Isuzu Diesel Engine 4JA1 and 4JB1

INDUSTRIAL DIESEL ENGINE A-4JA1, A-4JB1 MODELS
WORKSHOP MANUAL
2003 ISUZU MOTORS LIMITED
FOREWORD
This Workshop Manual is designed to help you perform necessary maintenance, service, and repair procedures on applicable Isuzu industrial engines. Information contained in this Workshop Manual is the latest available at the time of publication. Isuzu reserves the right to make changes at any time without prior notice. This Workshop Manual is applicable to 1998 and later models.
NOTICE
Before using this Workshop Manual to assist you in performing engine service and maintenance operations, it is recommended that you carefully read and throughly understand the information contained in Section - 1 under the headings General Repair Instruction and Notes on The Format of This Manual
TABLE OF CONTENTS
SECTION 1. SECTION 2. SECTION 3. SECTION 4. SECTION 5. SECTION 6. SECTION 7. SECTION 8. SECTION 9. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE ASSEMBLY (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (DISASSEMBLY) ENGINE ASSEMBLY (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (INSPECTION AND REPAIR) ENGINE ASSEMBLY (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (REASSEMBLY) 1 17 29 47 81
LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 ENGINE ELECTRICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
SECTION 10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 SECTION 11. SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 SECTION 12. REPAIR STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 SECTION 13. CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
GENERAL INFORMATION
SECTION 1
GENERAL INFORMATION
TABLE OF CONTENTS ITEM PAGE
2 2 6 7
General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on the format of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main data and specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS

1. Before performing any service operation with the engine mounted, disconnect the grounding cable from the battery. This will reduce the chance of cable damage and burning due to short circuiting. 2. Always use the proper tool or tools for the job at hand. Where specified, use the specially designed tool or tools. 3. Use genuine ISUZU parts. 4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove them. Replace them with new ones. 5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation. It is especially important to keep fastening parts separate. These parts vary in hardness and design, depending on their installation position. 6. All parts should be carefully cleaned before inspection or reassembly. Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions. 7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly. 8. If necessary, use a sealer on gaskets to prevent leakage. 9. Nut and bolt torque specifications should be carefully followed. 10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine or disconnecting pipes and hoses. To not do so is extremely dangerous. 11. Always check and recheck your work. No service operation is complete until you have done this.
NOTES ON THE FORMAT OF THIS MANUAL

This Workshop Manual is applicable to ISUZU industrial engine or engines which is or are stated in the title. When more than two engine models are dealt in the manual, such engines have common parts and components as well as data and specifications, unless otherwise specified. 1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual. 2. Common technical data such as general maintenance items, service specifications, and tightening torques are included in the "General Information" section. The section ENGINE ASSEMBLY is an exception. This parts are divided in three sections to facilitates indexing. 3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and reassembly.
GENERAL INFORMATION 4. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page. 5. For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex procedures are covered in detail. 6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area. A brief explanation of the notation used follows.
Parts marked with an asterisk (*) are included in the repair kit. Parts within a square frame are to be removed and installed as a single unit, and their disassembly steps or reassembly steps are shown in the illustrations respectively. The number tells you the service operation sequence.
10
6 1 2 7 8
13 12
5 11
Removal of unnumbered parts is unnecessary unless replacement is required. The "* Repair Kit" indicates that a repair kit is available. The parts listed under "Disassembly Steps" or "Reassembly Steps" are in the service operation sequence.
16
17
14
15
Repair kit
Disassembly Steps - 2
1. 2. 3. L 4. 5. 6. L 7. 8. L 9. Water by-pass hose Thermostat housing Water pump Injection nozzle holder Glow plug and glow plug connector Cylinder head cover Rocker arm shaft and rocker arm Push rod Cylinder head 10. Cylinder head gasket L 11. Crankshaft damper pulley with dust seal 12. Timing gear case cover 13. Timing gear cover 14. Timing gear oil pipe 15. Idler gear B and shaft L 16. Idler gear A 17. Idler gear shaft
The removal or installation of parts marked with a triangle ( L ) is an important operation. Detailed information is given in the text.
Inverted Engine
GENERAL INFORMATION 7. Below is a sample of the text of the Workshop Manual. This is the item shown in the illustration. It is marked with a triangle (L) on the Major Components page. Letters and numbers contained in a circle refer to the illustration. Special tools are identified by the tool name and/or number. The illustration shows how the special tool is to be used. Symbols indicate the type of service operation or step to be performed. A detailed explanation of these symbols follows. Service data and specifications are given in this table.
4. Camshaft Timing Gear 1) Install the thrust plate 1 . 2) Apply engine oil to the bolt threads 2 .
2
3) Install the camshaft timing gear with the timing mark stamped side facing out. Camshaft Timing Gear Bolt Torque
1
kgfm(lb.ft/Nm)
11.0 1.0 (79.5 7.2/107.8 9.8)
13. Crankshaft Rear Oil Seal 1) Apply engine oil to the oil seal lip circumference and the oil seal outer circumference. 2) Use the oil seal installer to install the oil seal to the cylinder body. Oil Seal Installer: 5-8840-0141-0
14. Flywheel Housing

8 6 10 3 2 7 1 5 9
1) Apply liquid gasket to the shaded area shown in the illustration. 2) Tighten the flywheel housing bolts to the specified torque a little at a time in the sequence shown in the illustration. Flywheel Housing Bolt Torque M10x1.25 (0.40x0.05) Bolt
4
kgfm(lb.ft/Nm)
5.61.0 (40.57.2/ 54.99.8) 10.51.0 (76.07.2/103.09.8) 9.81.0 (71.07.2/ 96.09.8)
M12x1.25 (0.47x0.05) Bolt M12x1.75 (0.47x0.07) Bolt
8. The following symbols appear throughout this Workshop Manual. They tell you the type of service operation or step to perform.
....
Removal
....
Adjustment
....
Installation
....
Cleaning
....
Disassembly
...
Important operation requiring extra care
....
Reassembly
....
Specified torque (tighten)
....
Alignment (marks)
....
Special tool use required or recommended(Isuzu tool or tools) Commercially available tool use required or recommended Lubrication (oil)
....
Directional indication
....
....
Inspection
....
....
Measurement
....
Lubrication (grease)
....
Sealant application
GENERAL INFORMATION 9. Measurement criteria are defined by the terms "standard" and "limit". A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable. "Limit" should be thought of as an absolute value. A measurement which is outside the "limit" indicates that the applicable part or parts must be either repaired or replaced. 10. Components and parts are listed in the singular form throughout the Manual. 11. Directions used in this Manual are as follows: Front The cooling fan side of the engine viewed from the flywheel. Right The right hand side viewed from the same position. Left The left hand side viewed from the same position. Rear The flywheel side of the engine. Cylinder numbers are counted from the front of the engine. The front most cylinder is No. 1 and rear most cylinder is the final cylinder number of the engine. The engine's direction of rotation is counterclockwise viewed from the flywheel.
GENERAL INFORMATION
MAIN DATA AND SPECIFICATIONS

Engine Model A-4JA1 Item Engine type Combustion chamber type Cylinder liner type No. of cylinders - Bore x Stroke Total piston displacement Compression ratio (To 1) *Engine dimensions Length x Width x Height *Engine weight (Dry) Fuel injection order *Fuel injection timing (B.T.D.C.) Specified fuel Injection pump Governor *Low idle speed Injection nozzle Injection starting pressure kgf/cm (psi/MPa)
2
A-4JB1
4JB1T
Water cooled, four-cycle, in-line, overhead valve Direct injection Dry mm(in.) lit(cid) mm(in.) kg(lb.) degrees 4 - 93.0 x 92.0 (3.66 x 3.62) 2.449 (152.4) 18.4 805 x 625 x 729 218 (480) 4 - 93.0 x 102.0 (3.66 x 4.02) 2.771 (169.0) 18.2 739 x 625 x 746 220 (486) 1 3 4 2 14 Diesel fuel In-line plunger, Bosch A type Bosch distributor VE type 4 - 93.0 x 102.0 (3.66 x 4.02) 2.771 (169.0) 18.2 578 x 771 x 577 245 (540)
(31.7 x 24.6 x 28.7) (29.1 x 24.6 x 29.4) (22.8 x 30.4 x 22.7)
Variable speed mechanical type rpm 850 1,000 Multi-hole type 185 (2630/18.1) Cartridge papaer element Sediment/water level indicating type 31 (441/3.04) 0.40 (0.0157) 0.40 (0.0157) Pressurized circulation Trochoid type Cartridge paper element, full flow Not equipped lit.(qts) 5.5 (5.8) 6.6 (7.0) 4.6 (4.9) 6.4 (6.8) 4.6 (4.9) 6.3 (6.7) Water cooled built in oil filter Pressurized forced circulation lit.(qts) 5.0 (5.3) Belt driven impeller type Wax pellet type V-A V-kW 12 35 12 2.2 mm(in.) mm(in.) kgf/cm (psi/MPa)
2
Fuel filter type Water sedimentor (if so equipped) Compression pressure Valve clearance (at cold) Intake Exhaust Lubrication method Oil pump Main oil filter type Partial oil filter *Lubricating oil volume Oil cooler (if so equipped) Cooling method Coolant volume Water pump Thermostat type *Alternator *Starter
Specifications marked with an asterisk (*) will vary according to engine application.
GENERAL INFORMATION
TIGHTENING TORQUE SPECIFICATIONS

The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
STANDARD BOLT
Strength Class Bolt Identification
kgfm (lb.ft/Nm)
4.8 (4T)
(7T)
Refined
8.8
Non-Refined
9.8 (9T)
Bolt Diameter pitch (mm) M 6 1.0 M 8 1.25 M10 1.25 M12 1.25 M14 1.5 M16 1.5 M18 1.5 M20 1.5 M22 1.5 M24 2.0 *M10 1.5 *M12 1.5 *M14 2.0 *M16 2.0
No mark
0.4 0.8 (2.9 5.8/3.9 7.8) 0.8 1.8 (5.8 13.0/7.8 17.7) 2.1 3.5 (15.2 25.3/20.6 34.3) 5.0 7.5 (36.2 54.2/49.0 73.6) 7.8 11.7 (56.4 84.6/78.5 114.7) 10.6 16.0 (76.7 115.7/103.0 156.9) 15.4 23.0 (111.1 166.4/151.0 225.6) 21.0 31.6 (151.9 228.6/205.9 307.9) 25.6 42.2 (185.2 305.2/251.1 413.8) 36.6 55.0 (264.7 397.8/358.9 539.4) 2.0 3.4 (14.5 24.6/19.6 32.4) 4.6 7.0 (33.3 50.6/45.1 68.7) 7.3 10.9 (52.8 78.8/71.6 106.9) 10.2 15.2 (73.8 110.0/100.0 149.1)
0.5 1.0 (3.6 7.2/4.9 9.8) 1.2 2.3 (8.7 16.6/11.8 22.6) 2.8 4.7 (20.3 34.0/27.5 46.1) 6.2 9.3 (44.8 67.3/60.8 91.2) 9.5 14.2 (68.7 102.7/93.2 139.3) 13.8 20.8 (99.8 150.4/135.3 204.0) 19.9 29.9 (143.9 216.3/195.2 391.3) 27.5 41.3 (198.9 298.7/269.7 405.0) 37.0 55.5 (267.6 401.4/362.9 544.3) 43.9 72.5 (317.5 523.9/430.5 711.0) 2.8 4.6 (20.3 33.3/27.5 45.1) 5.8 8.6 (42.0 62.2/56.9 84.3) 9.0 13.4 (65.1 96.9/88.3 131.4) 13.2 19.8 (95.5 143.2/129.5 194.2) 1.7 3.1 (12.3 22.4/16.7 30.4) 3.8 6.4 (27.5 46.3/37.3 62.8) 7.7 11.6 (55.7 83.9/75.5 113.8) 11.6 17.4 (83.9 125.6/113.8 170.6) 16.3 24.5 (118.9 177.2/159.9 240.3) 23.4 35.2 (169.3 254.6/229.5 345.2) 32.3 48.5 (233.6 350.8/316.8 475.6) 43.3 64.9 (313.2 469.4/424.6 636.5) 56.5 84.7 (408.7 612.6/554.1 830.6) 3.7 6.1 (26.8 44.1/36.3 59.8) 7.3 10.9 (52.8 78.8/71.6 106.9) 10.9 16.3 (78.8 118.9/106.9 159.9) 15.6 23.4 (112.8 169.3/162.8 229.5)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such as casting. Those shown in parentheses in the strength class indicate the classification by the old standard.
GENERAL INFORMATION
TIGHTENING TORQUE SPECIFICATIONS

