and put it together with the rocker
rocker arm shaft tentatively first. When the rocker
arm shaft.
arm shaft ASM is installed on the cylinder head,
tighten them up fast. 5. Install the camshaft bracket.
• Assemble in the reverse order of disassembly. • Install the camshaft bracket on the rocker arm
shaft with the bolts indicated with an arrow
tightened tentatively. When the rocker arm shaft
ASM is installed on the cylinder head, tighten them
up fast.
2. Install the rocker arm.

• Apply engine oil in an inside diameter of the rocker
arm, the roller and the rocker arm pin and install it
on the rocker arm shaft.

Name
Name 1. Bridge Cap
1. Camshaft Bracket 2. Bridge
2. Rocker Arm
3. Wave Washer • Loosen an adjusting screw of the rocker arm, apply
4. Rocker Arm engine oil over the roller part of the rocker arm and
5. Rocker Arm Bracket install it on the cylinder head.
6. Camshaft Bracket
7. Rocker Arm Shaft • Loosen the bolts indicated with an arrow a little, it
will become easier to install it.
Installation
• If the bridge cap comes off, apply engine oil over
the inside of the bridge cap and put it together with
the bridge.
Caution:
Pay full attention so as not to drop the bridge cap in the
gear case of the rear part of the cylinder head or the
hole into which oil pours back in the front.
• Apply engine oil on a screw of the bolts and nuts.
• Tighten up the tightening bolts of the rocker arm

ASM tentatively, and gradually tighten up the entire
rocker arm ASM horizontally according to the order
of the nut on the rocker arm side.
Tightening torque:
4HK1
Bolt (3) = 56 Nm (41 lb ft)
Nut (1), Bolt (2), (4) = 27 Nm (20 lb ft)
6HK1
Nut (1) – (4) and Bolt (10) – (13) = 27 Nm (20 lb ft)
Bolt (5) – (9) = 56 Nm (41 lb ft)
4 6 8 9 7 5 3 1
2
11 12 13 10
Name
1. Camshaft Bracket Fixing Nut
2. Camshaft Bracket Fixing Bolt
3. Rocker Arm Bracket Fixing Bolt
4. Rocker Arm Shaft Set Bolt
• Adjustment of valve clearance
Refer to “Function Check”.

Camshaft ASM
Components
4HK1
Name
1. Bearing Cap 3. Knock Pin
2. Bearing 4. Camshaft Gear
6HK1
!"#$$%%
Name
1. Bolt 7. Sub Gear
2. Washer 8. Dish Spring
3. Gear 9. Snap Ring
4. Pin 10. Pin
5. Spring 11. Camshaft
6. Pin
Removal Caution:
Put the removed bearings in order with a tag, for
example, by cylinder.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
6. Remove the bearing lower.
!"#$$%&
Name
Disassembly 1. Snap Ring
1. Remove the scissors gear ASM. (6HK1) 2. Dish Spring
3. Sub Gear
• Fix the hexagon portion of the camshaft in a vise
4. Spring
using a mouth ring. Use snap ring pliers to remove
5. Camshaft Gear
the sub gear.
2. Remove the camshaft gear.
Caution:
Take care not to damage to the cam portion and the • Remove the fastening bolts of the camshaft gear
journal portion of the camshaft. and put the block of wood in a puller to remove the
camshaft gear.
!"#$$%&
Name
1. Wood
3. Remove the knock pin.

4. Inspect the camshaft visually.
• Check if the journal and cam parts of the camshaft
are worn or damaged, if so, replace it.
• If the height of the cam lobe is the limit or less,
replace the camshaft.
Height of the cam lobe mm (in)

Intake air Exhaust
Standard 52.8 (2.08) 54.5 (2.15)
Limit 51.8 (2.04) 53.5 (2.11)
5. Check the axial play of the camshaft.

• Use a thickness gauge to measure an end
clearance of the camshaft gear and the camshaft
bracket.

camshaft gear or the camshaft.
End clearance of the camshaft mm (in)

Standard 0.085 – 0.205 (0.033 – 0.008) 7. Check if the camshaft journal is worn.
Limit 0.25 (0.009) • Use a micrometer to measure wear which is not
even with a diameter of the camshaft journal.
Caution:
• If the measured uneven wear exceeds the limit,
Measure an end clearance of the camshaft before
disassembling.
External diameter of the camshaft journal mm (in)

part
Standard 39.950 – 39.975 (1.5728 – 1.5738)
Limit 39.850 (1.5688)
Partial wear of the camshaft journal part mm (in)

Limit 0.05 (0.0019)
6. Check if the cam lobe is worn.

• Use a micrometer to measure the height of the
cam lobe.
Clearance of the journal part mm (in)

Standard 0.020 – 0.087 (0.0008 – 0.0034)
Limit 0.15 (0.0059)
8. Check for bent of the camshaft.

• Place the camshaft on a V block to measure a
bend with a dial gauge.
• Rotate the camshaft slowly to measure how much

the dial indicator shook. If it exceeds the limit,
Reassembly
Bent of the camshaft mm (in) 1. Install the knock pin.
Limit 0.05 (0.0019) 2. Install the camshaft gear.
• With the side of the camshaft gear center boss part
stuck out being on the camshaft side, install the
camshaft gear along with the knock pin.
Caution:
Be careful not to damage the cam and journal parts
when tightening up the gear.
9. Measure a camshaft journal oil clearance.

a. Measure an inside diameter of the camshaft
bearing with a dial gauge.
b. Read the difference between the inside
diameter of the camshaft bearing and the
diameter of the camshaft journal.
If the measured oil clearance exceeds the limit,
replace the camshaft bearing.
3. Install the scissors gear ASM. (6HK1)
• Fix the hexagon portion of the camshaft in a vise • Before installing the camshaft to the cylinder head,
using a mouth ring. Assemble the spring with its rotate the sub gear using the special tool to
left end contacting the pin of camshaft main gear to prevent the spring force which acts on the sub
make a gap on the right. gear from affecting. Align the hole of the sub gear
• Assemble the sub gear so that its pin is inserted with the camshaft main gear and install the phase
into the gap between the right side of pin of the alignment pin from the sub gear side to match the
camshaft main gear and the right end of the spring. teeth.
Special tool
Scissors gear spring wrench: 5-8840-2674-0
!"#$$%&
Name !"#$$%&
1. Snap Ring • Assemble onto the cylinder head.
2. Dish Washer
3. Sub Gear
4. Spring
5. Camshaft Gear
• Use snap ring pliers to assemble the snap ring and

the dish washer securely.
!"#$$%&
Fixing torque
N.m (lb ft)
142 (105)
!"#$$%$
Special Tool
5-8840-2674-0
Scissors gear spring
wrench
!"#$$%&
Installation 4HK1
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.
4HK1
!"#$$%%
6HK1
6HK1
4. Install the baring upper to the bearing cap.

5. Install the bearing cap.
!"#$$%& • Apply engine oil on the bearing upper.
2. Install the camshaft bearing lower.
• Direct the front mark of the bearing cap toward the
• Apply engine oil over the camshaft bearing lower front of the engine and put it together with the
and install it on the cylinder head. cylinder head in numerical order.
• Put together the camshaft ASM so as to make the
“B” (4HK1) or “x” (6HK1) mark meets the upper
face of the cylinder head.
• Apply engine oil over the screw part and tighten up

the bearing cap with the specified torque.


Valve Stem Seal, Valve Spring

Components

Name
1. Camshaft Bearing Cap 6. Valve Spring
2. Camshaft Bearing 7. Spring Upper Seat
3. Camshaft 8. Split Collar
4. Rocker Arm Shaft ASM 9. Bridge
5. Valve Stem Oil Seal 10. Valve Spring Seat
Removal 5. Remove the bridge (2).

1. Remove the cylinder head cover. Caution:
Refer to “Cylinder Head Cover”. Keep the removed bridge and bridge cap properly so
2. Remove the rocker arm shaft ASM. that they may be put back to the original place.
4. Remove the bridge cap (1).
8. Remove the valve spring.
Put the removed valve springs in order by cylinder
number.
9. Remove the valve stem oil seal.
• Use pliers to remove the oil seal.
10. Remove the valve spring seat.
Name
1. Bridge Cap
2. Bridge
Caution:
hole into which oil pours back in the front. Caution:
Do not reuse the removed oil seal.
6. Remove the split collar.
• Apply compressed air over the cylinder from the
glow plug holes to keep the valve at the home Inspection
position.
Check the valve spring.
• Use a replacer to compress the valve spring to Caution:
remove the split collar. Check the valve spring visually and if there is clear
damage or wear-out, replace it.
Special tool 1. Free length
Valve spring replacer: 5-8840-2621-0 (J-43263)
• Measure free length of the spring and if it is shorter
Pivot: 8-9439-6862-0 (EN-46721)
than the specified limit, replace the spring.
4HK1
Free length of the valve spring mm (in)

Intake air Exhaust
Standard 65.9 (2.59) 68.1 (2.68)
Limit 62.9 (2.48) 65.1 (2.56)
6HK1
Free length of the valve spring mm (in)

Intake air Exhaust
Standard 59.9 (2.36) 68.1 (2.68)
Limit 58.7 (2.31) 66.7 (2.63)
7. Remove the spring upper seat.

• Remove the special tool to remove the upper seat.
4HK1
Tension of the valve spring N (lb)

Intake air Exhaust
Installation
46.0 (1.81) 46.0 (1.81)
length mm (in)
Standard 348 (78) 383 (86)
Limit 330 (74) 356 (80)
6HK1
Tension of the valve spring N (lb)

Intake air Exhaust
Installation
46.0 (1.81) 46.0 (1.81)
length mm (in)
Standard 348 (78) 378 (38.5)
2. Valve spring squareness
• Use a surface plate and a square to measure the Limit 309 (31.5) 329 (33.5)
valve spring squareness.
If the measured value exceeds the specified limit,
the valve spring must be replaced.
4HK1
Valve spring squareness mm (in)

Limit 3.0 (0.12)
6HK1
Valve spring squareness mm (in)

Limit 3.4 (0.13)
Installation
1. Install the valve stem oil seal.
• Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a valve
stem seal installer.
Caution:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted or
the garter spring has not come off.
3. Tension
• Use a spring tester to compress the spring to the
installation height. Measure tension of the
compressed spring. If the measurement is lower
than the limit, replace the spring.
Special tool 3. Install the spring upper seat.
4HK1 4. Install the split collar.
Valve stem seal installer: 8-9439-6815-0 (EN-47685) • Apply compressed air over the cylinder from the
6HK1 glow plug holes to keep the valve at the home
Valve guide oil seal installer: 5-8840-2625-0 (J- position.
43267)
• Use a replacer to compress the valve spring and
install the split collar.
Special tool
Pivot: 8-9439-6862-0 (EN-46721)
2. Install the valve spring.