The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
FLANGED HEAD BOLT

Bolt head marking Nominal size (dia. x pitch)
M6 1 M 8 1.25 M10 1.25 *M10 1.5 M12 1.25 *M12 1.75 M14 1.5 *M14 2 M16 1.5 *M16 2 0.5 0.9 (3.61 6.50/4.6 8.5 1.1 2.0 (7.95 14.46/10.78 19.61) 2.3 3.9 (17.35 28.20/23.53 38.24) 2.3 3.8 (16.63 27.48/22.55 37.26) 5.6 8.4 (40.50 60.75/54.91 82.37) 3.5 9.5 (37.61 56.41/50.99 76.49) 8.5 12.7 (61.48 91.85/83.35 124.54) 7.6 11.5 (57.14 85.34/77.47 115.71) 11.8 17.7 (85.34 128.02/115.71 173.57) 11.2 16.7 (81.00 120.79/109.83 163.77) 0.6 1.2 (4.33 8.67/5.88 11.76) 1.4 2.9 (4.33 8.67/5.88 11.76) 3.6 6.4 (26.03 44.12/35.30 59.82) 3.5 5.8 (25.31 41.95/34.32 56.87) 7.9 11.9 (57.14 86.07/77.47 116.69) 7.3 10.9 (52.80 78.83/71.58 106.89) 11.7 17.6 (84.62 127.30/114.73 172.59) 11.1 16.6 (80.28 120.06/108.85 162.79) 17.1 26.5 (125.85 189.50/170.63 256.93) 16.6 24.9 (120.06 180.10/162.79 244.18)
kgfm (lb.ft/Nm)
1.9 3.4 (13.74 24.59/18.63 33.34) 4.3 7.2 (31.10 52.07/42.16 70.60) 4.1 6.8 (29.65 49.18/40.20 66.68) 8.7 13.0 (62.92 94.02/85.31 127.48) 8.1 12.2 (58.58 88.24/79.43 119.64) 12.6 18.9 (91.13 136.70/123.56 185.34) 11.8 17.7 (85.34 128.02/115.71 173.57) 18.0 27.1 (130.19 196.01/176.52 265.76) 17.2 25.7 (124.40 186.61/168.67 253.01)
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
GENERAL INFORMATION
SPECIAL PARTS FIXING NUTS AND BOLTS

Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket kgfm(lb.ft./Nm)
0.8 1.8 (5.8 13.0/7.8 17.6)
5.0 6.0 (36.2 43.4/49.0 58.8)
1.0 2.0 (7.2 14.4/9.8 19.6)
1st Step New bolt Reused bolt
2nd Step
3.0 5.0 8.2 9.2 (21.7 36.1/29.4 49.0) (59.4 66.5/80.4 90.2) 8.0 9.0 10.0 11.0 (57.9 65.1/78.4 88.2) (72.4 79.6/98.1 107.9)
GENERAL INFORMATION
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley, Flywheel, and Oil Pan kgfm(lb.ft./Nm)
11.5 12.5 (83.2 90.4/112.8 122.6) 8.0 9.0 (57.9 65.1/78.4 88.2)
16.0 18.0 (115.7 130.2/159.6 176.5)
20.1 24.5 (145.4 177.2/197.1 240.3)
1.4 2.4 (10.1 17.3/13.7 23.5) 1.4 2.4 (10.1 17.3/13.7 23.5)
14 24 (1.4 2.4/4.4 7.2)
10
GENERAL INFORMATION
Timing Gear Case, Flywheel Housing, Camshaft, and Timing Gear kgfm(lb.ft./Nm)
M10 x 1.25 (0.39 x 0.05) M12 x 1.25 (0.47 x 0.05) M12 x 1.75 (0.47 x 0.07) 4.6 6.6 (33.3 47.7/45.1 64.7) 9.6 11.6 (69.4 83.9/94.1 113.8) 8.8 10.8 (63.7 78.1/86.3 105.9)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5)
10.0 12.0 (72.4 86.8/98.1 117.7)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.0 1.5 (7.2 10.9/9.8 14.7)
6.6 8.7 (48 63/66 85)
11
GENERAL INFORMATION
Cooling and Lubricating System kgfm(lb.ft./Nm)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5)
12
GENERAL INFORMATION
Intake and Exhaust Manifold kgfm(lb.ft./Nm)
1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5)
13
GENERAL INFORMATION
Engine Electrical kgfm(lb.ft./Nm)
1.4 2.4 (10.1 17.3/13.7 23.5)
2.0 2.5 (14.4 18.1/19.6 24.5)
3.6 4.6 (26.0 33.3/35.3 45.1)
6.0 8.0 (43.4 57.9/58.8 78.4)
14
GENERAL INFORMATION
Fuel Injection System kgfm(lb.ft./Nm)
20 4.0 (14.4 28.9/19.6 39.2)
3.2 4.4 (23.1 31.8/31.4 43.2) 1.4 2.4 (10.1 17.3/13.7 23.5) 1.4 2.4 (10.1 17.3/13.7 23.5)
1.4 2.4 (10.1 17.3/13.7 23.5) 1.4 2.4 (10.1 17.3/13.7 23.5) 1.4 2.4 (10.1 17.3/13.7 23.5)
15
MEMO
16
MAINTENANCE
SECTION 2
MAINTENANCE
Model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Injection pump identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Compression pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine repair kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
17
MAINTENANCE
MAINTENANCE
Servicing refers to general maintenance procedures to be performed by qualified service personnel. Maintenance interval such as fuel or oil filter changes should be refered to INSTRUCTION MANUAL.
MODEL IDENTIFICATION
Engine Serial Number The engine number is stamped on the rear left hand side of the cylinder body.
INJECTION PUMP IDENTIFICATION

A
Pump No. .............. NP - PE ...................... (LICENCE BOSCH)
Injection volume should be adjusted after referring to the adjustment data applicable to the injection pump installed. The injection pump identification number (A) is stamped on the injection pump identifications plate. Note: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number. Use of the wrong service data will result in reduced engine performance and engine damage. 1 ZEXEL (Manufacturer of the injection pump) identification number 2 ISUZU Parts Number
A Identification number
In-line type
Distributor type
LUBRICATING SYSTEM
Main Oil Filter Replacement Procedure 1. Loosen the drain plug to drain the engine oil. 2. Wait a few minutes and then retighten the drain plug. 3. Loosen the used oil filter by turning it counterclockwise with a filter wrench. Filter Wrench
18
MAINTENANCE 4. Clean the oil cooler fitting face. This will allow the new oil filter to seat properly. 5. Apply a light coat of engine oil to the O-ring. 6. Turn in the new oil filter until the filter O-ring is fitted against the sealing face.
7. Use a filter wrench to turn in the filter an additional 1 and 1/4 of a turn. Filter Wrench 8. Check the engine oil level and replenish to the specified level if required. 9. Start the engine and check for oil leakage from the main oil filter.
FUEL SYSTEM
Fuel Filter Replacement Procedure 1. Loosen the used fuel filter by turning it counterclockwise with the filter wrench. Filter Wrench
2. Clean the upper cover fitting face. This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring. 4. Supply fuel to the new fuel filter to facilitate bleeding. 5. Turn in the new fuel filter until the filter O-ring is fitted against the sealing face. Be very careful to avoid fuel spillage. 6. Use a filter wrench to turn in the fuel filter an additional 1/3 to 2/3 of a turn.
19
MAINTENANCE
Water Separator (Water Sedimentor) (Optional Equipment)

Check the water separator float 1 level. If the float 1 has reached level 2 , loosen the drain plug 3 (at the bottom side of the water separator) to drain the water. Drain Plug Torque
3
2 1
kgfm(lb.ft./Nm)
0.9 1.5 (6.5 10.9/8.8 14.7)
Air Bleeding 1. For the engine equipped with in-line type injection pump
1) Loosen the priming pump cap 1 on the injection pump. 2) Loosen the fuel return eye bolt 2 on the fuel filter. 3) Operate the priming pump until there are no more bubbles visible in the fuel being discharged from the fuel return eye bolt on the fuel filter. 4) Retighten the fuel return eye bolt on the fuel filter. 5) Loosen the bleeder bolt 3 while operating the injection pump priming pump to check that the air has been bled completely. 6) Operate the priming pump several times to check for fuel leakage around the injection pump and the fuel filter.
2.
Air bleeding screw
For the engine equipped with distributor type injection pump
1) Loosen the bleeder screw on the injection pump overflow valve. 2) Operate the priming pump until fuel mixed with foam flows from the bleeder screw. 3) Tighten the bleeder screw. 4) Operate the priming pump several times and check for fuel leakage.
080ES004
20
MAINTENANCE Injection Nozzle Injection Nozzle Inspection Use a nozzle tester to check the injection nozzle opening pressure and the spray condition. If the opening pressure is above or below the specified value, the injection nozzle must be replaced or reconditioned. If the spray condition is bad, the injection nozzle must be replaced or reconditioned. Injection Nozzle Opening Pressure 185 (2,630/18.1)
1 2 3
kgf/cm2(psi/MPa)
Spray Condition (1) Correct (2) Incorrect (Restrictions in orifice) (3) Incorrect (Dripping)
Injection Nozzle Adjustment 1. Clamp the injection nozzle in a vise. 2. Use a wrench to remove the injection nozzle retaining nut. 3. Install the injection nozzle 1 , the push rod 2 , the spring 3 , and adjusting shim 4. Retaining Nut Torque kgfm(lb.ft./Nm) 4.0 5.0 (28.9 36.2/39.2 49.0) 4. Attach the injection nozzle holder to the injection nozzle tester.
1
5. Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure. If the injection nozzle does not open at the specified pressure, install or remove the appropriate number of adjusting shims to adjust it.
Adjusting Shim Availability Range Increment Total No. of Shims (Reference) 0.025 (0.001) 40
mm(in.) 0.50 1.50 (0.02 0.06)
Removing or installing one shim will increase or decrease the nozzle opening pressure approximately 3.77 kgf/cm2 (53.6 psi/370kPa). WARNING: TEST FLUID FROM THE INJECTION NOZZLE TESTER WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN EASILY PUNCTURE A PERSON S SKIN. KEEP YOUR HANDS AWAY FROM THE INJECTION NOZZLE TESTER AT ALL TIMES.
21
MAINTENANCE
COOLING SYSTEM
D C B
Cooling Fan Drive Belt Fan belt tension is adjusted by moving the alternator. A Crankshaft damper pulley B Alternator pulley
A
C Cooling fan drive pulley D Depress the drive belt mid-portion with a 10 kgf (22 lb/98 N) force. Drive Belt Deflection 10.0 (0.39) mm(in.)
Thermostat Operating Test 1. Completely submerge the thermostat in water. 2. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat.
1 2
3. Check the thermostat initial opening temperature. Thermostat Initial Opening Temperature 82 (180) 4. Check the thermostat full opening temperature. Thermostat Full Opening Temperature C(F) 95 (203) Valve Lift at Fully Open Position 8.0 (0.315) 1 Thermostat 2 Agitating Rod 3 Wooden Piece mm(in.) C(F)
22
MAINTENANCE
VALVE CLEARANCE ADJUSTMENT

1. Retighten the rocker arm shaft bracket bolts in sequence as shown in the illustration. Rocker Arm Shaft Bracket Bolt Torque
3 1 2 4
kgfm(lb.ft/Nm)
5.0 6.0 (36.2 43.4/49.0 58.8)
TDC
2. Bring the piston in either the No. 1 cylinder or the No. 4 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft damper pulley TDC line is aligned with the timing pointer.
3. Check for play in the No. 1 intake and exhaust valve push rods. If the No. 1 cylinder intake and exhaust valve push rods have play, the No. 1 piston is at TDC on the compression stroke. If the No. 1 cylinder intake and exhaust valve push rods are depressed, the No. 4 piston is at TDC on the compression stroke.
Adjust the No. 1 or the No. 4 cylinder valve clearances while their respective cylinders are at TDC on the compression stroke. Valve Clearance 0.40 (0.016) Loosen each valve clearance adjusting screw as shown in the illustration. (At TDC on the compression stroke of the No. 1 cylinder) Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end. 4. Turn the valve clearance adjusting screw until a slight drag can be felt on the feeler gauge. 5. Tighten the lock nut securely. mm(in.)
23
MAINTENANCE Rotate the crankshaft 360. Realign the crankshaft damper pulley TDC line with the timing pointer. Adjust the clearances for the remaining valves as shown in the illustration. (At TDC on the compression stroke of the No. 4 stroke)
INJECTION TIMING
Injection Timing Confirmation Procedure 1. In-line type injection pump 1) Rotate the crankshaft clockwise to align the camshaft gear timing mark O with the timing gear case cover pointer. The No. 1 cylinder will now be at the point where nearly injection timing. 2) Remove the No. 1 fuel injection pipe.
2 3
3) Remove the delivery valve holder 1 , the delivery valve spring 2 , and the delivery valve 3 . 4) Tighten the delivery valve holder to the specified torque. Delivery Valve Holder Torque kgfm(lb.ft/Nm) 4.0 4.5 (28.9 32.5/39.2 44.1)
5) Operate the injection pump priming pump while slowly rotating the crankshaft until fuel stops flowing from the delivery valve holder.
TDC 17
6) Conform that the crankshaft damper pulley notched line is aligned with the timing gear case cover pointer. Injection Timing (Static BTDC) 14
7) Remove the delivery valve holder.

3 2 1
8) Install the delivery valve 1 , the delivery valve spring 2 , and the delivery valve holder 3 . 9) Tighten the delivery valve holder to the specified torque. 10) Install the fuel injection pipes and tighten them to the specified torque. Fuel Injection Pipe Torque kgfm(lb.ft/Nm) 2.0 4.0 (14.4 28.9/19.6 39.2) 11) Operation to air breeding.
24
MAINTENANCE 2. Distributor type injection pump
1) Rotate the crankshaft clockwise to align the camshaft gear timing mark O with the timing gear case cover pointer. The No. 1 cylinder will now be at the point where nearly injection timing. 2) Remove injector pump distributor head plug. 3) Fit a dial gauge and set lift to 1 mm (0.039 in). 4) Set crankshaft damper pulley Top Dead Center mark about 45 before Top Dead Center from the pointer. 5) Set dial gauge in the 0 position. Measuring device: 5-8840-0145-0 6) Turn the crankshaft a little rightwise and leftwise and see if the pointer is stable in the 0 position. 7) Turn the crankshaft in the normal direction and read the measuring devices indication at TDC. Starting Timing 0.5 (0.02)
080ES002
mm(in.)
8) If the injection timing is outside the specified range, continue with the following steps. 9) Loosen the injection pump fixing nuts and bracket bolts. 10) Adjust the injection pump setting angle. If injection timing will be advanced, move the injection pump away from the engine. If injection timing will be retarded, move the injection pump toward the engine. Tighten the pump fixing nut, adjust bolt and pump distribution head plug to the specified torque.
080ES003
Pump Fixing Bolt 1.9 (13.7/18.6) Injection Pump Distributor Head Plug 1.7 (12.3/16.7)
kgfm(lb.ft/Nm)
kgfm(lb.ft/Nm)
25
MAINTENANCE
COMPRESSION PRESSURE MEASUREMENT

1. Start the engine and allow it to run for several minutes to warm it up. 2. Stop the engine and cut the fuel supply. 3. Remove all of the glow plugs from the engine. Compression Gauge :5-8840-2675-0 Adapter :5-8840-9029-0
4. Set a compression gauge to the No. 1 cylinder glow plug hole. 5. Turn the engine over with the starter motor and take the compression gauge reading. Compression Pressure Standard 31 (441/3.04) kgf/cm2(psi/MPa) at 200 rpm Limit 22 (313/2.157)
26
MAINTENANCE
RECOMMENDED LUBRICANTS
ENGINE TYPE Without turbocharger With turbocharger TYPES OF LUBRICANTS Diesel engine oil CC or CD grade Diesel engine oil CD grade
ENGINE OIL VISCOSITY CHART
ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE
[Single grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 20, 20W ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 40 ;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 10W SAE 30 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
Ambient Temperature
30C (22F)
15C (5F)
0C (32F)
15C (59F)
25C 30C (77F) (86F)
[Multi grade] ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 10W30 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 15W40, 20W40 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
27
MAINTENANCE
ENGINE REPAIR KIT

All of the numbered parts listed below are included in the Engine Repair Kit. The gaskets marked with an asterisk (*) are also included in the Top Overhaul Kit. 20 19 2 17 18
15 13 12 1
14 19 11 6 19 10 5
7 9
8 16
* * *
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Cylinder head gasket Cylinder head cover gasket Head cover cap nut gasket Drain cock gasket Crankshaft rear oil seal Gear case gasket Gear case cover gasket Oil pan drain plug gasket Oil pan gasket Oil filter gasket
* * * * *
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Water pump gasket Water outlet pipe gasket Thermostat housing gasket Intake manifold gasket Exhaust manifold gasket Crankshaft front oil seal Nozzle holder O-ring Nozzle holder gasket Joint bolt gasket Vacuum pump pipe gasket
28
ENGINE ASSEMBLY ( 1 )
SECTION 3
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
29
ENGINE ASSEMBLY
GENERAL DESCRIPTION
This illustration is based on the A-4JA1 engine.
The A-4J Series of industrial engines features the unique ISUZU troidal square combustion chamber. This design provides superior fuel economy for a wide range. Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold. Chrome plated dry type cylinder liners provide the highest durability. The laminated steel sheet cylinder head gasket is very durable. This type of gasket eliminates cylinder head bolt retightening. The tufftrided crankshaft has a long service life. Because it is tufftrided, it cannot be reground. The crankshaft main bearings and the connecting rod bearings are aluminum plated. These bearings are especially sensitive to foreign material such as metal scraps. It is very important that the oil ports and other related parts be kept clean and free of foreign material.
30
DISASSEMBLY
These disassembly steps are based on the A-4JA1 engine.
21
20
18
7 8
13
14
12
11 10
16
17
19
15
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cooling fan and spacer Cooling fan drive belt Cooling fan drive pulley Alternator and adjusting plate Fuel pipe (Fuel filter to injection pump) Fuel pipe (Fuel filter to feed pump) Fuel pipe (Fuel filter leak off) Fuel filter Oil pipe (Injection pump to cylinder body) Rear engine hanger 11. Fuel leak off pipe
L 12. Fuel injection pipe with clip L 13. Injection pump
14. 15. 16. 17. 18. 19. 20. L 21.
Intake manifold Starter Oil filter Oil pressure switch Cooling water rubber hose Cooling water intake pipe Front engine hanger Exhaust manifold
31
Important Operations (Disassembly Steps - 1)
12. Fuel Injection Pipe with Clip 1) Loosen the injection pipe sleeve nuts at the delivery valve side. Do not apply excessive force to the injection pipes. 2) 3) Loosen the injection pipe clips. Remove the injection pipes.
13. Injection Pump 1) 2) 3) Remove the six injection pump bracket bolts from the cylinder body timing gear case. Remove the injection pump rear bracket bolts from the rear bracket. Pull the injection pump with the injection pump timing gear free from the rear.
Note: Plug the injection pump delivery holder ports with the shipping caps (or the equivalent) to prevent the entry of foreign material.
21. Exhaust Manifold Loosen the exhaust manifold bolts a little at a time in the numerical order shown in the illustration.
32
6 1 2 7 8
13 12
10
5 11
16
17
14
15
Repair kit
1. 2. 3. L 4. 5. 6. L 7. 8. L 9. Water by-pass hose Thermostat housing Water pump Injection nozzle holder Glow plug and glow plug connector Cylinder head cover Rocker arm shaft and rocker arm Push rod Cylinder head 10. Cylinder head gasket
L 11. Crankshaft damper pulley with
12. 13. 14. 15. L 16. 17.
dust seal Timing gear case cover Timing gear cover Timing gear oil pipe Idler gear B and shaft Idler gear A Idler gear shaft Inverted Engine
33
16 7 6 14
15
4 3 11 13
12 9
3a
10
1a Repair kit
1. 1a. 2. L 3. 3a. 4. 5. L 6. Oil pan Oil pan (If so crankcase equipped) Crankcase (If so equipped) Flywheel Rear flywheel (If so equipped) Flywheel housing Oil pump with oil pipe Camshaft with camshaft timing gear and thrust plate 7. Timing gear case L 8. Connecting rod cap with lower bearing
L
9. Piston and connecting rod with upper bearing L 10. Crankshaft bearing cap with lower bearing 11. Crankshaft thrust bearing 12. Crankshaft with crankshaft timing gear L 13. Crankshaft upper bearing L 14. Tappet 15. Crankshaft rear oil seal 16. Cylinder body
34
4. Injection Nozzle Holder 1) Remove the nozzle holder bracket nuts.
2)
Use the nozzle holder remover and the sliding hammer to remove the nozzle holder together with the holder bracket. Nozzle Holder Remover: 5-8840-2034-0 Sliding Humme: 5-8840-0019-0
7. Rocker Arm Shaft and Rocker Arm Loosen the rocker arm shaft bracket bolts in numerical order a little at a time. Note: Failure to loosen the rocker arm shaft bracket bolts in numerical order a little at a time will adversely effect the rocker arm shaft.
9. Cylinder Head
6 2 10 14 15 11 7 3
Loosen the cylinder head bolts in numerical order a little at a time. Note: Failure to loosen the cylinder head bolts in numerical order a little at a time will adversely effect the cylinder head lower surface.
13
17 16
12 8
35
ENGINE ASSEMBLY ( 1 ) 11. Crankshaft Damper Pulley with Dust Seal 1) 2) Block the flywheel with a piece of wood to prevent it from turning. Use the damper pulley remover to remove the damper pulley. Damper Pulley Remover
16. Idler Gear A Measure the camshaft timing gear backlash, the crankshaft timing gear backlash, and the idler gear A end play before removing the idler gear A and shaft.
Timing Gear Backlash Measurement 1) Set a dial indicator to the timing gear to be measured. Hold both the gear to be checked and the adjoining gear stationary. 2) Move the gear to be checked as far as possible to both the right and the left. Take the dial indicator reading. If the measured value exceeds the specified limit, the timing gear must be replaced. Timing Gear Backlash Standard 0.100.17 (0.00390.0067) Limit 0.30 (0.012) mm(in.)
Idler Gear A End Play Measurement Insert a feeler gauge between the idler gear and the thrust collar to measure the gap and determine the idler gear end play. If the measured value exceeds the specified limit, the thrust collar must be replaced. Idler Gear End Play Standard 0.07 (0.0028) Limit 0.30 (0.012) mm(in.)
36