• Install it with the paint mark or the narrow side of
the spring pitch being the lower side (cylinder head
side).
Paint mark 5. Apply engine oil over the bridge and install it.
Intake air Light blue Caution:

Move it up and down to check if it moves smoothly.
Exhaust Yellow
6. Apply engine oil over the bridge cap and install it.
Caution:
hole into which oil pours back in the front.
Name
1. Spring Pitch
2. Paint Mark
Special Tool
5-8840-2621-0
J-43263
Valve spring replacer
8-9439-6862-0
EN-46721
Pivot ASM
Name
1. Bridge Cap
2. Bridge
7. Install the camshaft ASM. 8-9439-6815-0

Refer to “Camshaft ASM”. EN-47685
8. Install the rocker arm shaft ASM. Valve stem seal installer
Refer to “Rocker Arm Shaft ASM”. (4HK1)
5-8840-2625-0
J-43267
Valve guide oil seal
installer
(6HK1)
Cylinder Head
Components

Name
1. Bridge Cap 9. Idle Gear C Cover
2. Bridge 10. Idle Gear C
3. Bridge Guide 11. Glow Plug
4. Split Collar 12. Intake And Exhaust Valves
5. Spring Upper Seat 13. Cylinder Head
6. Valve Spring 14. Valve Spring Seat
7. Valve Stem Oil Seal 15. Thermostat
8. Valve Guide 16. Water Outlet Pipe
Caution: Removal
To avoid electric shock;
1. Drain the coolant.
Set the switch to the ‘OFF’ position and disconnect
battery negative cable before checking or repairing the 2. Remove the engine harness.
fuel injector, wiring or/and connectors. 3. Disconnect the front exhaust pipe.
4. Remove the turbocharger.
Refer to the “Turbocharger and Exhaust Manifold”.
5. Remove the left-hand EGR adapter and right-hand
EGR pipe.
6. Remove the EGR water feed pipe.
7. Remove the EGR water return pipe.
8. Remove the EGR cooler.
9. Remove the water feed pipe for coolant water for
the EGR cooler and the water return pipe.
Name
1. Harness Bracket
2. Harness Connector
3. Fuel Injector Terminal Nut
4. Nozzle Leak-Off Pipe
17. Remove the fuel leak-off hose.

18. Remove the fuel leak-off pipe (2).
* 4HK1 is shown for illustration. 4HK1
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
10. Remove the fan guide bracket.

11. Remove the left-hand intake pipe between the
inter-cooler and the inlet duct.
13. Remove radiator upper hose.
14. Loosen the fuel injector terminal nuts alternately to
the same level, and remove the terminal.
15. Loosen the fuel injector harness bracket bolt,
remove the inside connector, and remove the
harness bracket.
Name
16. Remove the nozzle leak-off pipe (4).
1. High Pressure Pipe
2. Leak-Off Pipe
6HK1 6HK1
1
1 2
WSHK0019 !"#$$%$
Name Name
1. High Pressure Pipe 1. Water Bypass
2. Leak-Off Pipe
20. Remove the EGR valve and EGR valve connector.
19. Remove the water bypass hose from the cylinder 21. Remove the cam angle sensor connector.
head side.
• Remove the engine coolant temperature sensor Refer to “Rocker Arm Shaft ASM”.
connector.
4HK1 Refer to “Camshaft ASM”.
24. Remove the bridge cap carefully so that it does not
fall into inside the engine.
25. Remove the bridge.
Caution:
Store the removed bridge and bridge cap so that they
can be placed in their original locations.
26. Remove the glow plug connector.
27. Remove the glow plug.
Name
1. Water Bypass
28. Remove the injection pipe clip, and remove the 31. If you have difficulty in removing the fuel injector,
injection pipe. set the fuel injector remover in the fuel injector,
4HK1 tighten the attachment part on the joint of the leak-
off pipe and pull out the fuel injector upward.
Special tool
Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)
Caution:
When removing an fuel injector ID code, be sure to
attach the cylinder number.
When pulling out the fuel injector using a special tool,
check that the fuel injector sleeve does not come off.
Name
1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip
6HK1
Name
1. Sliding Hammer
2. Fuel Injector Remover
WSHK0021
3. Fuel Injector ASM
Name
1. Fuel Injection Pipe Caution:
2. Fuel Injection Pipe Clip Attach a cylinder number to the removed fuel injector
when storing it.
29. Remove the common rail. Be sure not to make the nozzle touch something.
• Remove the common rail pressure sensor
connector.
30. Remove the fuel injector bracket.

6HK1
32. Remove the lower head cover. WSHK0022

• Loosen the cylinder head bolts in the order Disassembly
described in the drawing.
1. Remove the case ASM.
Caution: • Be sure not to lose the gasket.
Be sure not to overlook (1) and (2) because they are
attached with the flywheel housing with M10 bolts. 2. Remove the inlet cover.
• Remove the cylinder head gasket. • Remove liquid gasket adherent to the removed
inlet cover.
Caution:
Replace the head gasket with a new one once it was
removed.
4HK1

3. Remove the A/C compressor bracket.
4. Remove the exhaust manifold.
• Remove the heat protector and remove the
exhaust manifold.
5. Remove the exhaust gasket.

6. Disconnect the water outlet pipe.
7. Remove the thermostat.

Name
8. Remove the idle gear C cover. 1. Idle Gear C
• Put the edge of a driver on the outer circle of the 2. Shaft
sealing cup as shown in the drawing, tap it lightly,
reverse it, then pull it out with pliers or other 10. Remove the split collar.
equipment. 11. Remove the spring upper seat.
12. Remove the valve spring.
• Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Pivot: 8-9439-6862-0 (EN-46721)
• Remove the special tool, then remove the upper
sheet and springs.
Sort the removed valve springs by cylinder

number.
9. Remove the idle gear C.
13. Remove the intake and exhaust valves.

• Sort the removed valves according to cylinders by
using tags and others.
Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272)
14. Remove the valve stem oil seal.

• Use pliers to remove the oil seals.
16. Put the nozzle sleeve remover on the nozzle
sleeve from the bottom side of the cylinder head,
then pull out the nozzle sleeve.
Special tool
Nozzle sleeve remover: 5-8840-2623-0 (J-43265)
Caution:
• Be sure not to scratch the bottom side of the
cylinder head.
• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.
15. Remove the valve guide.

• Use the valve guide replacer to press out the
valve guides from the bottom side of the cylinder
head.
Name
1. Nozzle Sleeve
17. Remove the bridge guide.

• Electrically weld the nut on the head of the bridge
guide, attach the sliding hammer and pull it out.
• Check the following causes in the case of leak of
the seal surface of the cylinder head, corrosion, air
leak and defective gasket.
– Improper installation
– Defective tightening of the cylinder head.
– Winding seal surface of the cylinder block.
a. Damage on the screw surface or extracted
cylinder head bolt due to extra tightening torque
Caution:
Replace suspicious bolt.
b. Inside the combustion chamber, glow plug hole.
• Check whether there is a crack between the
valve seats and in the cylinder head of the
exhaust port part, and replace the cylinder head
if there is serious damage or crack. Check the
collar if necessary.
Name
1. Nut
18. Remove the oil seal.

• Press the tool against the oil seal. Strike the tool to
remove the seal from the inside of the cylinder
head.
c. Flatness of the under surface of the cylinder

head
• Use a straight edge ruler and sickness gauge to
measure the four sides and diagonal lines as
shown in the drawing, and replace if they
exceed the limit.
Distortion of the under surface of the mm (in)

cylinder head
Inspection Standard 0.05 (0.002) or less
1. Check the cylinder head ASM. Limit 0.20 (0.0079)
• Remove varnish, soot and others adhered on the
metal surface completely. Use metal brush and
others so that the seal surface of the surface
where the gasket is installed is not hurt.
Distortion of the exhaust manifold mm (in)

Standard 0.3 (0.0118) or less
Limit 0.5(0.0197)

d. Flatness of the surface where the exhaust
manifold and inlet cover are installed
measure the four sides and diagonal lines as
shown in the drawing, and replace if they
exceed the limit.
2. Bridge cap
Distortion of the surface where the mm (in) • Inspect abrasion and deformation of the surface
manifold and cover are installed where the cap and the rocker arm adjust bolt
Standard 0.05 (0.002) or less contact.
Limit 0.2 (0.0079) • If the amount of abrasion is 0.1 mm (0.0039 in) or

larger, or if it abrades away in a zonal shape,
replace it.
Abrasion of the bridge cap mm (in)

Limit 0.1 (0.0039)

e. Flatness of the exhaust manifold
measure the flatness. If it exceeds the limit,
replace the exhaust manifold.
3. Bridge 6HK1
• Make sure the bridge moves smoothly along the
bridge guide. The external diameter of the valve stem mm (in)
Standard Limit
• Measure the gap between the bridge and bridge
guide. Intake valve 8 (0.315) 7.88 (0.3102)
Exhaust valve
Gap mm (in)
Assembly standard 0.020 (0.00079) a
0.057 (0.00224)
Usage limit 0.1 (0.0039)
• Measure the gap between the valve guide and

valve stem within 10 mm (0.39 in) from the
valve guide, using a dial gauge.
• If the measured value exceeds the limit, replace
the valve guide and valve altogether.
4HK1
Name
1. Bridge Gap between the valve guide and mm (in)
2. Bridge Guide valve stem
Standard Limit
4. Check the valve guide.
Intake valve 0.038 (0.00150) – 0.20 (0.00787)
Caution: 0.071 (0.00280)
If there is a scratch or abnormal abrasion in the valve
stem and the inner diameter part of the valve guide, Exhaust valve 0.064 (0.00252) – 0.25 (0.00984)
replace it with new one along with valve guide. 0.096 (0.00378)
a. Measure the valve guide clearance.
6HK1
• Measure the diameter of the valve stem with a
micro meter. Gap between the valve guide and
If the diameter of the valve stem is smaller than mm (in)
valve stem
the limit, replace the valve and valve stem
altogether. Standard Limit
4HK1 Intake valve 0.039 (0.00153) – 0.20 (0.00787)
0.062 (0.00244)
The external diameter of the valve stem mm (in)
Exhaust valve 0.064 (0.00252) – 0.25 (0.00984)
Standard Limit 0.096 (0.00378)
Intake valve 8.946 (0.3522) – 8.88 (0.3496)
8.962 (0.3528)
Exhaust valve 8.921 (0.3512) – 8.80 (0.3465)
8.936 (0.3518)
4HK1
Thickness of valve mm (in)

Standard Limit
Intake valve 1.8 (0.0709) 1.3 (0.0512)
Exhaust valve 1.75 (0.0689) 1.3 (0.0512)
6HK1
Thickness of valve mm (in)

Standard Limit
Intake valve 1.88 (0.074) 1.3 (0.0512)
Exhaust valve 1.75 (0.0689) 1.3 (0.0512)
5. Inspect abrasion of the bridge gap.

• Measure the contact surface of bridge cap and the
rocker arm, using a dial gauge.
• If the abrasion exceeds the limit, or there is an

abnormal abrasion (zonal abrasion), replace the
bridge cap.
Abrasion of the bridge cap mm (in)

Limit 0.1 (0.00394)
Valve seat
• Remove carbon, water stain and others on the
under surface of the cylinder head.
Install the valve in the cylinder head.
Measure the depth of the valve from the under
surface of the cylinder head, using a depth
gauge or straight edge ruler.
If the value exceeds the limit, replace the valve
insert or the cylinder head ASM.
4HK1
Depth of the valve mm (in)

Standard 0.7 (0.0276) a 1.2 (0.0472)
6. Check the valve. Limit 2.5 (0.0984)
Thickness of valve
• Measure the thickness of the valve. 6HK1
Depth of the valve mm (in)
the valve and valve guide altogether.
Standard Limit
Intake valve 1 (0.039) 2.5 (0.098)
Exhaust valve 1.3 (0.051) 2.8 (0.11)
• Measure the contact width of the valve seat. If Repair of the seat surface
the seat contact surface has a scratch or is
• Remove carbon from the surface of the valve
rough, or if the abrasion of the contact surface
seat.
exceeds the limit, modify or replace it.
• Use a seat cutter to minimize the scratch and
Contact width of the valve seat mm (in) other roughness (15/45/75q-blade), thereby
returning the contact width to the standard
Standard Limit value.
Intake valve 2.5 (0.0984) 3.0 (0.1181)
Exhaust valve 2.0 (0.0787) 2.5 (0.0984)
Caution:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Contact surface of the valve seat
Do not let the valve cutter pilot waver inside the valve
• If the contact surface of the valve seat is guide.
defective, modify it or replace the valve, valve
guide and valve seat altogether.
Angle of the contact Exhaust side of 4HK1 and
surface: 6HK1: 45q
Intake side of 6HK1: 30q
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve
seat insert.
• Cool the valve seat insert for two to three
minutes. Contraction fur to cooling makes it
easier to remove the valve seat insert.
• Remove the valve seat insert, using a screw
driver. Be sure not to hurt the cylinder head.
• Attach compound in the valve insert seat.