3. Flywheel 1)
1 5 3 2 4 6
Block the flywheel with a piece of wood to prevent it from turning. Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration.
2)
6. Camshaft with Camshaft Timing Gear and Thrust Plate 1) 2) Note: Be careful not to damage the camshaft journal, the cam, and the camshaft during the disassembly procedure. Remove the thrust plate bolts. Pull the camshaft free along with the camshaft timing gear and the thrust plate.
8. Connecting Rod Cap with Lower Bearing If the connecting rod lower bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
9. Piston and Connecting Rod with Upper Bearing 1) Remove carbon deposits from the upper portion of the cylinder wall with a scraper before removing the piston and connecting rod. Move the piston to the top of the cylinder and tap it with a hammer grip or similar object from the connecting rod lower side to drive it out.
2)
If the connecting rod upper bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
37
ENGINE ASSEMBLY ( 1 ) 10. Crankshaft Bearing Cap with Lower Bearing 1) Measure the crankshaft end play at the center journal of the crankshaft. Do this before removing the crankshaft bearing caps. If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced. Crankshaft End Play Standard 0.10 (0.0039) 2)
3 7 10 6 2
mm(in.) Limit 0.30 (0.0118)
Loosen the crankshaft bearing cap bolts in numerical order a little at a time. If the crankshaft bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
13. Crankshaft Upper Bearing If the crankshaft upper bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
14. Tappet If the tappets are to be reinstalled, mark their fitting positions by tagging each tappet with the cylinder number from which it was removed.
15. Crankshaft Rear Oil Seal (Axial Type) Remove the flywheel housing. With the oil seal pushed in deep, install the special tool as shown in the illustration and remove the oil seal. Oil Seal Remover: 5-8840-2360-0
38
DISASSEMBLY
SINGLE UNIT
ROCKER ARM SHAFT AND ROCKER ARM
6
7 5 4 3
Disassembly Steps
L 1. Rocker arm shaft snap ring L 2. Rocker arm L 3. Rocker arm shaft bracket
5. Rocker arm shaft spring 6. Rocker arm shaft snap ring 7. Rocker arm shaft
4. Rocker arm
39
Important Operations
1. Rocker Arm Shaft Snap Ring 2. Rocker Arm 3. Rocker Arm Shaft Bracket 1) 2) 3) Use a pair of snap ring pliers to remove the snap rings. Remove the rocker arms. Remove the rocker arm shaft bracket. If the rocker arms and rocker arm shaft brackets are to be reinstalled, mark their installation positions by tagging each rocker arm and rocker arm shaft bracket with the cylinder number from which it was removed.
40
CYLINDER HEAD
1 2 3 5 6
Disassembly Steps
L 1. Split collar
2. Valve spring upper seat 3. Valve spring L 4. Intake and exhaust valves
5. Valve stem oil seal 6. Valve spring lower washer 7. Cylinder head
41
1. Split Collar 1) 2) Place the cylinder head on a flat wooden surface. Use the spring compressor to remove the split collar. Do not allow the valve to fall from the cylinder head. Spring Compressor: 9-8523-1423-0
4. Intake and Exhaust Valve If the intake and exhaust valves are to be reinstalled, mark their installation positions by tagging each valve with the cylinder number from which it was removed. If there is excessive valve wear or damage, the valve must be replaced. Refer to Page 50 of Inspection and Repair for the valve and valve seat insert procedure. Note: If there is excessive valve guide wear or damage, the valve guide must be replaced. Refer to Page 49 of Inspection and Repair for the valve guide replacement procedure. The valve and the valve guides must be replaced as a set. Never replace only one or the other.
42
PISTON AND CONNECTING ROD
6 7 4
Disassembly Steps
L L L L
1. 2. 3. 4.
Connecting rod bearing Piston ring Piston pin snap ring Piston pin
L L
5. Connecting rod 6. Piston pin snap ring 7. Piston
43
1. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
2. Piston Ring 1) 2) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. Use a piston pin replacer to remove the piston rings. Piston Ring Replacer Do not attempt to use some other tool to remove the piston rings. Piston ring stretching will result in reduced piston ring tension. 3. Piston Pin Snap Ring 4. Piston Pin Snap Ring Use a pair of snap ring pliers to remove the piston pin snap rings.
5. Piston Pin 7. Piston Tap the piston pin out with a hammer and a brass bar. If the pistons are to be reinstalled, mark their installation positions by tagging each piston with the cylinder number from which it was removed.
44
CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE
4 3 2 1
Disassembly Steps
L 1. Camshaft timing gear L 2. Thrust plate
3. Feather key 4. Camshaft
45
1. Camshaft Timing Gear 2. Thrust Plate 1) Clamp the camshaft in a vise. Take care not to damage the camshaft.
2)
Use the universal puller 1 to pull out the camshaft timing gear 2 . Universal Puller: 5-8840-0086-0 Remove the thrust plate 3 .
3)
46
SECTION 4
Inspection and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
47
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face. 2. Regrind the cylinder head lower face if the measured values are greater than the specified limit but less than the maximum grinding allowance.
If the measured values exceed the maximum grinding allowance, the cylinder head must be replaced. Cylinder Head Lower Face Warpage Standard
A E C B D F
mm(in) Maximum Grinding Allwance 0.3 (0.012) mm(in) Limit 91.65 (3.60)
Limit 0.2 (0.008)
0.05 (0.002) or less
Cylinder Head Height (Reference) Standard 91.95 (3.620) 92.05 (3.624) Note:
If the cylinder head lower face is reground, valve depression must be checked.
Exhaust Manifold Fitting Face Warpage

Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage. Regrind the manifold cylinder head fitting faces if the measured values are greater than the specified limit but less than the maximum grinding allowance. If the measured values exceed the maximum grinding allowance, the cylinder head must be replaced.
48
ENGINE ASSEMBLY ( 2 ) Manifold Fitting Face Warpage Standard 0.05 (0.002) or less Limit 0.2 (0.008) mm (in) Maximum Grinding Allwance 0.4 (0.016)
VALVE GUIDE
Valve Stem and Valve Guide Clearance Measuring Method - I 1. With the valve stem inserted in the valve guide, set the dial indicator needle to 0. 2. Move the valve head from side to side. Read the dial indicator. Note the highest dial indication. If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Clearance Standard Intake Valve Exhaust Valve 0.039 0.069 (0.0015 0.0027) 0.064 0.096 (0.0025 0.0038) mm(in) Limit 0.20 (0.008) 0.25 (0.0098)
Measuring Method - II 1. Measure the valve stem outside diameter. Refer to the Item Valve Stem Outside Diameter. 2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter.
Valve Guide Replacement Valve Guide Removal Use a hammer and the valve guide replacer to drive out the valve guide from the cylinder head lower face. Valve Guide Replacer: 9-8523-1212-0
49
ENGINE ASSEMBLY ( 2 ) Valve Guide Installation 1. Apply engine oil to the valve guide outer circumference. 2. Attach the valve guide replacer to the valve guide. 3. Use a hammer to drive the valve guide into position from the cylinder head upper face. Valve Guide Replacer: 9-8523-1212-0
4. Measure the height of the valve guide upper end from the upper face of the cylinder head. Valve Guide Upper End Height (H) (Reference) 13.0 (0.512)
H
mm(in)
Note: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set.
VALVE AND VALVE SEAT INSERT

Valve Stem Outside Diameter Measure the valve stem diameter at three points. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Outside Diameter Standard Intake Valve Exhaust Valve 7.949 7.961 (0.3129 0.3134) 7.921 7.936 (0.3118 0.3124) mm(in) Limit 7.88 (0.3102) 7.88 (0.3102)
Valve Thickness Measure the valve thickness. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Intake and Exhaust Valve Thickness Standard 1.8 (0.071) Limit 1.5 (0.059) mm(in)
50
ENGINE ASSEMBLY ( 2 ) Valve Depression

2
1. Install the valve 1 to the cylinder head 2 . 2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert must be replaced.
Valve Depression Standard Intake Exhaust 0.73 (0.029) 0.70 (0.028) Limit
mm(in) 1.28 (0.050) 1.20 (0.047)
Valve Contact Width 1. Check the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces. 2. Measure the valve contact width. If the measured value exceeds the specified limit, the valve seat insert must be replaced. Valve Contact Width Standard Intake Exhaust 1.7 (0.067) 2.0 (0.079) Limit 2.2 (0.087) 2.5 (0.098) mm(in)
Valve Seat Insert Replacement

2 3
Valve Seat Insert Removal 1. Arc weld the entire inside circumference 1 of the valve seat insert 2.
2. Allow the valve seat insert to cool for a few minutes. This will invite contraction and make removal of the valve seat insert easier.
1
51
ENGINE ASSEMBLY ( 2 ) 3. Use a screwdriver 3 to pry the valve seat insert free. Take care not to damage the cylinder head 4 . 4. Carefully remove carbon and other foreign material from the cylinder head insert bore.
Valve Seat Insert Installation

3 1
1. Carefully place the attachment 1 (having a smaller outside diameter than the valve seat insert) on the valve seat insert 2 . Note: The smooth side of the attachment must contact the valve seat insert. 2. Use a bench press 3 to gradually apply pressure to the attachment and press the valve seat insert into place. Note: Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result.
150 90 30
Valve Seat Insert Correction 1. Remove the carbon from the valve seat insert surface. 2. Use a valve cutter (15 , 45 , and 75 blades) to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve Seat Angle Note: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve guide. 45
52
ENGINE ASSEMBLY ( 2 ) 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while tapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.
VALVE SPRING
Valve Spring Free Height Use a vernier caliper to measure the valve spring free height. If the measured value is less than the specified limit, the valve spring must be replaced. Valve Spring Free Height Standard 49.7 (1.96) Limit 48.2 (1.90) mm(in)
Valve Spring Inclination Use a surface plate and a square to measure the valve spring inclination. If the measured value exceeds the specified limit, the valve spring must be replaced. Valve Spring Inclination Standard
Square
mm(in) Limit 2.5 (0.098)
1.5 (0.06) or less
Valve Spring Tension Use a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, the valve spring must be replace. Valve Spring Tension Compressed Height 38.9 mm (1.53 in) Standard 32.6 (71.9/319.6) kgf(lb/N) Limit 29.0 (63.9/284.4)
53

Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on a V-block. 2. Use a dial indicator to measure the rocker arm shaft central portion run-out. If the run-out is very slight, correct the rocker arm shaft run-out with a bench press. The rocker arm must be at cold condition. If the measured rocker arm shaft run-out exceeds the specified limit, the rocker arm shaft must be replaced. Rocker Arm Shaft Run-Out Standard 0.2 (0.008) Limit 0.6 (0.024) mm(in)
Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm fitting portion outside diameter. If the measured value is less than the specified limit, the rocker arm shaft must be replaced. Rocker Arm Shaft Outside Diameter Standard 18.98 19.00 (0.747 0.748) Limit 18.85 (0.742) mm(in)
Rocker Arm Shaft and Rocker Arm Clearance 1. Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter. Rocker Arm Bushing Inside Diameter Standard 19.01 19.03 (0.748 0.749) Limit 19.05 (0.750) mm(in)
2. Measure the rocker arm shaft outside diameter. If the measured value exceeds the specified limit, replace either the rocker arm or the rocker arm shaft. Rocker Arm and Rocker Arm Shaft Clearance Standard 0.01 0.05 (0.0004 0.002) Limit 0.2 (0.008) mm(in)
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ENGINE ASSEMBLY ( 2 ) 3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm oil port.
Rocker Arm Correction