• Insert the valve into the valve guide.
• Attach compound on the valve seat surface,
rotate the valve and hit it lightly to grind them,
and confirm that it has even contact all round.
Caution:
Remove compound completely after grinding.
Name
1. Arc-Weld
2. Valve Seat Insert
3. Screw Driver
Install the valve seat insert

• Carefully place a washer (the outer diameter is
smaller than the valve seat insert) on the valve
seat insert.
• Use the press to apply pressure gradually on
the washer, thereby pushing the valve seat
insert.
Caution:
Do not apply too much pressure with the press.
Attach compound on the valve seat surface, rotate the
valve and hit it lightly to grind them, and confirm that it
Replace the valve seat insert has even contact all round.
Name Name
1. Press 1. Cylinder Head
2. Attach Compound 2. Oil Seal Installer
3. Valve Seat
2. Install the bridge guide.
• Apply engine oil on the outer diameter of the guide,
Reassembly then use the installer to hammer it into the depth of
the finishing part of the hole of the cylinder head.
1. Install the oil seal. (Note: the height of the bridge guide is about
• Install on the surface of injection pipe insert. 37.5 mm (1.48 in) from the upper surface of the
head)
• Hammer it in so that the seal does not incline.
Special tool
Caution: Bridge guide installer: 5-8840-2626-0 (J-43268)
Be sure not to hurt the rip. Engine oil
Special tool
Oil seal installer: 5-8840-2627-0 (J-43269)
3. Nozzle sleeve
• Install the O-ring on the nozzle sleeve, apply
engine oil.
• Apply seal material on the taper section.
Loctite No. TL620

Special tool
Nozzle sleeve installer: 5-8840-2624-0 (J-43266)
Name
1. Apply Seal Material
2. O-Ring Name
1. Punch Bar
• Install the nozzle sleeve on the cylinder head, 2. Ball
insert the guide sleeve. 3. Guide Sleeve
4. Nozzle Sleeve
• Use the guide sleeve to push in so that the nozzle 5. Bracket
sleeve fully contacts with the under surface of the 6. Bolt
cylinder head.
4. Install the valve guide.
• Insert the sleeve and fix it with the tighten and bolt.
• Hammer in the valve guide from the upper surface
• Insert the ball (bearing steel ball 9.525 mm of the cylinder head, using the valve guide
0.375 in) into the guide sleeve, attach the punch replacer.
bar and hammer out the ball.
Caution:
• Leave the cylinder head floating so that the ball
comes off from the under surface.
Special tool Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272) 4HK1
Valve stem seal installer: 8-9439-6815-0 (EN-47685)
6HK1
Valve guide oil seal installer: 5-8840-2625-0 (J-
43267)
Height from the upper surface of the cylinder head

to the edge surface of the valve guide: 13.9 mm
(0.5472 in) – 14.3 mm (0.5630 in)
Caution: 6. Install the intake and exhaust valves.

When replacing the valve guide, it must be replaced • Apply engine oil on the valve stem part and install
together with the valve. the valve.
5. Install the valve stem oil seal. 7. Install the valve spring.
• Apply engine oil on the outer diameter of the valve • Install the valve spring with the paint mark or the
guide, use the valve stem seal installer to install narrower side of the spring pitch on the under side
the oil seal. (the cylinder head side).
Caution:
After installation of the valve stem seal, confirm that the Paint mark
oil seal is not inclining and the garter spring is in place.
Intake side Light blue
Exhaust side Yellow
Name
1. Spring Pitch
2. Paint Mark Name
1. Idle Gear C
8. Install the spring upper seat. 2. Shaft
9. Install the split collar.
11. Install the idle gear C cover.
• Use a replacer to compress the valve spring and
install the split collar. • Apply liquid gasket (Loctite 262 or 962T) on the
outer diameter of the idle gear C cover, use the
Special tool sealing cup setting tool to hammer it in so that the
Valve spring replacer: 5-8840-2621-0 (J-43263) measurements follow the drawing.
Pivot: 8-9439-6862-0 (EN-46721)
Special tool
Sealing cup installer: 5-8840-2222-0 (EN-47690)
10. Install the idle gear C. WSHK0023

• Apply engine oil on the idle gear C shaft and the 12. Install the thermostat.
inner diameter of the idle gear, install the idle gear
C so that the side with gear groove is on the side of • Install the thermostat on the position shown in the
the rear surface of the engine. drawing.
• Tighten the idle gear C to the specified torque.
• Do not use impact wrench and like.

4HK1 4HK1
6HK1
Name
1. Thermostat
6HK1
WSHK0025
14. Install the exhaust gasket.

15. Install the exhaust manifold.
WSHK0024 • Install the distance tube conical spring and the nut
on the stud of the cylinder head in this order.
Name
1. Thermostat
13. Connect the water outlet pipe.

• Tighten the water outlet pipe to the specified
torque.
• Tighten it up together with the fan shroud bracket.

6HK1
WSHK0014
Name • Install the heat protector.
1. Distance Tube
2. Conical Spring
3. Nut
16. Install the inlet cover.
• Tighten the exhaust manifold in the order • Apply liquid gasket (ThreeBond 1207C or
described in the drawing. equivalent) in accordance with the groove of the
inlet cover, with the bead diameter of I2.5 mm
Tightening torque: 34 Nm (25 lb ft) (0.0984 in) ~ 5.5 mm (0.2165 in).
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
4HK1

• Tighten in the order described in the drawing.
• Tighten the stud bolts (6) and (9) jointly with the
common rail.

4HK1

6HK1
Installation
1. Install the cylinder head gasket.
• Select the cylinder head gasket. (4HK1 only)
• Clean the head of the piston and the upper surface

of the cylinder block.
13 9 5 4 3 8 12
• Use a dial gauge to measure the extrusion of the
piston. Measure at two points of each cylinder.
• The following drawing shows the measurement

14 10 6 1 2 7 11
points and the standard point of the cylinder block.
WSHK0026
17. Install the inlet pipe.

Measurement Head of the piston (2) and (3)

points:
Standard point: Upper surface of the (1)
cylinder block
Caution: 4HK1 only
Note that there are three options for the head gasket
according to the amount of extrusion of piston shown in
the following table. (4HK1 only)
• Calculate the average piston extrusion amount of
each cylinder. (4HK1 only)
• Calculate the maximum amount of the average

amount of each cylinder. (4HK1 only)
• Select a gasket of an appropriate grade based on

the maximum protrusion amount. (4HK1 only)
Name
1. Grade Recognition Hole
• Apply liquid gasket
• Apply liquid gasket (ThreeBond 1207B or

equivalent) on the joint (1) of the cylinder block and
the flywheel housing with the bead diameter of
3 mm (0.118 in).
• Install the cylinder head within seven minutes after

applying liquid gasket.
Gasket Recognized Piston protrusion mm (in)
Grade amount
0.539 (0.2122) a
A (no hole)
0.618 (0.02433)
0.619 (0.02437) a
B (1 hole)
0.698 (0.02748)
0.699 (0.02752) a
C (2 holes)
0.779 (0.03067)
(4HK1 only)
• Install the cylinder head gasket.
• Install the cylinder head gasket with the parts

number upside, along with the cylinder head rear
gear case and knock pin.
Tightening torque:
M14 bolt (4HK1: 1 ~ 18, 6HK1: 1 ~ 26)
2nd step = 147 Nm (108 lb ft)
3rd step = 30q ~ 60q
M10 bolt (4HK1: 19, 20; 6HK1: 27, 28)
4th step = 38 Nm (28 lb ft)
Use a stud bolt for (4HK1: 16).
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
4HK1

• Install the cylinder head, adjusting the knock pin of
the cylinder block.
Caution:
Be sure not to hurt the head gasket when installing it.
6HK1

• Apply molybdenum disulfide on the screw part and
setting face of the head bolt of M14, and apply
engine oil on the screw part and setting face of the
head bolt of M10.
• Use a torque wrench and angle gauge to tighten WSHK0027

the head bolts in the order described in the
3. Install the fuel injector on the cylinder head.
drawing.
4. Apply molybdenum disulfide on the screw part and
setting face of the fuel injector tighten bolt and
tighten it tentatively.
Important:
Reinstall each fuel injector to the original cylinder from
which it was removed during the disassembly
procedure.
Name
1. Fuel Injector ASM
2. Fuel Injector Tighten Bolt

Tightening torque: 19 Nm (14 lb ft) * 4HK1 is shown for illustration.
• Install the common rail pressure sensor. Name

1. Fuel Injection Pipe
6. Install the injection pipe. 2. Fuel Injection Pipe Clip
• Apply a thin coat of engine oil on the outer
diameter of the sleeve nut on the side of the fuel 7. Final tighten the injection clamp bolts to the
injector and install the injection pipe. specified torque.
• Use a spanner to tighten the sleeve nut until it
completely contacts both on the fuel injector and 8. Tighten the injection pipes to the specified torque.
common rail. Tightening torque: 44 Nm (32 lb ft)
• Tighten the injection pipe clip with the designated
torque.


Name
Name 1. Bridge Cap
1. Injection Clamp Bolt 2. Bridge
2. Injection Pipe Sleeve Nut
9. Install the glow plug. Refer to “Camshaft ASM”.
Tightening torque: 20 Nm (15 lb ft) 14. Install the rocker arm shaft ASM.
10. Install and tighten the glow connector with the
15. Install and tighten the camshaft speed sensor with
designated torque.
the designated torque.
Tightening torque: 1.2 Nm (10.5 lb in)
11. Apply engine oil over the bridge and install it.
Caution:
Move it up and down to check if it moves smoothly.
12. Apply a thin coat of engine oil inside the bridge
cap, install it.
16. Connect the water bypass hose.

• Install the engine coolant temperature sensor on
the thermostat housing.
17. Install the leak off pipe.

Leak off pipe tightening torque:
18. Install the fuel leak-off hose.
• Install the fuel leak-off hose on the fuel leak-off 4HK1
pipe and fix it with a clip.
19. Clip a new gasket to the fuel nozzle leak-off pipe

and install the fuel leak-off pipe.
6HK1
!"#$$%&
21. Install the terminal nuts on the fuel injector.
Caution:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
20. Install the fuel injector harness connector from
unified.
inside, tighten the harness bracket with the
designated torque. • Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
26. Connect the exhaust pipe.
• Connect the front exhaust pipe and tighten to the
specified torque.
Exhaust manifold side

Exhaust brake side

27. Install the engine harness.
28. Replenish the coolant.
Name
1. Fuel Injector
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut

23. Connect the radiator upper hose.
24. Install the EGR valve & EGR cooler.
For details of installation, refer to “EGR Valve and
EGR Cooler” of the section of exhaust system.
Name
1. EGR Adapter
2. Water Return Pipe
3. EGR Cooler
4. EGR Pipe
5. Water Feed Pipe
25. Install the oil level gauge and guide tube.

Special Tool
Illustration Tool Number/Description Illustration Tool Number/Description
8-9439-6815-0
5-8840-0019-0
EN-47685
J-23907
Valve stem seal installer
Sliding hammer
(4HK1)
5-8840-2625-0
5-8840-2628-0 J-43267
J-43272 Valve guide oil seal
Valve guide replacer installer
(6HK1)
5-8840-0266-0
5-8840-2621-0
J-45059
J-43263
KM470-B
Valve spring replacer
Angle gauge
5-8840-2624-0 8-9439-6862-0
J-43266 EN-46721
Nozzle sleeve installer Pivot ASM
5-8840-2626-0 5-8840-2222-0
J-43268 EN-47690
Bridge guide installer Sealing cup installer
5-8840-2627-0
J-43269
Oil seal installer
5-8840-2623-0
J-43265
Nozzle sleeve remover
5-8840-2826-0
EN-46720
Fuel injector remover
Piston, Connecting Rod

Components
Name
1. Snap Ring 5. Connecting Rod
2. Piston 6. Piston Pin
3. Bearing 7. Piston Ring
4. Connecting Rod Cap
Removal
Refer to “Oil Pan”.
5. Remove the cylinder head.
6. Remove the connecting rod cap.
Caution:
Sort the removed bearings according to cylinders by
using tags.
7. Remove the piston and connecting rod.

• Remove carbon on the upper side of the cylinder
liner with a scraper.
• Pull out the piston and connecting rod towards the

cylinder head.
Caution:
Be sure not to damage the oil jet and cylinder liner
when pushing out the connecting rod.
2. Remove the snap ring.

3. Remove the piston pin.
Caution:
Sort the disassembled piston pins, pistons and
connecting rods together in the order of cylinders.
8. Remove the connecting rod bearing.
Caution:
Sort the bearings in the order of cylinders when reusing
them so that they will not be confused with the bearing
of other cylinders.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Caution:
Sort the piston rings in the order of cylinders when
reusing them so that they will not be confused with the
pistons and piston rings of other cylinders.
4. Remove the connecting rod from the piston.
5. Piston
• Clean carbon carefully that is adhered to the head
of the piston and the groove of the piston ring.
Caution:
Do not use wire brush to clean the piston because it
scratches the piston.
Inspect the piston with eyes for cracks, burns and other
excessive wear, and replace it if there is any
abnormality.
6. Measure the gap between the piston and the inner
diameter of the cylinder liner.
Cylinder liner inner diameter Gap between the piston and the inner mm (in)
• Use a cylinder bore dial indicator to measure the diameter of the cylinder liner
liner inner diameter both in the thrust and radial
directions in the designated position. Standard 0.082 a 0.130
(0.0032 a 0.0051)
• Measurement position (from the upper surface of
the cylinder block) 6HK1
1. 20 mm (0.79 in) 2. 110 mm (4.33 in)
3. 190 mm (7.48 in) Piston diameter mm (in)
• Measure the liner inner diameter based on the Standard 114.974 a 114.989
average value of the actual measurement values (4.52652 a 4.52711)
on 6 positions.
Gap between the piston and the inner mm (in)
Cylinder liner inner diameter mm (in) diameter of the cylinder liner
115.021 a 115.050 (4.52838 a 4.52952) Standard 0.042 a 0.066
(0.00165 a 0.00259)
Caution:
If it is found that the gap between the cylinder liner
inner diameter and the piston exceeds the standard
value, replace the piston or cylinder liner.
Name
1. 20 mm (0.79 in)
2. 110 mm (11.00 cm)
3. 190 mm (19.00 cm)
7. Piston replacement
Piston outside diameter
• You do not need to select grades because there is
• Use a micrometer to measure the outside diameter
only one grade for each of the piston and the
of the piston in the right angle to the piston pin in
cylinder liner inner diameter.
the designated position.
If you replace the cylinder liner, you must select
• Measurement position (from the upper surface of the cylinder block (1, 2, 3) because there are two
the piston) 82 mm (3.2 in). types of the liner outer diameter.
• Refer to “Cylinder Block” if you replace the cylinder
4HK1 liner.
Piston diameter mm (in) Caution:

Standard 114.920 a 114.949 The head of piston has a marking of grade B or C when
(4.52440 a 4.52554) it is shipped from the factory.

Name piston ring.
1. Front Mark Cut
8. Inspect the piston ring. Piston ring gap mm (in)

Measure the joint of the piston ring (remove carbon
on the ring joint) Standard Limit
• Insert the piston ring into the cylinder liner. Top ring 0.2 – 0.3 1.2
(0.0079 – 0.0118) (0.047)
• Use the piston to push the ring to reach the under
Second ring 0.3 – 0.45 1.2
edge of the cylinder liner.
(0.0118 – 0.0177) (0.047)
Oil ring 0.2 – 0.04 1.2
(0.0079 – 0.0157) (0.047)
Measure the clearance between the piston ring

groove and the piston.
• Remove carbon on the piston ring groove
completely.
• Put the piston ring in the piston ring groove, use a

sickness gauge to measure the gap between
them.
• If the clearance between the piston ring groove

and the piston exceeds the limit, replace the piston
and the piston ring.
Piston ring and piston ring groove mm (in)

• Use a sickness gauge to measure the gap of the clearance
ring joint.
Piston ring Standard Limit
Top ring 0.067 – 0.087 0.20
(0.0026 – 0.0034) (0.0079)
Second ring 0.03 – 0.07 0.15
(0.0012 – 0.0028) (0.0059)
Oil ring 0.01 – 0.03 0.15
(0.0004 – 0.012) (0.0059)
9. Inspect the piston pin. • Inspect to make sure that there is a resistance to
• Inspect the piston pin with eyes for cracks, the extent which the piston can push the piston pin
scratches and other damages, replace it if lightly in normal temperatures.
necessary.
• If it feels a large looseness or instability in normal
• Use a micrometer to measure the outer diameter temperatures, replace the piston or piston pin.
of the piston pin. If the measured value exceeds
the limit, replace the piston pin.
4HK1
Piston pin outer diameter mm (in)

Standard 35.995 – 36.000 (1.4171 – 1.4173)
Limit 35.970 (1.4161)
6HK1
Piston pin outer diameter mm (in)

Standard 4.0 (1.5748)
Limit 39.95 (1.5728)
• Measure the bush of the small edge of the

connecting rod. If the clearance between the
bushing inner diameter and the pin diameter
exceeds the limit, replace the bushing or
connecting rod ASM, and the pin.
Piston pin and connecting rod small end mm (in)

bushing clearance
Standard 0.012 – 0.027
(0.0005 – 0.0011)
Limit 0.05(0.0020)
10. Measure the clearance between the piston and the

piston pin. Name
1. Setting Bar
• Apply engine oil on the piston pin. Use your finger 2. Connecting Rod
to push it in the piston hole and rotate it. If the pin 3. Nut
smoothly rotates without instability, the clearance 4. Collar
is normal. If there is instability, measure the 5. Bushing
clearance. If the clearance exceeds the limit, 6. Collar
replace the piston and the piston pin.
• Place the connecting rod bushing replacer base on
Piston pin and piston pin hole clearance mm (in) the bench press, tighten the fixation bolt.
Standard 0.004 – 0.017 (0.00016 – 0.00067) • Use the bench press to replace the bush.
Limit 0.04 (0.0016)
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
11. Remove the bushing. (EN-47682)
• Set the collar, connecting rod and collar on the
setting bar as shown in the drawing.
• Tighten the nut.
Name
1. Bolt
2. Connecting Rod Bushing Replacer
12. Measure the connecting rod alignment.

• Use a connecting rod aligner to measure the
torsion and parallel level of the big end hole and
the small end hole. If the measured value exceeds
the limit, replace it.
Connecting rod alignment mm (in)

(per length of 100 mm (3.94 in))
Standard Limit
Distortion and 0.05 (0.002) 0.20 (0.008)
Parallelism
– Remove the cap.

– Measure the largest width of the plastigauge to
calculate the oil clearance. If the clearance
exceeds the limit, replace the bearing ASM.
Crank pin and bearing clearance mm (in)

Standard 0.036 – 0.077 (0.0014 – 0.0030)
Limit 0.10 (0.0039)
– Remove the plastigauge from the bearing and

crank pin.
13. Measure the bearing oil clearance.
• Measure the oil clearance between the connecting
rod bearing and the crank pin with the following
method.
– Remove the connecting rod cap. Sort the

removed caps according to the cylinder
number.
– Clean the bearing and the shaft pin.
– Check the bearing. If it is damaged or worn
seriously, replace the bearing ASM.
• Place the plastigauge on the crankshaft pin.
• Install the bearing cap and tighten the bolt with the
designated torque.
Apply molybdenum disulfide on the screw part and
the bearing surface.
Connecting rod bearing cap bolt torque: Nm (lb ft) 14. Select the connecting rod bearing.
1st step 39 (29) • Refer to the bearing selection table when installing
a new connecting rod or replacing bearings in use.
2nd step 60q
3rd step 30q • Select and install the bearing, paying attention to
the large edge hole diameter of the connecting rod.
Caution:
Do not rotate the crankshaft.
Reassembly
1. Install the bush
• Place the connecting rod bushing replacer base on
the bench press, set the connecting rod and
tighten the fixation bolt.
Special tool
Connecting rod bushing replacer: 5-8840-2340-0
(EN-47682)
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
Bearing selection table

Big end hole Bearing Oil clearance
diameter recognition
mm (in)
Grade color
Name
A Green 0.036 – 0.077 1. Bolt
(0.0014 – 0.0030) 2. Connecting Rod Bushing Replacer
B Yellow 0.036 – 0.077
(0.0014 – 0.0030) • Set the collar, new bushing and collar on the
setting bar as shown in the drawing.
• Tighten the nut.
• Adjust the oil hole of the connecting rod and the oil
hole of the bush, and use the bench press to install
the bush.
Name
1. Grade Identification Color
Name Name
1. Setting Bar 1. Snap Ring
2. Connecting Rod 2. Front Mark
3. Nut 3. Forging Mark (Projecting)
4. Collar
5. Bushing 4. Apply enough engine oil on the piston pin, push it
6. Collar in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
• After installing the new bush, use a grinder to
machine the pin hole so that the pin clearance Caution:
equals the standard value. Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.
2. Install the piston.

3. Install the connecting rod.
• Install it so that the front mark of the head of the 6. Use piston ring setting tool to install the piston ring.
piston and the connecting rod forging mark • Install the oil ring so that the joint angle of the ring
(projecting) on the connecting rod face the same and coil expander is in the opposite 180q direction.
direction.
• Install the top ring and second ring in this order so
• Use snap ring pliers to install the snap ring of one that the marks “1N”and “2N” face upward.
side.
Special tool Make sure that there is not gap in the position indicated
Piston ring setting tool: 1-8522-1029-0 in the drawing when the oil ring coil expander was
installed.
Name
1. Oil ring
2. Second Ring Installation
3. Top Ring 1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, apply
6HK1
engine oil on the bearing.
2. Install pistons and connecting rod ASM.

• Apply enough engine oil on the piston ring, ring
groove and piston side surface.
3
• Dislocate the piston ring joint so that (1) is top ring,

(3) is 2nd ring and (2) is oil ring, as shown in the
drawing.
2 • Face the piston front mark cut to forward, use the
piston ring compressor to insert the piston in the
cylinder liner.
Caution:
1 • Be sure not to make the connecting rod touch the
oil jet when pushing in the piston.
• Be sure not to hurt the inside of the liner when
!"#$$%& pushing in the piston.
Name
1. Oil ring
2. Second Ring
3. Top Ring
Caution:
Note that the shapes are different for top ring and
second ring. (Second ring has undercut)
Special tool Special tool
Piston ring compressor: 5-8840-9018-0 (J-8037) Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Make sure that the crankshaft rotates smoothly.
3. Install the connecting rod cap.