2
Inspect the rocker arm valve stem contact surfaces for step wear 1 and scoring 2 . If the contact surfaces have light step wear or scoring, they may be honed with an oil stone. If the step wear or scoring is severe, the rocker arm must be replaced.
CYLINDER BODY
Cylinder Body Upper Face Warpage 1. Remove the cylinder body dowel. 2. Remove the cylinder liner. Refer to Cylinder Liner Replacement.
3. Use a straight edge 1 and a feeler gauge 2 to measure the four sides and the two diagonals of the cylinder body upper face.
Cylinder Body Upper Face Warpage Standard 0.05 (0.002) or less Limit 0.2 (0.008)
mm(in)
A E C B D F
If the measured value is more than the limit, the cylinder body must be replaced.
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ENGINE ASSEMBLY ( 2 ) Cylinder Body Height (Reference) Standard 247.945 248.105 (9.7616 9.7679) 4. Reinstall the cylinder liner. Refer to Cylinder Body Bore Measurement. 5. Reinstall the cylinder body dowel. mm(in)
X Y X Y
Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder bore at measuring point 1 in the thrust X X and axial Y Y directions of the crankshaft. Measuring Point 1 : Maximum wear portion [11 15 mm (0.43 0.59 in)] If the measured value exceeds the specified limit, the cylinder liner must be replaced. Cylinder Liner Bore Standard 93.021 93.060 (3.662 3.663) Limit 93.10 (3.665) mm(in)
Note: The inside of the dry type cylinder liner is chrome plated. It cannot be rebored or honed. If the inside of the cylinder liner is scored or scorched, the cylinder liner must be replaced.
Cylinder Liner Projection Inspection

1
1. Hold a straight edge 1 along the top edge of the cylinder liner to be measured. 2. Use a feeler gauge 2 to measure each cylinder liner projection. Cylinder Liner Projection Standard mm(in)
0 0.10 (0 0.0039) The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0.03 mm (0.0012 in).
56
2
Cylinder Liner Replacement Cylinder Liner Removal 1. Insert the cylinder liner remover 1 into the cylinder body (from the lower side of the cylinder body) unit it makes firm contact with the cylinder liner.
Cylinder Liner Remover: 5-8840-2039-0 (A-4JA1, A-4JB1) 2. Use a bench press 2 to slowly force the cylinder liner from the cylinder body. 3. Discard the cylinder liner. Note: Take care not to damage the cylinder body upper face during the cylinder liner removal procedure. 4. Measure the cylinder body upper face warpage. Refer to Cylinder Body Upper Face Warapage.
Cylinder Liner Grade Selection Measure the cylinder body inside diameter and select the proper cylinder liner grade number corresponding to the cylinder body inside diameter. Standard Fitting Interference (Reference) 0.001 0.019 (0.00004 0.00075) If the cylinder liner fitting interference is too small, engine cooling efficiency will be adversely affected. If the cylinder liner fitting interference is too large, it will be difficult to insert the cylinder liner into the cylinder body.
X W Y Z X W Z Y
mm(in)
Cylinder Body Bore Measurement 1. Take measurements at measuring point 1 across positions (W W), (X X), (Y Y) and (Z Z). Measuring Point 1 : 98 mm (3.86 in) 2. Calculate the average value of the four measurements to determine the correct cylinder grade.
Cylinder Liner Grade Nominal Dimension Cylinder Body Bore Diameter 95.001 95.010 (3.74019 3.74055) 95.011 95.020 (3.74059 3.74094) 95.021 95.030 (3.74098 3.74133) 95.031 95.040 (3.74138 3.74173) Liner Grade 1 2 3 4
95
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ENGINE ASSEMBLY ( 2 ) Cylinder Liner Installation 1. Cylinder Liner Installation Using The Special Tool. 1) Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores. 2) Use compressed air to blow-dry the cylinder liner and bore surfaces. Note: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation. 3) Insert the cylinder liner 1 into the cylinder body 2 from the top of the cylinder body.
1 2
4) Set the cylinder liner installer 3 to the top of the cylinder liner. Cylinder Liner Installer: 5-8840-2040-0 5) Position the cylinder body so that the installer center 3 is directly beneath the bench press shaft center 4. Note: Check that the cylinder liner is set perpendicular to the bench press and that there is no wobble. 6) Use the bench press to apply a seating force of 500 kgf (1,102.5 lb/4,900 N) to the cylinder liner. 7) Apply a force of 2,500 kgf (5,512.5 lb/24,500 N) to fully seat the cylinder liner. 8) After installing the cylinder liner, measure the cylinder liner projection. Refer to Cylinder Liner Projection Inspection.
2. Cylinder Liner Installation Using Dry Ice If the cylinder liner is a chrome plated dry type, it is advisable to use dry ice during the installation procedure. Cooling the cylinder liner with dry ice will cause the cylinder liner to contact, thus making installation easier. Note: It is important that the cylinder liner be inserted to the cylinder body immediately after it has been cooled.
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ENGINE ASSEMBLY ( 2 ) WARNING: DRY ICE MUST BE USED WITH GREAT CARE. CARELESS HANDLING OF DRY ICE CAN RESULT IN SEVERE FROSTBITE. Piston Selection Select the same grade number as the one for the cylinder liner inside diameter. Grade of cylinder inside diameter AX CX AX CX Grade of piston AX CX CX AX Combination OK OK NG NG
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X
Piston Grade Selection

Z Y
W Y Z
Measure the cylinder liner bore. Then select the appropriate piston grade for the installed cylinder liner. 1. Measure the cylinder liner bore. There are two measuring points ( 1 and 2 ). Measure the cylinder liner bore in four different direction (W W, X X, and Z Z) at both measuring points. Calculate the average value of the eight measurements to determine the correct cylinder liner bore. Measuring Points 1 : 20 mm (0.79 in) for all A-4J models 2 : 140 mm (5.51 in) for A-4JA1 160 mm (6.30 in) for A-4JB1 Cylinder Liner Bore Standard 93.021 93.060 (3.662 3.663) Note: It is most important that the correct piston grade be used. Failure to select the correct piston grade will result in engine failure. Limit 93.10 (3.665) mm(in)
X 1
2. Measure the piston outside diameter. Piston Measuring Point 1 : 70 mm (2.76 in) Piston Grade Grade AX
1
mm(in) Piston Outside Diameter 4JA1 4JB1 92.989 93.004 (3.6610 3.6615) 93.005 93.020 (3.6616 3.6622) mm(in)
92.979 92.994 (3.6606 3.6611) 92.995 93.010 (3.6612 3.6618)
CX
Cylinder Liner and Piston Clearance 0.017 0.055 (0.0007 0.0022) Note:
:Cylinder liner kit clearances are preset. However, the cylinder liner installation procedure may result in slight decreases in cylinder liner clearances. Always measure the cylinder liner clearance after installation to be sure that it is correct.
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TAPPET AND PUSH ROD

Visually inspect the tappet camshaft contact surfaces for pitting, cracking, and other abnormal conditions. The tappet must be replaced if any of these conditions are present. Refer to the illustration at the left. 1 2 3 4 5 Pitting Cracking Normal contact Irregular contact Irregular contact
Note: The tappet surfaces are spherical. Do not attempt to grind them with an oil stone or similar tool in an effort to repair the tappet. If the tappet is damaged, it must be replaced.
Tappet Outside Diameter Measure the tappet outside diameter with a micrometer. If the measured value is less than the specified limit, the tappet must be replaced. Tappet Outside Diameter Standard 12.97 12.99 (0.5106 0.5114) Limit 12.95 (0.5098) mm(in)
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ENGINE ASSEMBLY ( 2 ) Tappet and Cylinder Body Clearance Standard 0.03 (0.0012) Limit 0.1 (0.0039) mm(in)
Push Rod Curvature 1. Lay the push rod on a surface plate. 2. Roll the push rod along the surface plate and measure the push rod curvature with a thickness gauge. If the measured value exceeds the specified limit, the push rod must be replaced. Push Rod Curvature Limit 0.3 (0.012) 3. Visually inspect both ends of the push rod for excessive wear and damage. The push rod must be replaced if these conditions are discovered during inspection. mm(in)
CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear, and the camshaft bearings for excessive wear and damage. The camshaft and the camshaft bearings must be replaced if these conditions are discovered during inspection.
Camshaft Journal Diameter

X
Use a micrometer to measure each camshaft journal diameter in two directions ((X X) and (Y Y)). If the measured value is less than the specified limit, the camshaft must be replaced. Camshaft Journal Diameter Standard 49.945 49.975 (1.9663 1.9675) Limit 49.60 (1.953) mm(in)
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ENGINE ASSEMBLY ( 2 ) Cam Height Measure the cam height (H) with a micrometer. If the measured value is less than the specified limit, the camshaft must be replaced.
H
Cam Height H Standard 42.08 (1.65) Limit 41.65 (1.64)
mm(in)
Camshaft Run-Out 1. Mount the camshaft on V-blocks. 2. Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the camshaft must be replaced. Camshaft Run-Out Standard 0.02 (0.0008) Camshaft and Camshaft Bearing Use an inside dial indicator to measure the camshaft bearing inside diameter. Camshaft Bearing Inside Diameter Standard 50.0 50.03 (1.9685 1.9697) Limit 50.08 (1.9716) mm(in) Limit 0.10 (0.004) mm(in)
If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit, the camshaft bearing must be replaced. Camshaft Bearing Clearance Standard 0.05 (0.002) Limit 0.12 (0.005) mm(in)
Camshaft Bearing Replacement Camshaft Bearing Removal 1. Remove the cylinder body plug plate. 2. Use the camshaft bearing replacer to remove the camshaft bearing. Bearing Replacer: 5-8840-2038-0
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ENGINE ASSEMBLY ( 2 ) Camshaft Bearing Installation 1. Align the bearing oil holes with the cylinder body oil holes. 2. Use the camshaft bearing replacer installer to install the camshaft bearing. Bearing Replacer: 5-8840-2038-0
Camshaft End Play

1
1. Before removing the camshaft gear 1 , push the thrust plate 2 as far as it will go toward the camshaft gear 3. 2. Use a feeler gauge to measure the clearance between the thrust plate and the camshaft journal. If the measured value exceeds the specified limit, the thrust plate must be replaced. Camshaft End Play Standard 0.050 0.114 (0.002 0.0045) Limit 0.2 (0.008) mm(in)
3 2
Thrust Plate Replacement Thrust Plate Removal 1. Use the universal puller 1 to remove the camshaft timing gear 2 . Universal Puller: 5-8840-0086-0 2. Remove the thrust plate 3 .
1
Thrust Plate Installation 1. Install the thrust plate. 2. Apply engine oil to the bolt setting face and the bolt threads. 3. Install the camshaft gear. Camshaft Gear Torque kgfm(lb.ft/Nm) 10.0 12.0 (72.4 86.8/98.1 117.7)
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CRANKSHAFT AND BEARING

Inspect the surface of the crankshaft journals and crankpins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions. Note: To increase crankshaft strength, tufftriding (Nitrizing Treatment) has been applied. Because of this, it is not possible to regrind the crankshaft surfaces.
Crankshaft Tufftriding Inspection

The portion to be tested shall be held horizontally so as not to let the test solution flow. The sliding surface of the pin or journal. Approximately 10mm Test liquid should not be applied to the area around the oil port.
1. Use an organic cleaner to thoroughly clean the crankshaft. There must be no traces of oil on the surfaces to be inspected. 2. Prepare a 5 10% solution of ammonium cuprous chloride (dissolved in distilled water). 3. Use a syringe to apply the solution to the surface to be inspected. Hold the surface to be inspected perfectly horizontal to prevent the solution from running. Note: Do not allow the solution to come in contact with the oil ports and their surrounding area.
Judgment 1. Wait for thirty to forty seconds. If there is no discoloration after thirty or forty seconds, the crankshaft is usable. If discoloration appears (the surface being tested will become the color of copper), the crankshaft must be replaced. 2. Steam clean the crankshaft surface immediately after completing the test.
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ENGINE ASSEMBLY ( 2 ) Note: The ammonium cuprous chloride solution is highly corrosive. Because of this, it is imperative that the surfaces being tested be cleaned immediately after completing the test.
Crankshaft Run-Out 1. Set a dial indicator to the center of the crankshaft journal. 2. Gently turn the crankshaft in the normal direction of rotation. Read the dial indicator as you turn the crankshaft. If the measured value exceeds the specified limit, the crankshaft must be replaced. Crankshaft Run-Out Standard 0.05 (0.002) or less Limit 0.08 (0.0031) mm(in)
Bearing Tension Check to see if the bearing has enough tension, so that a good finger pressure is needed to fit the bearing into position.
Crankshaft Journal and Crankpin Diameter