• Install the bearing on the connecting rod cap and
apply engine oil.
4. Install the cylinder head.
• Install the cap, matching the numbers (1, 2, 3, 4) of Refer to the “Cylinder Head”.
the caps and connecting rods. 5. Install the camshaft ASM.
8. Install the oil pan.
Name
1. Top And Back Recognition Boss
2. Big End Diameter Grade Mark
3. Cylinder Number
• Apply molybdenum disulfide on the screw part and

the setting face of the tightening bolt and tighten it
with the designated torque.
Tightening torque:
2nd step = 60q
3rd step = 30q
Special Tool
5-8840-2340-0
EN-47682 1-8522-1029-0
Connecting rod bushing Piston ring setting tool
replacer
5-8840-0266-0
5-8840-9018-0
J-45059
J-8037
KM470-B
Piston ring compressor
Angle gauge
Flywheel
Components
Name
1. Flywheel Housing 3. Washer
2. Flywheel ASM 4. Crankshaft Position Sensor
Removal 4HK1
1. Remove the starter motor.
• Remove the ground cable of the starter motor.
• Remove the two nuts on the upper side and lower

side that fix the starter, remove the starter from the
fly wheel housing.
6HK1 Special tool
!"#$$%$
2. Remove the crankshaft position sensor.
• Remove to prevent contact damage when the • Gradually loosen the flywheel installation bolts in
flywheel is removed. the order shown in the drawing so that the flywheel
does not rotate.
• Do not throw or drop because it is vulnerable to
shock. • After loosening all the bolts, remove the stopper to
* 4HK1 is shown for illustration. remove the flywheel.
3. Remove the washer and flywheel. 4. Take out the ring gear.
• Install the crankshaft stopper to the starter • Put a bar on the ring gear and hit it with a hammer
installing portion of the flywheel housing. to remove it.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
Inspection Installation
1. Visual check 1. Install the ring gear.
• Inspect the flywheel friction surface for cracks and • After heating the ring gear with a gas burner
damages, and replace it if it has abnormality. equally, install it in the flywheel.
• Inspect the tooth part of the ring gear, replace the • In the case of shrinkage cooling of the ring gear,
ring gear if it has damage or serious wear. maintain the flatness by applying weight of 68.6 kN
(15,400 lbf).
2. Measurement of the friction surface
• Measure the depth of the flywheel friction surface. Caution:
• Install the ring gear so that the side with a pattern
• Adjust it if the measured value is within the faces forward.
standard value and the limit. • Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is
complete.
the flywheel.
Depth of the friction surface of the flywheel mm (in)

Standard 19 (0.75)
Limit 20 (0.79)
Depth = From the pressure installation surface to the

friction surface.

3. Install the washer.
• Install the flywheel to match with the knock pins of
the crankshaft, tighten them in the order shown in
the illustration.
• Apply molybdenum disulfide on the screw part and 4HK1
setting face of the bolt.
• Install the crankshaft stopper to the starter

installing portion of the flywheel housing.
Tightening torque:
2nd step = 120q a 150q
Special tool
Angle gauge: 5-8840-0266-0 (J-45059)
6HK1
!"#$$%$
• Install the ground cable of the starter motor.
4. Install and tighten the crankshaft position sensor

with the designated torque.
5. Install the starter motor on the flywheel housing
with nuts and tighten them with the designated
torque.
N.m (lb ft)
60 60
WSHK0067
Special Tool
5-8840-2230-0
EN-47680
Crankshaft stopper
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Front Cover
Components
4HK1
6HK1
10 9 8
5
11
12 7 6
WSHK0171
Name
1. Adjusting Plate 7. Crankshaft Pulley
2. Generator 8. Water Pump ASM
3. Front Cover 9. Fan Belt
4. Oil Pan Gasket 10. Water Pump Pulley
5. Oil Pan 11. Spacer
6. Front Oil Seal 12. Fan ASM
Removal
1. Remove the front oil seal.
Refer to “Crankshaft Front Oil Seal”.
3. Remove the water pump.
Refer to the “Water Pump” in the cooling system
section.
4. Remove the front cover.
• Remove the generator adjust plate.
• Install within seven minutes after applying liquid
gasket.
Caution:
Apply liquid gasket so that it does not adhere to the O-
ring.
4HK1
• Remove the oil relief valve (arrow), loosen the front

cover installation bolts and remove the front cover.
Name
1. O-Ring
6HK1
Installation
1. Install the front cover.
• Clean the cylinder block front surface. In particular,
remove liquid gasket leaked during installation of
the crankcase.
• Install two O-rings and apply liquid gasket 020EY00062

(ThreeBond 1207B or equivalent), or each
equivalent along with the groove of the front cover Name
installation surface. 1. O-Ring
• Align with the knock pin of the cylinder block and

Beat width 1.5 a 5mm (0.059 a 0.20 in) install the front cover.
Beat height 0.3 mm a 1.5 mm
(0.012 a 0.059 in) from the joint Caution:
surface Along with the front cover, install the water pump ASM
(before liquid gasket hardens).
4HK1
Tightening torque
Front cover bolt: 24 Nm (18 lb ft)
• Tighten bolt with (*) mark together with the adjust
plate of the generator.
• Tighten the oil relief valve (5) to the specified

1
torque.
Tightening torque
Oil relief valve: 39 Nm (29 lb ft)
WSHK0032
2. Install the water pump.

Refer to the “Water Pump” of the section of the
“Cooling System”
4. Install the front oil seal.
Name
1. Bolt: L = 35
2. Bolt: L = 25
3. Bolt: L = 65
4. Bolt: L = 30
5. Oil Relief Valve
6HK1
Tightening torque
Front cover bolts (13 bolts): 18Nm (13 lb ft)
• Tighten bolt with (*) mark together with the adjust
plate of the generator.
• When you remove the stud bolt (1), install in

original position.
Tightening torque
Stud bolt for water pump: 12.7 Nm (9.4 lb ft)
4HK1
N m{lb ft}
24 {18}
39 {29}
24 {18}
WSHK0037
6HK1
N m{lb ft}
24 {18}
20 {14}
39 {29}
18 {13}
WSHK0164
Crankshaft Front Oil Seal

Components

Name
1. Crankshaft Pulley 2. Crankshaft Front Oil Seal
Removal 4HK1
1. Drain coolant.
2. Remove the starter.
• Disconnect the starter ground cable.
• Unscrew two mounting nuts, upper and lower, from

the starter to dismount the starter from the flywheel
housing.
6HK1 Special tool
!"#$$%$
3. Disconnect the upper radiator hose on the engine
side. 10. Remove the crankshaft front oil seal.
4. Disconnect the coolant reserve tank hose on the • Remove the oil seal off with a screwdriver or the
radiator side. like avoiding damage to the oil seal contact surface
5. Disconnect the lower radiator hose on the engine on the front cover and the shaft.
side.
6. Remove the radiator (with the fan guide) detaching
right and left brackets.
7. Remove the fan ASM.
• Remove the fan ASM unscrewing four mounting
bolts.
8. Remove the fan belt.

9. Remove the crankshaft pulley.
• Loosen the pulley nut blocking the crankshaft from
turning by placing a crankshaft stopper on the
starter mounting position on the flywheel housing.
Caution:
Make sure that the stopper is properly fitted and
engaged with the ring gear.
Name
1. Felt
2. Slinger
3. Oil Seal
Caution:
11. Remove the front slinger.
• Use the slinger remover to remove the front
slinger.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
8-9439-6858-0 (For 6HK1)
1
5
3
2
• After pressing in the slinger, make sure that the

distance between crankshaft end surface and the
slinger is A as specified.
4HK1
Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
6HK1
• Install the slinger (1) to the end of adapter (2).

Distance (B): 34r0.1 mm (1.3r0.004 in)
6HK1 Special tool
4HK1
6HK1
(Use the parts listed below for the front oil seal.)
No. Part Name Oil seal

1 Sleeve (front) {
A
2 Adapter (front) {
3 Adapter ring (front) {
4 Washer (front) {
5 Center bolt {
6 Fixing bolt {
• Mount the adapter onto the crankshaft with fixing

bolts.
Distance (A): 18r0.3 mm (0.7r0.01 in)
Caution:
2. Install the crankshaft front oil seal.
• Press fit the oil seal using an oil seal installer,
setting tool.
Name
1. Adapter
• Apply engine oil to the lip of the oil seal and place it
on the front side adapter.
• Put the front side adapter ring in the sleeve and fix
the sleeve on the adapter with the center bolt and
Name a washer.
1. Oil Seal
2. Adapter (Front) • Tighten the bolt until the sleeve touches the
3. Adapter Ring (Front) adapter to press fit the front oil seal.
4. Fixing Bolt
5. Sleeve (Front)
6. Washer (Front)
7. Center Bolt
4HK1
Name
1. Oil Seal Name
2. Adapter Ring 1. Adapter Ring
3. Sleeve 2. Sleeve
4. Bolt and Washer 3. Adapter
4. Oil Seal
6HK1
• After you have press-fitted the front oil seal,

confirm the measurement shown (depth from the
end surface of the crankshaft to the oil seal) and
check for deflection of the oil seal. Distance (B): 8.5r0.15 mm (0.33r0.006 in)
3. Install the damper to the crankshaft pulley. (6HK1)
• Tighten in the sequence shown.

WSHK0033
4. Install the crankshaft pulley.

Name
• Apply engine oil to the threads of the fastening 1. Crankshaft Pulley
bolts. 2. Generator
3. Fan Pulley
• Install the crankshaft pulley aligning with the knock
pins on the crankshaft.
b. Fan belt adjustment
• Tighten in the sequence shown. • Loosen the adjustment bolt (1) of the AC
generator and adjust the fan belt moving the
Tightening torque: 200 Nm (148 lb ft) generator.
Tightening torque: (2) = 24 Nm (18 lb ft)
(3) = 40 Nm (30 lb ft)
5. Install the fan belt.

a. Inspection of fan belt deflection
• Check with a scale if the belt deflection is within Name
the specified limits when pressure of 98 N 1. Adjusting Bolt
(22 lb) is applied mid-way along the belt’s 2. Fixing Bolt
longest run. Also check the belt for damage. 3. Fixing Bolt
Amount of fan belt deflection mm (in)
6. Tighten the fan ASM to the specified torque.
for new belt 5.0 – 5.8 (0.19 – 0.23)
for reused belt 6.1 – 6.9 (0.24 – 0.27)
7. Install the radiator.
8. Connect the lower radiator hose.
9. Connect the coolant reserve tank hose.
10. Connect the upper radiator hose.
11. Install the starter in the flywheel housing with nuts
and tighten to the specified tightening torque.
• Connect the starter ground cable.

12. Fill the radiator with coolant.
Special Tool
5-8840-2703-0
5-8840-2230-0
J-43282
EN-47680
Crankshaft stopper
(4HK1)
8-94396-856-0
1-8521-0027-0
Slinger remover
(6HK1)
Crankshaft Rear Oil Seal

Components
Name
1. Flywheel 2. Crankshaft Rear Oil Seal
Removal
Refer to the “Flywheel”.
2. Remove the crankshaft rear oil seal.
• Remove the oil seal off with a screwdriver or the
like avoiding damage to the oil seal contact surface
on the flywheel housing and the shaft.
Name
1. Felt
2. Slinger
3. Oil Seal
3. Use the slinger remover to remove the slinger.
Caution:
If the oil seal has been removed, both the oil seal and
slinger must be replaced as a set.
Special tool
Slinger remover:
1-8521-0027-0 (For 4HK1 and 6HK1)
5-8840-2360-0 (For 4HK1)
8-9439-6858-0 (For 6HK1)
5
3
2
Installation
1. Install the front slinger using installer, setting tool.
Special tool
4HK1
6HK1 • After pressing in the slinger, make sure that the
Oil seal setting tool: 8-94396-856-0 distance between crankshaft end surface and the
• Install the slinger (1) to the end of adapter (2). slinger is A as specified.
4HK1
Name
Distance (A): 17.3r0.3 mm (0.7r0.01 in) 1. Adapter (Rear)
Distance (B): 10.8r0.1 mm (0.4r0.004 in) 2. Fixing Bolt
6HK1 3. Center Bolt
4. Sleeve (Rear)
5. Collar (Rear)
6. Adapter Ring (Rear)
7. Oil Seal
Special tool
4HK1
6HK1
A
No. Part Name Oil seal

1 Sleeve (rear) {
2 Adapter (rear) {
3 Collar (rear) {
4 Adapter ring (rear) {
5 Center bolt {
Distance (A): 17r0.3 mm (0.7r0.01 in) 6 Fixing bolt {
Caution:
• Put a collar on the fixing bolt and mount the
adaptor onto the crankshaft.
2. Install the crankshaft rear oil seal.
• Press-fit the rear oil seal using an oil seal installer,
setting tool.
* 4HK1 is shown for illustration. * 4HK1 is shown for illustration.

• After you have pressed in the rear oil seal, confirm
Name
the measurement shown (depth from the end
1. Collar
surface of the crankshaft to the oil seal).
2. Fixing Bolt
3. Adapter
• Apply engine oil to the lip of the oil seal and place it
in the rear side adapter.
• Put the rear side adapter ring in the sleeve and put
the sleeve on the adapter and fix with the center
bolt.
Name
1. Rear Part of The Crankshaft
2. Oil Seal
3. 4HK1: 7.8 r 0.3 mm (0.31 r 0.012 in),
6HK1: 7.5 r 0.15 mm (0.3 r 0.006 in)
4. Collar
5. Adapter Ring
6. Sleeve
* 4HK1 is shown for illustration. 7. Adapter
Name
1. Sleeve
2. Adapter Ring
• Tightening the center bolt until the sleeve touches

the adapter to press fit the oil seal.
Special Tool
1-8521-0027-0
Slinger remover
5-8840-2703-0
J-43282
(4HK1)
8-94396-856-0
(6HK1)
Crankshaft
Components

Name
1. Upper Bearing 5. Lower Bearing
2. Upper Thrust Bearing 6. Lower Thrust Bearing
3. Gear 7. Crankcase
4. Crankshaft
Removal 4. Remove the cylinder head.

Refer to “Cylinder Head Cover”. 5. Remove the fuel supply pump.
Refer to “Fuel Supply Pump” in the fuel system
2. Remove the rocker arm shaft.
section.
6. Remove the crankshaft front oil seal.
3. Remove the camshaft.
7. Remove the crankshaft rear oil seal. 6HK1
9. Remove the water pump.
Refer to the “Water Pump” in the Cooling System 3 7 11 15 19 23 24 20 16 12 8 4 1
Section.
Refer to the “Front Cover”.
26 30 34 38 37 33 29
11. Remove the timing gear train.
Refer to the “Timing Gear Train”. 27 31 35 39 36 32 28
12. Remove the oil pump.

Refer to the “Oil Pump”.
13. Remove the piston and connecting rod. 2 6 10 14 18 22 25 21 17 13 9 5
Refer to the “Pistons and Connecting Rod”.
14. Remove the crankcase.
• Gradually loosen crankcase mounting bolts in the
sequence shown and remove the crankcase using WSHK0034
the replacer holes (arrowed holes in the figure). 15. Remove the lower thrust bearing.
4HK1 16. Remove the lower crankshaft bearings.

17. Remove the crankshaft ASM.
18. Remove the upper thrust bearing.
19. Remove the upper crankshaft bearings.
Special tool
Crankshaft gear puller: 8-9439-6819-0 (EN-41222)
Disassembly
Name
1. Remove the gear.
1. Alignment Mark
• Remove the gear using a gear puller.
Special tool
Crankshaft gear puller: 8-9439-6818-0 (EN-47684) Inspection
1. Thrust clearance
• Set a dial gauge as shown and measure the
crankshaft thrust clearance.
• If the thrust clearance exceeds the limit, replace

the thrust bearings in a pair.
Axial play of the crankshaft mm (in)

Standard 0.104 a 0.205 (0.0041 a 0.0081)
Limit 0.35 (0.0138)
Caution:
Measure the thrust clearance before dismounting.
Reassembly
1. Install the gear.
• Heat the gear to 170 – 250qC (338 – 482qF) and
install it aligning the groove on the gear with the
pin on the crankshaft.
• Insert the gear at one push into the flange with its
end side with the alignment mark “S” facing
outward. If you are fitting the gear while it is cold,
beat the gear in until it impinges on the end using
the installer.
* 4HK1 is shown for illustration. * 4HK1 is shown for illustration.

2. Main bearing clearance • Place Plastigauge on the crankshaft journal as
• Remove the crankcase. shown.
Set out disassembled main bearings in the order of
the numbers. • Place the lower bearings at original positions on
the crankcase.
• Remove the crankshaft. Remove the main bearing.
• Clean the crankshaft journal and the upper and

lower bearings.
• Check the bearings for damage or excessive wear.
If you find damage or excessive wear in the check,

replace the bearings in pairs.
• Place the upper bearings and the crankshaft on

the cylinder block. Install the crankshaft so that it
becomes horizontal.
Caution:
Turn the crankshaft about 30q to allow the bearings to
settle in.
• Install the crankcase and tighten bolts to the

specified tightening torque.
• Tighten the crankcase in the sequence shown

using a torque wrench and an angle gauge.
Tightening torque:
M14 bolt 4HK1: (1 a 10), 6HK1: (1 a 14)
2nd step = 132 Nm (97 lb ft)
3rd step = 30q a 60q
M10 bolt 4HK1: (11 a 27), 6HK1: 15 a 39)
• Tighten bolts from 1 to 10 (M14) and confirm that
they are tightened to a torque of 142 Nm (105
lb ft) or more.
Special tool
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
Caution:
Do not rotate the crankshaft after tightening the
crankcase.
• Loosen the bolts and gently remove the
crankcase.
4HK1
• Measure the widest part of the Plastigauge
flattened by tightening the crankcase to determine
the clearance.
4HK1
Journal oil clearance mm (in)

Standard Limit
No.1, 2, 4, 5 0.037 a 0.072 0.11
(0.0015 a 0.0028) (0.0043)
No.3 0.051 a 0.086 0.11
(0.0020 a 0.0034) (0.0043)
6HK1
Journal oil clearance mm (in)

Standard Limit
6HK1 No. 1, 2, 3, 5, 6, 0.063 a 0.094 0.14
7 (0.0025 a 0.0037) (0.0055)
No. 4 0.093 a 0.124 0.14
(0.0037 a 0.0049) (0.0055)
37 33 29 25 21 17 16 20 24 28 32 3639
14 10 6 2 3 7 11
13 9 5 1 4 8 12
38 34 30 26 22 18 15 19 23 27 31 35
WSHK0035
• If the journal oil clearance exceeds the limit, 4. Measure the journal and the crank pin diameters
replace the main bearings altogether or the and uneven wear.
crankshaft. • Measure outer diameters of the journal and the pin
and calculate differences between the maximum
• Remove the plastigauge from the bearing and and the minimum values. Take measurements at
crank pin. four positions for both the journal and the pin.
Inspection of crankshaft
• Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil seal
contact surface for excessive wear and damage.
• Check the oil port for clogging.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowly
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
4HK1
Crankshaft run-out mm (in)

Standard 0.05 or less (0.0020 or less)
Limit 0.30 (0.012)
4HK1
6HK1 Crankshaft outside diameter mm (in)
Crankshaft run-out mm (in) Standard Limit
Standard 0.06 or less (0.0024 or less) Journal #1, 2, 4, 5 81.905 a 81.925 81.85
(3.22460 a 3.22538) (3.222)
Limit 0.45 (0.018)
Journal #3 81.891 a 81.911 81.85
(3.22408 a 3.22483) (3.222)
Pin 65.902 a 65.922 65.850
(2.59456 a 2.59535) (2.5925)
6HK1
Crankshaft outside diameter mm (in)

Standard Limit
Journal No. 1, 2, 3, 81.905 a 81.925 81.85
5, 6, 7 (3.22460 a 3.22538) (3.222)
Journal No. 4 81.875 a 81.895 81.85
(3.22341 a 3.22421) (3.222)
Pin 72.902 a 72.922 72.850
(2.87015 a 2.87093) (2.8681)
Caution:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
shall not polish the surface of the crankshaft.
Selection of crankshaft bearing

• When installing new crankshaft bearings or Caution:
replacing bearings in use, make reference to the Be careful about difference in the shape of the bearings
Bearing Selection Table. when installing them.
• Select and install new bearings paying close
attention to the cylinder block journal internal
diameter grade and the crankshaft journal
diameter grade.
• Journals are numbered from 1 to 5 (4HK1) or 1 to
7 (6HK1) from left to right when viewed so that the
numbers are in normal reading orientation.
Name
1. Upper Bearing
2. Oil Gallery
4. Oil Groove
5. Lower Bearing
Bearing selection table
4HK1
Combination of grades Oil clearance mm (in)

Cylinder block Crank journal Bearing identification #1, 2, 4, 5 #3
Grade Grade color
1 1 Black 0.039 a 0.070 0.053 a 0.084
(0.00154 a 0.00276) (0.00209 a 0.00331)
1 2 Brown 0.037 a 0.068 0.051 a 0.082
(0.00146 a 0.00267) (0.00201 a 0.00323)
2 1 Blue 0.041 a 0.072 0.055 a 0.086
(0.00161 a 0.00283) (0.00217 a 0.00339)
2 2 Black 0.039 a 0.070 0.053 a 0.084
(0.00154 a 0.00276) (0.00209 a 0.00331)
6HK1
Combination of grades Oil clearance mm (in)

Cylinder block Crank journal Bearing identification #1, 2, 3, 5, 6 #4
Grade Grade color
1 1 Black 0.065 a 0.092 0.095 a 0.122
(0.00256 a 0.00362) (0.00374 a 0.00480)
1 2 Brown 0.063 a 0.089 0.093 a 0.119
(0.00248 a 0.00350) (0.00366 a 0.00469)
2 1 Blue 0.067 a 0.094 0.097 a 0.124
(0.00264 a 0.00370) (0.00382 a 0.00488)
2 2 Black 0.065 a 0.091 0.095 a 0.121
(0.00256 a 0.00358) (0.00374 a 0.00476)
Installation
1. Install the crankshaft upper bearing.
• Install the upper bearing in the cylinder block and
apply oil.
Caution:
When replacing the crankshaft bearings, select grades
referring to the Crankshaft Bearing Grade Selection.
Do not apply oil to the bearing installation surface on
the cylinder block and external surface of the bearing.

2. Install the upper thrust bearing.
• Install the upper thrust bearing in the front side of 5. Install the lower thrust bearing.
the cylinder block journal No.5 (4HK1) or No.7 • Install the lower thrust bearing in the rear side of
(6HK1). In doing this, you may attach the upper the crankcase journal No.5 (4HK1) or No.7
thrust bearing to the cylinder block with grease. (6HK1).
Then, be sure to wipe up excess grease.
• Install the thrust bearing so that the oil groove
Caution: contacts the crankshaft.
Install the thrust bearing so that the oil groove contacts
the crankshaft.