1 2 1 2 3 4
1. Use a micrometer to measure the crankshaft journal diameter across points (1 1) and (2 2). 2. Use the micrometer to measure the crankshaft journal diameter at the two points ( 3 and 4 ). 3. Repeat Steps 1 and 2 to measure the crankpin diameter. If the measured values are less than the limit, the crankshaft must be replaced.
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ENGINE ASSEMBLY ( 2 ) Crankshaft Journal Diameter Standard A-4JA1 A-4JB1 Crankpin Diameter Standard 52.915 52.930 (2.0833 2.0839) Crankshaft Journal and Crankpin Uneven Wear Standard 0.05 (0.002) or less Limit 0.08 (0.0031) 59.917 59.932 (2.3589 2.3595) 69.917 69.932 (2.7526 2.7531) mm(in) Limit 59.910 (2.3587) 69.910 (2.7524) mm(in) Limit 52.906 (2.0829)
mm(in)
Crankshaft Journal and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankshaft journal diameter exceeds the specified limit, the bearing and/or the crankshaft must be replaced. Crankshaft Bearing Cap Bolt Torque kgfm(lb.ft./Nm)
16.0 18.0 (115.7 130.2/156.9 176.5) Crankshaft brg cap Bolt Torque Crankshaft Journal and Bearing Clearance Standard 0.035 0.080 (0.0014 0.0031) mm(in) Limit 0.11 (0.0043)
Connecting Rod Bearing Inside Diameter 1. Install the bearing to the connecting rod big end. 2. Tighten the bearing cap to the specified torque. Connecting Rod Bearing Cap Bolt Torque kgfm(lb.ft/Nm)
8.0 9.0 (57.9 65.1/78.4 88.2) 3. Use a inside dial indicator to measure the connecting rod bearing inside diameter.
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ENGINE ASSEMBLY ( 2 ) Crankpin and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or the crankshaft must be replaced. Crankpin and Bearing Clearance Standard 0.029 0.066 (0.0011 0.0026) Limit 0.10 (0.0039) mm(in)
Clearance Measurements (With Plastigage)

Crankshaft Journal and Bearing Clearance 1. Clean the cylinder body, the journal bearing fitting surface, the bearing caps, and the bearings. 2. Install the bearings to the cylinder body. 3. Carefully place the crankshaft on the bearings. 4. Rotate the crankshaft approximately 30 to seat the bearing. 5. Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing. 6. Install the bearing caps with the bearing.
7. Tighten the bearing caps to the specified torque. Crankshaft Bearing Cap Bolt Torque kgfm(lb.ft/Nm)
16.0 18.0 (115.7 130.2/156.9 176.5) Do not allow the crankshaft to turn during bearing cap installation and tightening. 8. Remove the bearing cap.
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ENGINE ASSEMBLY ( 2 ) 9. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. If the measured value exceeds the limit, perform the following additional steps. 1) Use a micrometer to measure the crankshaft outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. If the crankshaft journal and bearing clearance exceeds the limit, the crankshaft and/or the bearing must be replaced. Crankshaft Journal and Bearing Clearance Standard 0.035 0.080 (0.0014 0.0036) Limit 0.11 (0.0043) mm(in)
Crankpin and Bearing Clearance 1. Clean the crankshaft, the connecting rod, the bearing cap, and the bearings. 2. Install the bearing to the connecting rod and the bearing cap. Do not allow the crankshaft to move when installing the bearing cap. 3. Prevent the connecting rod from moving. 4. Attach the Plastigage to the crankpin. Apply engine oil to the Plastigage to keep it from falling.
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ENGINE ASSEMBLY ( 2 ) 5. Install the bearing cap and tighten it to the specified torque. Do not allow the connecting rod to move when installing and tightening the bearing cap. Connecting Rod Bearing Cap Bolt Torque kgfm(lb.ft/Nm)
8.0 9.0 (57.9 65.1/78.4 88.2) 6. Remove the bearing cap. 7. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. If the measured value exceeds the specified limit, perform the following additional steps. 1) Use a micrometer to measure the crankpin outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. If the crankpin and bearing clearance exceeds the specified limit, the crankshaft and/or the bearing must be replaced. Crankpin and Bearing Clearance Standard 0.029 0.066 (0.0011 0.0026) Limit 0.10 (0.0039) mm(in)
Crankshaft Timing Gear Replacement

1
Crankshaft Timing Gear Removal 1. Use the crankshaft gear remover 1 to remove the crankshaft gear 2 . 2. Remove the crankshaft feather key. Crankshaft Timing Gear Remover: 9-8840-2057-0
Crankshaft Timing Gear Installation 1. Install the crankshaft gear. 2. Use the crankshaft gear installer 1 to install the crankshaft gear 2 .
1 2
The crankshaft gear timing mark (X X) must be facing outward. Crankshaft Gear Installer: 9-8522-0020-0
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CRANKSHAFT PILOT BEARING

Check the crankshaft pilot bearing for excessive wear and damage and replace it if necessary.
Crankshaft Pilot Bearing Replacement Crankshaft Pilot Bearing Removal Use the pilot bearing remover to remove the pilot bearing. Pilot Bearing Remover: 5-8840-2000-0 Sliding Hammer: 5-8840-0019-0
Crankshaft Pilot Bearing Installation 1. Place the crankshaft pilot bearing horizontally across the crankshaft bearing installation hole. 2. Tap around the edges of the crankshaft pilot bearing outer races with a brass hammer to drive the bearing into the crankshaft bearing installation hole. Pilot Bearing Installer: 5-8522-0024-0 Note: Strike only the crankshaft pilot bearing outer races with the hammer. Do not strike the bearing inner races. Bearing damage and reduced bearing service life will result.
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FLYWHEEL AND RING GEAR

1
Flywheel 1. Inspect the flywheel friction surface for excessive wear and heat cracks. 2. Measure the flywheel friction surface wear amount (depth) The flywheel friction surface area actually making contact with the clutch driven plate (the shaded area in the illustration) will be smaller than the original machined surface area. There will be a ridge on the flywheel surface area. Be sure to measure the surface wear in the area inside the ridge. If the measured value is between the standard and the specified limit, the flywheel may be reground. If the measured value exceeds the specified limit, the flywheel must be replaced. Flywheel Friction Surface Depth 1 Limit 1.0 (0.04) or more Note: Because a ridge is produced at the flywheel friction surface as illustrated, do not measure the friction surface wear amount at the non-ridge area but be sure to measure it at the rear-friction surface which is shown in the illustration by shaded area. mm(in)
Ring Gear Inspect the ring gear. If the ring gear teeth are broken or excessively worn, the ring gear must be replaced.
Ring Gear Replacement Ring Gear Removal Strike around the edges of the ring gear with a hammer and diesel to remove it.
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ENGINE ASSEMBLY ( 2 ) Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200C (390F). 2. Install the ring gear when it is sufficiently heated. The ring gear must be installed with the chamfer facing the clutch. Note: Another method of heating the ring gear to invite thermal expansion is to soak a rag in diesel fuel, wrap the diesel fuel soaked rag around the rim of the ring gear, and then light the rag.
PISTON
Piston Grade Selection and Cylinder Liner Bore Measurement Refer to the Section CYLINDER BODY, Item Cylinder Liner Bore Measurement for details on piston grade selection and cylinder or liner bore measurement.
PISTON RING
Piston Ring Gap 1. Insert the piston ring horizontally into the cylinder liner. 2. Use a piston inserted upside down to push the piston ring into the cylinder liner until it reaches either measuring point 1 or measuring point 2 . Cylinder liner diameter is the smallest at these two points. Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal. 3. Use a feeler gauge to measure the piston ring gap.
2 1
Measuring Point 1 : 10 mm (0.39 in) Measuring Point 2 : 120 mm (4.72 in)
or
If the piston ring gap exceeds the specified limit, the piston ring must be replaced.
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ENGINE ASSEMBLY ( 2 ) Piston Ring Gap Standard 1 s t Compression Ring 2nd Compression Ring Oil Ring 0.20 0.40 (0.008 0.016) 0.10 0.30 (0.004 0.012) mm(in) Limit 1.5 (0.059)
Piston Ring and Piston Ring Groove Clearance Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston. If the clearance between the piston ring and the piston ring groove exceeds the specified limit, the piston ring must be replaced. Piston Ring and Piston Ring Groove Clearance Standard 1 s t Compression Ring 2nd Compression Ring Oil Ring 0.090 0.125 (0.0035 0.0049) 0.050 0.075 (0.002 0.003) 0.030 0.070 (0.0012 0.0028) 0.15 (0.006) mm(in) Limit
Visually inspect the piston. If a piston ring groove is damaged or distorted, the piston must be replaced.
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PISTON PIN
Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points. If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin Diameter Standard 31.0 (1.220) Piston Pin and Piston Clearance Use an inside dial indicator to measure the piston pin hole (in the piston). Piston Pin Hole Standard 29.002 29.007 Piston Pin and Piston Pin Hole Clearance 0.002 0.015 (0.00008 0.0006) Piston Pin and Connecting Rod Small End Bushing Clearance Use a caliper calibrator and a dial indicator to measure the piston pin and connecting rod small end bushing clearance. If the clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit, replace the piston pin and/or the connecting rod bushing. Piston Pin and Connecting Rod Small End Bushing Clearance Standard 0.008 0.020 (0.0003 0.0008) Limit 0.05 (0.002) mm(in) mm(in) mm(in) Limit 30.97 (1.219) mm(in)
Connecting Rod Bushing Replacement Connecting Rod Bushing Removal 1. Clamp the connecting rod in a vise. 2. Use the connecting rod bushing remover to remove the connecting rod bushing. Connecting Rod Bushing Replacer
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ENGINE ASSEMBLY ( 2 ) Connecting Rod Bushing Installation 1. Clamp the connecting rod in a vice. 2. Use the connecting rod bushing installer to install the connecting rod bushing. Connecting Rod Bushing Replacer:
3. Use a piston pin hole grinder 1 fitted with a reamer 2 to ream the piston pin hole.
1
CONNECTING ROD
Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole. If either the measured distortion or parallelism exceed the specified limit, the connecting rod must be replaced. Connecting Rod Alignment Per Length of 100 mm (3.94 in) Standard Distortion Parallelism 0.05 or Less (0.002) mm(in) Limit 0.20 (0.008) 0.15 (0.006)
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ENGINE ASSEMBLY ( 2 ) Connecting Rod Side Face Clearance 1. Install the connecting rod to the crankpin. 2. Use a feeler gauge to measure the clearance between the connecting rod big end side face and the crankpin side face. If the measured value exceeds the specified limit, the connecting rod must be replaced. Connecting Rod and Crankpin Side Face Clearance Standard 0.23 (0.009) Limit 0.35 (0.014) mm(in)
IDLER GEAR SHAFT AND IDLER GEAR