6. Install the crankcase.
3. Install the crankshaft ASM.
• Apply liquid gasket (ThreeBond 1207B or
• Apply engine oil to the crankshaft journal and
equivalent) to the crankcase forming beads with
gently place the crankshaft on the cylinder block.
diameters of 3 – 4 mm (0.12 – 0.16 in).
• Press the crankshaft to the rear and insert the
• Install the crankcase within 7 minutes after you
upper thrust bearing in the rear side of the cylinder
have applied the liquid gasket.
block journal No.5 (4HK1) or No.7 (6HK1).
• Gently place the crankcase on the cylinder block.
Caution:
Install the thrust bearing so that the oil groove contacts
the crankshaft.

4. Install the lower crankshaft bearing.
4HK1
6HK1
12
2
10
2.5
10
15
8
5
8
2.5
2.5
WSHK0036
• Apply Molybdenum Disulfide to M14 bolts’ threads 6HK1
and setting faces and tighten them to the specified
tightening torque in the sequence shown.
• You need not apply engine oil to M10 bolts.

37 33 29 25 21 17 16 20 24 28 32 3639
Tightening torque:
M14 bolt 4HK1: (1 ~ 10), 6HK1: (1 ~ 14)
2nd step = 132 Nm (97 lb ft) 14 10 6 2 3 7 11
3rd step = 30q ~ 60q

13 9 5 1 4 8 12
M10 bolt 4HK1: (11 ~ 27), 6HK1: (15 ~ 39)
• Tighten the bolts (M14) from 1 to 10 (4HK1) or 1 to
38 34 30 26 22 18 15 19 23 27 31 35
14 (6HK1) and confirm that they are tightened to a
torque of 142 Nm (105 lb ft) or more.
Special tool
WSHK0035
Angle gauge: 5-8840-0266-0 (J-45059, KM470-B)
7. Install pistons and connecting rods.
Caution: Refer to the “Pistons and Connecting Rod”.
Confirm that the crankshaft turns smoothly. 8. Install the oil pump.
4HK1 Refer to the “Oil Pump”.
9. Install the timing gear train.
Refer to the “Timing Gear Train”.
10. Install the front cover.
Refer to the “Water Pump” in the Cooling System
Section.
15. Install the fuel supply pump.
Refer to the “Fuel Supply Pump”.
Special Tool
8-9439-6818-0 8-9439-6819-0
EN-47684 J-41222
Crankshaft gear puller Crankshaft gear installer
5-8840-0266-0
J-45059
KM470-B
Angle gauge
Cylinder Block
Components

Name
1. Cylinder Liner 2. Cylinder Block
Removal 5. Remove the fuel supply pump.

Refer to “Fuel Supply Pump” in the fuel system
section.
6. Remove the crankshaft front oil seal.
7. Remove the crankshaft rear oil seal.
4. Remove the cylinder head.
9. Remove the water pump. If the cylinder liner cannot be pulled free by hand,
Refer to the “Water Pump” in the Cooling System tap around the lower side of the liner with a
Section. hammer grip or similar object loosen it.
Inspection
11. Remove the timing gear train.
Refer to the “Timing Gear Train”. 1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
12. Remove the oil pump.
Refer to the “Oil Pump”. • Be careful not to damage the cylinder block.
13. Remove the piston and connecting rod. 2. Carefully remove the liquid gasket on the
Refer to the “Pistons and Connecting Rod”. crankcase mounting surface.
14. Remove the crankshaft. 3. Clean up the cylinder block.
Refer to the “Crankshaft”.
4. Visually inspect the cylinder block.
15. Remove the piston oil jet
• Conduct color check and hydraulic (or pneumatic)
test and if you find crack or other damage, replace
the cylinder block.
5. Cylinder liner wear measurement

• Check the internal surface of the liner for flaw or
damage.
• Measure the liner bore diameter at the most worn

part (it wears more in the rotation direction) at 15 –
20 mm (0.59 – 0.79 in) from the top end of the liner
with the liner installed in the cylinder block. If the
wear is over the application limit, replace it.
16. Remove the cylinder liner.


Cylinder liner bore diameter mm (in)
Standard 115.021 a 115.050
(4.52837 a 4.52952)
Limit 115.20 (4.5354)
Caution:
You need not select cylinder liner bore grade since the
liners are only available in one size.
6. Cylinder block upper face warpage
• Pull out the cylinder liners and remove water stains
on the cylinder block.
• Measure four sides and two diagonals of the top

surface of the cylinder block using a straight edge
(1) and a thickness gauge (2).
• Replace the cylinder block if the measurements

exceed limit values.
Cylinder block upper face warpage mm (in) Installation

Standard 0.05 or less (0.002 or less) 1. Cylinder liner grade selection
• Select liner outer diameter grades according to the
Limit 0.20 (0.079)
cylinder block bore grades stamped on the cylinder
block at arrowed positions in the figure.
• The cylinder liner grade is stamped on the outside

of the cylinder liner (1).
• Matching the grades of the cylinder block and the

liner outer diameter
Cylinder block (stamp) 1, 2 3

Liner outside diameter 1X 3X
Cylinder block bore and liner grade mm (in)

(Reference)
Grade (1, 2) / (1X) (3) / (3X)
Cylinder 118.001 a 118.020 118.021 a 118.030
block (4.64699 a (4.64649 a
Bore 4.64654) 4.64684)
diameter
Liner 117.991 a 118.000 118.001 a 118.010
outside (4.64531 a (4.64570 a
diameter 4.64566) 4.64605)
1
(Reference)
When replacing liners, a “liner set” let you obtain a
piston of proper grade for a given liner bore
012EY00065 diameter only by specifying a liner outside
diameter grade.
4HK1 2. Install the cylinder liners.
• Install the cylinder liners perpendicular to the
cylinder block.
• Do not hammer the liner or apply excessive forth to

insert it.
Caution:
Clean up and blow with compressed air the cylinder
block and the cylinder liners before installing them.
6HK1
3. Amount of the cylinder liner extrusion

Measure the amount of the cylinder liner extrusion
using a dial gauge.
Difference of the amount of the extrusion between
adjacent two cylinders should be within 0.03 mm
(0.0012 in).
Amount of the cylinder liner extrusion mm (in)

Standard 0.05 a 0.10 (0.0020 a 0.0039)
Caution:
Be sure to measure the cylinder liner extrusion
whenever you have replaced cylinder liners.
5. Install the crankshaft.

Refer to the “Crankshaft”.
6. Install pistons and connecting rods.
4. Install the piston oil jet. Refer to the “Pistons and Connecting Rod”.
• Align the knock pin of the oil jet with the pin hole of 7. Install the oil pump.
the cylinder block and tighten with the check valve. Refer to “Oil Pump”.
8. Install the timing gear train.
Tightening torque: 21 Nm (15 lb ft) Refer to the “Timing Gear Train”.
Caution: 9. Install the front cover.
Be careful not to deform or damage the oil jet nozzle. Refer to the “Front Cover”.
Refer to the “Water Pump” in the Cooling System
Section.
Refer to “Fuel Supply Pump” in the Fuel System
section.
Lubrication System
Precautions on Service Work • Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
• During each disassembly, remove the old gasket
coating due to clogging of the oil gallery and oil jet,
adhering to each part and mating part completely
and oil and water leakage may occur if the coating
using a scraper at the location, where the fluid
is insufficient.
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton • Always, the start and end of the application should
and apply the specified new fluid gasket at each be overlapped.
location.
Explanations on functions and operation
The lubrication system uses the filter element
combined with a full flow bypass, water-cooled oil
cooler, and oil jet for piston cooling.
Lubricating system diagram
Function Check 7. Stop the engine.
Oil pressure check 8. Remove the oil pressure gauge.
1. Check whether the engine oil is contaminated with 9. Install the oil pressure switch.
dirt, light oil, or water. If contaminated with dirt, 10. Start the engine and check for oil leakage.
light oil, or water (after examining the cause and
taking the appropriate measures for light oil or Engine oil
water contamination), replace the oil. • Ensure the engine is at a level ground. Before
2. Check the engine oil level. The oil level should be starting the engine or when 5 minutes or more
between the two holes of the level gauge. If the oil have elapsed after stopping the engine, check the
level is insufficient, replenish it. engine oil volume using the level gauge. The
3. Remove the oil pressure switch on the oil filter volume is appropriate if the engine oil is between
body. the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lower
4. Install the oil pressure gauge on the oil filter body.
limit. Also, check for contamination of the engine
oil.
Special tool
Oil pressure gauge: J43620-20
Hose: J43630
Connector (4HK1 only): J43630-14
Oil pressure testing adapter (4HK1 only): EN-46333
Name
1. Oil Pressure Testing Adapter (4HK1 only)
2. Connector (4HK1 only)
3. Hose
4. Oil Pressure Gauge
Name
5. Warm the engine. 1. Upper Limit
6. Measure the oil pressure, to check whether it is 2. Lower Limit
more than 343 kPa (50 psi) at 2000 rpm.
Engine oil leakage
• In the lift up condition, confirm that there are no
leaks from the cylinder head cover and oil pan.
Special Tool
J-43620-20
Oil pressure gauge
J-43630
Hose
J-43630-14
Connector
(4HK1)
J-46333
Oil pressure testing
adapter
(4HK1)
Oil Port Cover ASM

Components
Name
1. Oil Pressure Switch 3. O-Ring
2. Oil Port Cover
Removal
1. Remove the oil pressure switch.
2. Remove the oil port cover.
3. Remove the O-ring.
Installation
1. Install the O-ring on the oil port cover.
Name
1. O-Ring
2. O-Ring
2. Install the oil port cover on the cylinder block and
tighten it to the specified torque.
Tightening torque:
4HK1 48 Nm (35 lb ft)
6HK1 39.2 Nm (29 lb ft)
Name
1. Bolt M10X L = 80
2. Bolt M10X L = 25
3. Install the oil pressure switch to the oil port cover.

• Apply the liquid gasket (Loctite 262) on 2 to 3
peaks from the tip of the threaded part of the oil
pressure switch and install it at the position shown
in the figure.
Tightening torque: 41.2 Nm (30 lb in)

Oil Cooler
Components
4HK1
Name
1. Bypass Hose 5. Fuel Supply Pump
2. EGR Cooler Water Return Pipe 6. EGR Cooler Water Feed Pipe
3. Oil Cooler 7. Suction Pipe
4. Common Rail
6HK1
5 1 2 3 4
!"#$$%&
Name
1. EGR Cooler Water Return Pipe 4. Fuel Supply Pump
2. Oil Cooler 5. Suction Pipe
3. Common Rail
Removal
1. Remove the common rail.
section.
2. Remove the fuel supply pump.