Idler Gear Shaft Outside Diameter Use a micrometer to measure the idler gear shaft outside diameter. If the measured value is less than the specified limit, the idler gear must be replaced. Idler Gear Shaft Outside Diameter Standard 44.95 44.98 (1.770 1.771) Limit 44.90 (1.767) mm(in)
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ENGINE ASSEMBLY ( 2 ) Idler Gear A Inside Diameter 1. Use an inside dial indic ator to measure the idler gear Idler Gear Inside Diameter Standard 45.0 45.03 (1.7717 1.7728) Limit 45.10 (1.7756) mm(in)
If the clearance between the idler gear shaft outside diameter and the idler gear inside diameter exceeds the limit, the idler gear must be replaced. Idler Gear Shaft and Idler Gear Clearance Standard 0.025 0.085 (0.0010 0.0033) Limit 0.2 (0.008) mm(in)
Idler Gear B Bearing replacement Use a suitable bar and a bench press or hammer.
1 2
Bearing projection amount should be within the specified height. mm(in) Projection Height 1 2 0.4 0.6 (0.016 0.024) 23.7 24.0 (0.933 0.945)
TIMING GEAR CASE COVER

Replace the crankshaft front oil seal if it is excessively worn or damaged.
Crankshaft Front Oil Seal Replacement Oil Seal Removal Use a plastic hammer and a screwdriver to tap around the oil seal to free it from the gear case. Take care not to damage the oil seal fitting surfaces.
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Oil Seal Installation

1. Apply a coat of engine oil to the oil seal lip circumference. 2. Use the oil seal installer and the installer grip to insert the oil seal 1 mm (0.039 in) into the front portion of the timing gear case. Oil Seal Installer: 5-8840-2061-0
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MEMO
80
SECTION 5
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
81
REASSEMBLY SINGLE UNIT

3 2
4 5 6 1
Reassembly Steps
L 1. Rocker arm shaft
2. Rocker arm shaft snap ring 3. Rocker arm 4. Rocker arm shaft bracket
5. Rocker arm 6. Rocker arm shaft spring 7. Rocker arm shaft snap ring
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1. Rocker Arm Shaft 1) Position the rocker arm shaft with the large oil hole (Dia. 4 mm (0.157 in)) facing the front of the engine. 2) Install the rocker arm shaft together with the rocker arm, the rocker arm shaft bracket, and the spring.
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CYLINDER HEAD
7 6 5 3 2
Reassembly Steps
1. 2. L 3. L 4. Cylinder head Valve spring lower washer Valve stem oil seal Intake and exhaust valve
L L
5. Valve spring 6. Valve spring upper seat 7. Split collar
84
3. Valve Stem Oil Seal 1) Apply a coat engine oil to the oil seal inner face. 2) Use an oil seal installer to install the oil seal to the valve guide. Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve 1) Apply a coat of engine oil to valve stem. 2) Install the intake and exhaust valves. 3) Turn the cylinder head up to install the valve springs. Take care not to allow the installed valves to fall free.
5. Valve Spring 1) Turn the cylinder head up to install the valve springs. 2) Install the valve springs with the fine pitched end (painted pink) facing down. Take care not to allow the installed valves to fall free.
7. Split Collar 1) Use the spring compressor to push the valve spring into position. Spring Compressor: 9-8523-1423-0 2) Install the split collar to the valve stem. 3) Set the split collar by tapping around the bead of the collar with a rubber hammer.
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PISTON AND CONNECTING ROD
2 1 4
Reassembly Steps
L L L L
1. 2. 3. 4.
Piston Piston pin snap ring Connecting rod Piston pin
L L
5. Piston pin snap ring 6. Piston ring 7. Connecting rod bearing
86
1. Piston 2. Piston pin snap ring 3. Connecting rod 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use a pair of snap ring pliers to install the piston pin snap ring to the piston.
3) Install the piston to the connecting rod. The piston head front mark 1 and the connecting rod ISUZU casting mark 2 must be facing the same direction.
2
4. Piston pin 1) Apply a coat of engine oil to the piston pin and the piston pin hole. 2) Use your fingers to force the piston pin into the piston until it makes contact with the snap ring.
3) Use your fingers to force the piston pin snap ring into the piston snap ring groove. 4) Check that the connecting rod moves smoothly on the piston pin.
87
ENGINE ASSEMBLY ( 3 ) 6. Piston Ring

3
1) Use a piston ring replacer to install the three piston rings. Piston Ring Replacer: Install the piston rings in the order shown in the illustration. 1 Oil ring (Coil expander type) 2 2nd compression ring (Taper undercut type) 3 1st compression ring (Barrel face type) Note: Install the compression rings with the stamped side facing up. Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil before installing the oil ring. 2) Apply engine oil to the piston ring surfaces. 3) Check that the piston rings rotate smoothly in the piston ring grooves.
7. Connecting Rod Bearing Carefully wipe any oil or other foreign material from the connecting rod bearing back face and the connecting rod bearing fitting surface.
88
CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE
1 2 3 4
Reassembly Steps
1. Camshaft 2. Feather key
L
3. Thrust plate 4. Camshaft timing gear
89
4. Camshaft Timing Gear 1) Install the thrust plate 1 . 2) Apply engine oil to the bolt threads 2 .
2
3) Install the camshaft timing gear with the timing mark stamped side facing out. Camshaft Timing Gear Bolt Torque
1
kgfm(lb.ft/Nm)
10.0 12.0 (72.4 86.8/98.1 117.7)
90
MEMO
91
REASSEMBLY
1 7 8 2
13
14 15 5 3
4 9
15a
10
11
12
16
16a Repair kit
Reassembly Steps 1
L L L L L L
Cylinder body Tappet Crankshaft upper bearing Crankshaft with crankshaft timing gear Crankshaft thrust bearing Crankshaft bearing cap with lower bearing L 7. Timing gear case L 8. Camshaft with camshaft timing gear and thrust plate L 9. Piston and connecting rod with upper bearing
1. 2. 3. 4. 5. 6.
L L L L L L
10. 11. 12. 13. 14. 15. 15a L 16. 16a
Connecting rod cap with lower bearing Crankcase (If so equipped) Oil pump with oil pipe Crankshaft rear oil seal Flywheel housing Flywheel Rear flywheel (If so equipped) Oil pan Oil pan (If so crankcase equipped)
Inverted Engine
92
17 14 13 11 10
12
5 6
15 7
16
Repair kit
Reassembly Steps 2
L 1. Idler gear shaft L 2. Idler gear A L 3. Idler gear B
10. Push rod

L 11. Rocker arm shaft and rocker arm L 12. Water pump L 13. Thermostat housing
4. Timing gear oil pipe

L 5. Timing case cover
14. Water by-pass hose

L 15. Glow plug and glow plug connector
6. Timing gear case cover L 7. Crankshaft damper pulley with dust seal L 8. Cylinder head gasket L 9. Cylinder head
seal
L 16. Injection nozzle holder
17. Cylinder head cover
93
Important Operations (Reassembly Steps-1)
1. Cylinder Body Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder body, the oil holes, and the water jackets.
2. Tappet 1) Apply a coat of engine oil to the tappet 1 and the cylinder body tappet insert holes 2 .
1
2) Locate the position mark applied at disassembly (if the tappet is to be reused). Note: The tappet must be installed before the camshaft.
3. Crankshaft Upper Bearing The crankshaft upper bearings have an oil hole and an oil groove. The lower bearings do not. 1) Carefully wipe any foreign material from the crankshaft upper bearing and the crankshaft upper bearing fitting surfaces. 2) Locate the position mark applied at disassembly if the removed crankshaft upper bearings are to be reused. 4. Crankshaft with Crankshaft Timing Gear Apply an ample coat of engine oil to the crankshaft journals and the crankshaft bearing surfaces before installing the crankshaft. Note: Do not apply engine oil to the bearing back faces and the cylinder body bearing fitting surfaces.
94
ENGINE ASSEMBLY ( 3 ) 5. Crankshaft Thrust Bearing 1) Apply an ample coat of engine oil to the crankshaft thrust bearings. 2) Install the crankshaft thrust bearings to the crankshaft center journal. The crankshaft thrust bearing oil groove must be facing the sliding face.
6. Crankshaft Bearing Cap with Lower Bearing 1) Apply silicon adhesive to the cylinder body No. 5 bearing cap fitting surface at the points shown in the illustration. Note: Be sure that the bearing cap fitting surface is completely free of oil before applying the silicon adhesive. Do not allow the silicon adhesive to obstruct the cylinder thread holes and bearings. 2) Install the bearing caps. The bearing cap arrow marks must be facing the front of the engine. The arrow mark journal number must correspond to the journal to which the bearing cap is installed. Note:
1 2 3 Nile 5
The No. 4 journal bearing cap does not have a number stamped on it. 3) Apply a coat of engine oil to the bearing cap bolts. 4) Tighten the crankshaft bearing cap bolts to the specified torque a little at a time in the sequence shown in the illustration.
Crankshaft Bearing Cap Torque
kgfm(lb.ft/Nm)
16.0 18.0 (115.7 130.2/156.9 176.5)

3 7 2 6 10
5) Check to see that the crankshaft turns smoothly by rotating it manually. 7. Timing Gear Case 1) Tighten the timing gear case with timing gear case gasket to the specified torque. Timing Gear Case Bolt Torque kgfm(lb.ft/Nm) 1.4 2.4 (10.1 17.3/13.7 23.5) 2) Cut away any excessive flash from the timing gear gasket.
95
ENGINE ASSEMBLY ( 3 ) 8. Camshaft with Camshaft Timing Gear and Thrust Plate 1) Apply a coat of engine oil to the camshaft and the camshaft bearings. 2) Install the camshaft to the cylinder body. Take care not to damage the camshaft bearings. 3) Tighten the thrust plate to the specified torque. Thrust Plate Bolt Torque kgfm(lb.ft/Nm) 1.4 2.4 (10.1 17.3/13.7 23.5) 4) Check to see that the camshaft turns smoothly by rotating it manually.
9. Piston and Connecting Rod with Upper Bearing

3
10. Connecting Rod Bearing Cap with Lower Bearing 1) Apply a coat of engine oil to the circumference of each piston ring and piston.
2) Position the piston ring gaps as shown in the illustration. 1 1st compression ring 2 2nd compression ring 3 Oil ring 3) Apply a coat of molybdenum disulfide grease to the two piston skirts.
This will facilitate smooth break-in when the engine is first started after reassembly. 4) Apply a coat of engine oil to the upper bearing surfaces. Note: Do not apply engine oil to the bearing back faces and the connecting rod bearing fitting surfaces. 5) Apply a coat of engine oil to the cylinder wall.
96
ENGINE ASSEMBLY ( 3 ) 6) Position the piston head front mark so that it is facing the front of the cylinder body. 7) Use a piston ring compressor to compress the piston rings. Piston Ring Compressor 8) Use a hammer grip to push the piston in until the connecting rod makes contact with the crankpin. At the same time, rotate the crankshaft until the crankpin is at BDC. 9) Install the connecting rod bearing caps. The bearing cap front marks must be facing the front of the engine. The bearing cap number (at the side of the bearing cap) and the connecting rod number must be the same. Note: It is absolutely essential that the bearing caps be installed in the correct direction. Reversing the bearing cap direction will result in serious engine damage. 10) Apply a coat of engine oil to the threads and setting faces of each connecting rod cap bolt. 11) Tighten the connecting rod caps to the specified torque. Connecting Rod Cap Bolt Torque kgfm(lb.ft/Nm) 8.0 9.0 (57.9 65.1/78.4 88.2)
11. Crankcase (if so equipped) 1) Apply sealant to the No. 5 bearing cap arches, the bearing grooves, and the timing gear case arches at the positions shown in the illustration.
5 1 8 4 2 7 3 6
2) Apply sealant to the crankcase cylinder body fitting area. 3) Tighten the crankcase bolts to the specified torque a little at a time in the sequence shown in the illustration. Crankcase Bolt Torque kgfm(lb.ft/Nm) 1.4 2.4 (10.1 17.3/13.7 23.5)
97
ENGINE ASSEMBLY ( 3 ) 12. Oil Pump with Oil Pipe Install the oil pump with the oil pipe and tighten the bolts to the specified torque. Oil Pump Bolt Torque kgfm(lb.ft/Nm) 1.4 2.4 (10.1 17.3/13.7 23.5) Note: Take care not to damage the O-rings when tightening the oil pipe bolts. 13. Crankshaft Rear Oil Seal 1) Apply engine oil to the oil seal lip circumference and the oil seal outer circumference. 2) Use the oil seal installer to install the oil seal to the cylinder body. Oil Seal Installer: 5-8840-0141-0
13. Crankshaft Rear Oil Seal (Axial Type)