3. Remove the EGR cooler water return pipe.
• Remove the brackets to the water pipe at two
locations to make the pipe unsupported.
4. Remove the EGR cooler water feed pipe. (4HK1) • Screw the removed fixing bolt of the oil cooler into
5. Remove the clip on the head side of the water the replacer hole at the location 1 of the figure and
bypass hose (4HK1) and remove the hose from remove the oil cooler.
the suction pipe ASM.
4HK1

Name
1. Bypass Hose Disassembly
2. EGR Cooler Water Return Pipe 1. Remove the element mounting bolts.
3. EGR Cooler Water Feed Pipe
2. Remove the element.
4. Suction Pipe
6HK1
1 2
!"#$$%& * 4HK1 is shown for illustration.
Name Name
1. Suction Pipe 1. Element
2. EGR Cooler Water Return Pipe 2. O-Ring
6. Remove the oil cooler ASM with glow plug

controller bracket (4HK1 only). Reassembly
1. Install the O-ring on the oil cooler case.
2. Install the element.
3. Tighten the element fixing bolts using the specified
torque.
Name
1. O-Ring
* 4HK1 is shown for illustration. 2. O-Ring
3. Liquid Gasket
Name
1. Element – Align the oil cooler holes with the cylinder block
2. O-Ring studs.
– Install the oil cooler and glow plug controller
bracket to the cylinder block.
Installation – Tighten the bolts to the specified torque in the
1. Install the oil cooler ASM. order shown in the illustration.
• Apply liquid gasket (ThreeBond 1207B or Tightening torque: 24 Nm (18 lb ft)
equivalent) to the flange surface groove (cylinder • Liquid gasket quickly hardens.
block). Bead diameter must be between 2 and 4 Make it complete within 7 minutes after
mm (0.008 and 0.16 in). applying the liquid gasket.
Refer to the illustration for the offset position (no
more than 1 mm (0.04 in)). 4HK1
• Install the O-rings (1) and (2) to the oil passage
inlet and outlet. Do not allow the liquid gasket to
contact the O-ring.
6HK1 6HK1
!"#$$%$ !"#$$%&
2. Connect the water suction pipe.
Name
• Apply liquid gasket (ThreeBond 1207B) to the 1. Gasket
flange of the water suction pipe. Bead diameter 2. Suction Pipe
must be between 2 and 5 mm. Refer to the
illustration for the offset position (no more than
1 mm). (4HK1) Caution:
The water suction pipe must be installed immediately
• Install the water suction pipe to the oil cooler. Refer after the oil cooler (the pipe and cooler use the same
to the illustration. liquid gasket).
4HK1
• Tighten the bolts to the specified torque.
Tightening torque: 4HK1: 24 Nm (18 lb ft)

6HK1: 20 Nm (15 lb ft)
4HK1
3. Install the EGR cooler water feed pipe. (4HK1)

• Install the O-ring on the EGR cooler water feed
pipe.
• Install at the position shown in the figure and

tighten using the specified torque.
Name
1. Liquid Gasket
4HK1
4. Install the EGR cooler water pipe.

(4HK1)
5. Install the body cover ASM LH on the surface of
the oil cooler and cylinder block and tighten it using
the specified torque. (4HK1)
6. Remove the oil drain adapter. (4HK1)
• Refer to “Fuel Supply Pump” in the fuel system
section.

• Refer to the “Common Rail” in the fuel system
section.
Oil Pan
Components

Name
1. Oil Pan Gasket 2. Oil Pan
Removal Installation
1. Drain engine oil. 1. Install the oil pan.
2. Remove the oil pan. • At the seam between the cylinder block and the
front cover with the flywheel housing, apply the
liquid gasket (4H: ThreeBond 1207B or 6H:
1207C) to a bead diameter of 3 mm.
• Apply the liquid gasket and install the oil pan within
7 minutes.
4HK1 4HK1
6HK1 6HK1
WSHK0042
• Install the gasket using the studs of the crankcase,

flywheel housing, and front cover as guide and Name
mount the oil pan. 1. Oil Pan
Install the rubber ASM on the oil pan and secure it 2. Gasket
using nuts and bolts.
4HK1
• Tighten the locations (1), (2), (3), and (4) as shown
in the figure and then tighten others. (In any
sequence)

6HK1
• Fastening the oil pan from the part of A or B in
clock wise order.
• It tightens again by specified torque.
Tightening torque: 24.5 Nm (18 lb ft)
Oil Pump
Components

Name
1. Oil Pump ASM 5. Driven Gear And Shaft
2. Spring 6. Oil Pump Body
3. Ball 7. Gasket
4. Split Pin
Removal 9. Remove the rear oil seal of the crankshaft.

Refer to “Rear oil seal of Crankshaft”.
1. Drain engine oil.
2. Drain out the cooling water.
7. Remove the fuel supply pump ASM.
section.
11. Remove the flywheel housing.
• Make sure you remove the bolts shown in the
figure.
Disassembly
* 4HK1 is shown for illustration. 1. Remove the driven gear and shaft.
12. Remove the idle gear A. 2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Reassembly
1. Install the ball.
2. Install the spring.
3. Install the split pin and fold it according to (1).
13. Remove the oil pump ASM and gasket.
4. Apply engine oil on the driven gear and shaft and

mount them on the oil pump body.
• Measure the clearance between the gear surface
and the upper surface of the oil pump body using
the thickness gauge and square.
• If the gap between the gear and the body inner

wall exceeds the limit, replace the gear ASM or the
driven gear ASM.
Clearance between the gear side surface mm (in)

and the upper surface of the oil pump body
Standard 0.064 ~ 0.109 (0.0025 ~ 0.0043)
Limit 0.20 (0.0079)
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Measure the clearance between the gear and oil
pump body using a thickness gauge.
• If the gap between the gear and the body inner

wall exceeds the limit, replace the gear ASM or the
driven gear ASM.
Clearance between the gear and inner mm (in)

wall of the body
Standard 0.125 ~ 0.220 (0.0049 ~ 0.0087) 3. Measure the clearance between the driven gear
shaft and the bush.
Limit 0.30 (0.0118) • Measure the outside diameter of the driven gear
shaft using a micrometer.
Outside diameter of the driven gear shaft mm (in)

Standard 15.989 ~ 16.000 (0.62949 ~ 0.62992)
Limit 15.900 (0.62598)
2. Measure the clearance between the gear side

surface and the upper surface of the oil pump
body.
3. Install the idling gear A.
• Install the idling gear shaft at the position shown in
the figure and apply engine oil on the shaft.
• Rotate the crankshaft clockwise and bring the

piston of the No.1 cylinder to the top dead center.
• Measure the inside diameter of the bushes of the

oil pump body and cylinder block using the dial
gauge.
• If the clearance between the driven gear shaft and

bushing exceeds the limit, replace the driven gear
ASM. * 4HK1 is shown for illustration.
• Match the alignment marks of the crankshaft gear
Clearance between the driven gear shaft mm (in) and the idle gear A, and install them on the
and bush cylinder block.
Standard 0.04 ~ 0.07 (0.0016 ~ 0.0028)

Limit 0.20 (0.0079)

• Tighten the mounting bolts using the specified
torque.

Installation 4. Install the flywheel housing.
1. Install the gasket. • Clean the rear side of the cylinder block. Remove
the protruding fluid gasket thoroughly, especially,
2. Install the oil pump ASM.
when mounting the crankcase.
• Apply the liquid gasket (ThreeBond 1207B) Tightening torque: (6HK1)
uniformly on the inside surface of the bolt holes
Bolt holes marked with “1” = 96 Nm (71 lb ft)
(excluding the bolt holes indicated by arrows) as
shown in the figure.
• After applying the liquid gasket, quickly install it. Bolt holes marked with “4” = 53 Nm (39 lb ft)
4HK1 Bolt holes marked with “5” = 73 Nm (54 lb ft)
• The seal is tightened from the cylinder block side.
6HK1
!"#$$%&
• Align with the knock pin of the cylinder block and
install the flywheel housing.
Tightening torque: (4HK1)

4HK1
6HK1
1
1 2
5
1
3
6
1
3
4
1
!"#$$%%
6. Install the rear seal of the crankshaft.
Refer to “Rear Oil Seal of Crankshaft”.
8. Install the fuel supply pump ASM.
section.
12. Tighten the cylinder head cover.
Oil Pressure Switch

Inspection
Check the continuity between the switch terminal and
the body grounding in the no-load condition.
If there is no connectivity, replace with normal parts.
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and
confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the
circuit between the meter and the oil pressure
switch, and repair the disconnected locations.

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Isuzu 4H6H - Mecha - en

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ENGINE MECHANICAL (4HK1, 6HK1) 1A-1

ISUZU DIESEL ENGINE (4HK1, 6HK1)

Explanations on functions and operation Cylinder liner

Function check Caution:

Adjustment table (6HK1)

• If the No. 1 cylinder is the compression TDC,

• Attach the harness ASM to the fuel injector.

Tightening torque: 2 Nm (17 lb ft)

Compression gauge: 5-8840-2675-0 (J-26999-12)

• Measure each cylinder one by one.

Item Engine model 4HK1

Item Engine model 4HK1

Item Engine model 6HK1

Item Engine model 6HK1

Illustration Tool Number/Description

Cylinder Head Cover

4. Install the gasket on the head cover.

Tightening torque: 24 Nm (17 lb ft)

* 4HK1 is shown for illustration.

• Install within seven minutes after applying liquid

Tightening torque: 22 Nm (16 lb ft)

N.m (lb ft)

Turbocharger and Exhaust Manifold

Manifold installation plane surface mm (in)

* 4HK1 is shown for illustration.

Wheel shaft axial play

Tightening torque: 34 Nm (25 lb ft)

Tightening torque: 55 Nm (40 lb ft)

2. Install the gasket and turbocharger to the exhaust

Tightening torque: 52 Nm (38 lb ft)

4. Install the water feed pipe to the turbocharger.

Tightening torque: 41 Nm (30 lb ft)

Tightening torque: 24 Nm (17 lb ft)

Tightening torque: 24 Nm (17 lb ft)

Tightening torque (Cylinder block):

5. Install the water return pipe. Tighten the joint bolts

Tightening torque: 41 Nm (30 lb ft)

Tightening torque: 24 Nm (17 lb ft)

* 4HK1 is shown for illustration.

9. Install the air intake duct and tighten the bolts to

Tightening torque: 10 Nm (87 lb in)

12. Add cooling water to the radiator. (4HK1 only)

Tightening torque: 24 Nm (17 lb ft)

N.m (lb ft)

17.6 (13) 34.5 (25)

23.5 (17) 50.5 (37) 32.4 (24)

* 4HK1 is shown for illustration.

Timing Gear Train

• Loosen the fastening bolts of the flywheel little by

• After loosening all the bolts, remove the stopper to

8. Remove the rear oil seal.

* 4HK1 is shown for illustration.

10. Remove the oil pan.

* 4HK1 is shown for illustration.

• If the measurement exceeds the limit, replace the

Backlash of the timing gear mm (in)

• Measure backlash of the idle gear before removing

3. Outside diameter of idle gear shaft

• If the measurement exceeds the limit, replace the

• Measure an end clearance of the idle gear before

4. Clearance between the idle gear and the idle gear

Clearance between the idle gear A and the mm (in)

* 4HK1 is shown for illustration.

Tightening torque: 2 Nm (17 lb ft)

Tightening torque: 24 Nm (17 lb ft)

Tightening torque: 22 Nm (16 lb ft)

Tightening torque: 34 Nm (25 lb ft)

Tightening torque: 55 Nm (40 lb ft)

Tightening torque: 52 Nm (38 lb ft)

Tightening torque: 41 Nm (30 lb ft)

Tightening torque: 24 Nm (17 lb ft)

Tightening torque: 24 Nm (17 lb ft)

Tightening torque: 41 Nm (30 lb ft)

Tightening torque: 24 Nm (17 lb ft)

Tightening torque: 10 Nm (87 lb in)

Tightening torque: 24 Nm (17 lb ft)

Tightening torque: 133 Nm (98 lb ft)

Tightening torque: 4HK1: 133 Nm (98 lb ft)

Tightening torque: 30 Nm (22 lb ft)

Bolt tightening torque: 76 Nm (56 lb ft)

Tightening torque: 142 Nm (104 lb ft)

Tightening torque: 27 Nm (20 lb ft)