12.50.3
1) Tighten the adapter to the crankshaft rear and section with 2 bolts. 2) Insert the oil seal into the peripheral section of adapter. 3) Insert the sleeve into the adapter section, and 1) tighten it with a bolt (M12 x 1.75L = 70) until the adapter section hits the sleeve. 4) Remove the adapter and the sleeve. 5) With the seal pressed in, check the dimension of the oil seal section. Standard Dimension = 12.5 0.3 mm (0.492 0.012 in) Oil Seal Installer: 5-8840-9057-0
14. Flywheel Housing

6 8 10 3 2 7 1 5 9
1) Apply sealant to the shaded area shown in the illustration. 2) Tighten the flywheel housing bolts to the specified torque a little at a time in the sequence shown in the illustration. Flywheel Housing Bolt Torque M10x1.25 (0.39x0.05)
4
kgfm(lb.ft/Nm)
4.6 6.6 (33.3 47.7/45.1 64.7) 9.6 11.6 (69.4 83.9/94.1 113.8) 8.8 10.8 (63.7 78.1/86.3 105.9)
M12x1.25 (0.47x0.05) M12x1.75 (0.47x0.07)
98
ENGINE ASSEMBLY ( 3 ) 15. Flywheel 1) Block the flywheel with a piece of wood to prevent it from turning.
7 3 5 2 8 1 6 4
2) Apply a coat of engine oil to the threads of the flywheel bolts. 3) Tighten the flywheel bolts in the numerical order shown in the illustration. Flywheel Bolt Torque kgfm(lb.ft/Nm) 11.5 12.5 (83.2 90.4/112.8 122.6) 16. Oil Pan 1) Apply sealant to the No. 5 bearing cap arches, the bearing grooves, and the timing gear case arches at the positions shown in the illustration.
2) Fit the gasket rear lipped portion into the No. 5 bearing cap groove. Be absolutely sure that the lipped portion is fitted snugly in the groove.
5 1 8 4 2 7 3 6
3) Tighten the oil pan bolts to the specified torque a little at a time in the sequence shown in the illustration. Oil Pan Bolt Torque kgfm(lb.ft/Nm) 1.4 2.4(10.1 17.3/13.7 23.5)
99
1. Idler Gear Shaft The idler gear shaft oil hole must be facing up.
2. Idler Gear A
1 2
1) Apply engine oil to the idler gear 1 and the idler gear shaft 2 . 2) Position the idler gear setting marks X and Y so that they are facing the front of the engine.
Y 1 4
3) Align the idler gear X setting mark with the crankshaft timing gear 3 X X setting mark. 4) Align the idler gear Y setting mark with the camshaft timing gear 4 Y Y setting mark. 5) Tighten the idler gear bolt to the specified torque. Idler Gear A Bolt Torque
X 3
kgfm(lb.ft/Nm)
1.4 2.4 (10.1 17.3/13.7 23.5)
1 5
3. Idler Gear B 1) Apply engine oil to the idler gear and the idler gear shaft. 2) Align the idler gear 5 Z setting mark with the idler gear 1 Z setting mark. Idler Gear B Bolt Torque
Z
kgfm(lb.ft/Nm)
6.6 8.7 (48 63/66 85)
100
ENGINE ASSEMBLY ( 3 ) 5. Timing Case Cover 1) Before installing the timing gear case, apply a 3 mm x 5 mm (0.12 in x 0.20 in) strip of liquid gasket to the portion of the feather key indicated by the arrow in the illustration. 2) Check that the timing case cover O-ring is firmly inserted into the gear case groove. 3) Tighten the timing case cover bolts to the specified torque. Timing Case Cover Bolt Torque M 8x1.25 (0.31x0.05) Bolt M12x1.25 (0.47x0.05) Bolt kgfm(lb.ft/Nm)
1.4 2.4 (10.1 17.3/13.7 23.5) 6.7 8.7 (48.5 62.9/65.7 85.3)
7. Crankshaft Damper Pulley with Dust Seal 1) Block the flywheel ring gear with a piece of wood to prevent it from turning. 2) Tighten the crankshaft damper pulley to the specified torque. Crankshaft Damper Pulley Bolt Torque kgfm(lb.ft/Nm)
17.0 21.0(123.0 151.9/166.7 205.9) Take care not to damage the crankshaft damper pulley boss.
8. Cylinder Head Gasket The cylinder gasket TOP mark must be facing up.
Front
101
ENGINE ASSEMBLY ( 3 ) 9. Cylinder Head 1) Align the cylinder body dowels and the cylinder head dowel holes. Carefully set the cylinder head to the cylinder head gasket. 2) Apply engine oil to the cylinder head fixing bolt threads and setting faces.
13 17 9
5 1
4 8
12 16
3) Tighten the cylinder head bolts to the specified torque in two steps following the numerical order shown in the illustration. Cylinder Head Bolt Torque 1st Step kgfm(lb.ft/Nm) 2nd Step
18
14
2 10 6 3
7 11
15
New Bolt
3.0 5.0 8.2 9.2 (21.736.1/29.449.0) (59.466.5/80.490.2)
8.0 9.0 10.0 11.0 Reused Bolt (57.965.1/78.488.2) (72.479.6/98.1107.9) 11. Rocker Arm Shaft and Rocker Arm Tighten the rocker arm shaft bracket bolts in the numerical order shown in the illustration. Rocker Arm Shaft Bracket Bolt Torque kgfm(lb.ft/Nm) 5.0 6.0 (36.2 43.4/49.0 58.8)
12. Water Pump 1) Temporarily tighten the water pump bolt marked with an arrow in the illustration. This bolt will be tightened to the specified to torque when the alternator adjusting plate is installed. 2) Tighten the other water pump bolts to the specified torque. Water Pump Bolt Torque 13. Thermostat Housing 1) Install the thermostat housing. 2) Tighten the thermostat housing bolts to the specified torque. Thermostat Housing Bolt Torque kgf.m(lb.ft/N.m) 1.4 2.4 (10.1 17.3/13.7 23.5) kgfm(lb.ft/Nm) 1.4 2.4 (10.1 17.3/13.7 23.5)
102
ENGINE ASSEMBLY ( 3 ) 15. Glow Plug and Glow Plug Connector 1) Tighten the glow plugs to the specified torque. Glow Plug Torque kgfm(lb.ft/Nm) 2.0 2.5 (14.4 18.1/19.6 24.5) 2) Install the glow plug connectors.
16. Injection Nozzle Holder

3 5 4
1) Install the injection nozzle gasket 1 and the Oring 2 to the injection nozzle holder 3 . 2) Install the nozzle holder 3 together with the nozzle holder bracket 4 to the cylinder head. 3) Tighten the holder nuts with washer 5 to the specified torque. Injection Nozzle Holder Nut Torque kgfm(lb.ft/Nm) 3.2 4.4 (23.1 31.8 /31.4 43.2)
2 1
103
12
18
14
19
7 6
4 10
16
17
13
15
20
21
11
Reassembly Steps 3
L 1. Intake manifold L 2. Injection pump L 3. Fuel injection pump with clip L 11. Starter L 12. Exhaust manifold
4. Fuel leak off pipe 5. Oil pipe (Injection pump to cylinder body) 6. Fuel filter 7. Fuel pipe (Fuel filter to leak off) 8. Fuel pipe (Fuel filter to feed pump) 9. Fuel pipe (Fuel filter to injection pump) 10. Rear engine hanger
13. 14. L 15. L 16. 17. 18. 19. 20. 21.
Cooling water intake pipe Cooling water rubber hose Alternator and adjusting plate Oil filter Oil pressure switch Front engine hanger Cooling fan drive pulley Cooling fan drive belt Cooling fan and spacer
104
1. Intake Manifold Install the intake manifold gasket with the end having the sharp corners facing the front of the engine.
2. Injection Pump
1
1) Turn the crankshaft slowly clockwise to align the camshaft timing check hole pointer 1 with the camshaft timing gear O mark 2 .
2) Install the injection pump to the timing gear case.

3
Align the injection pump timing check hole pointer 3 with the timing gear O mark 4 . 3) Temporarily tighten the injection pump bracket bolt 5 .
4
This bolt will be finally tightened after the injection pump rear bracket bolts 6 .
4) Tighten the injection pump rear bracket bolts to the specified torque 6 . Injection Pump Rear Bracket Bolt Torque
6
kgfm(lb.ft/Nm)
1.4 2.4 (10.1 17.3/13.7 23.5) 5) Tighten the injection pump bracket bolt 5 to the specified torque. Injection Pump Bracket Bolt Torque
5 6
kgfm(lb.ft/Nm)
1.4 2.4 (10.1 17.3/13.7 23.5)
105
3. Fuel Injection Pipe with Clip 1) Temporarily tighten the injection pipe sleeve nut. 2) Set the clip in the prescribed position. Note: Make absolutely sure that the clip is correctly positioned. An improperly positioned clip will result in injection pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified torque. Injection Pipe Sleeve Nut Torque kgfm(lb.ft/Nm) 2.0 4.0(14.4 28.9/19.6 39.2)
11. Starter Tighten the starter bolts to the specified torque. Starter Bolt Torque kgfm(lb.ft/Nm) 6.0 8.0 (43.4 57.9/58.8 78.4)
12. Exhaust Manifold Tighten the exhaust manifold bolts to the specified torque a little at a time in the numerical order shown in the illustration. Exhaust Manifold Bolt Torque
6 2 3 7
kgf.m(lbft/Nm)
1.4 2.4(10.1 17.3/13.7 23.5)
106
ENGINE ASSEMBLY ( 3 ) 15. Alternator and Adjusting Plate Tighten the alternator bolts and the adjusting plate bolts to the specified torque. Alternator Bolt Torque kgfm(lb.ft/Nm) 3.6 4.6 (26.0 33.3/35.3 45.1) Tighten the adjusting plate bolts to the specified torque after cooling drive belt installation. Adjusting Plate Bolt Torque kgfm(lb.ft/Nm) 1.4 2.4 (10.1 17.3/13.7 23.5) 19. Oil Filter Tighten the oil filter bolts to the specified torque. Oil Filter Bolt Torque kgfm(lb.ft/Nm) 1.4 2.4 (10.1 17.3/13.7 23.5)
107
MEMO
108
LUBRICATING SYSTEM
SECTION 6
LUBRICATING SYSTEM
Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Oil filter with built-in oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
109
LUBRICATING SYSTEM

Item Oil pump type Delivery volume Pump speed Delivery pressure Oil temperature Engine oil Oil filter type Relief valve opening pressure Safety valve opening pressure Safety valve opening pressure kgf/cm (psi/kPa) kgf/cm2(psi/kPa)
2
A-4JA1A-4JB1 Trochoid Lit(qts)/min. kgf/cm (psi/kPa) C(F)

2
17.5 (18.4) 1000 4.0 (56.89/392.0) 47 53 (116.6 127.4) SAE 30 Full flow with cartridge paper element 4.3 4.7 (61.14 66.83/421.4 460.6) 0.8 1.2 (11.38 17.07/78.9 117.6) Water-cooled
Oil cooler type (if so equipped) kgf/cm (psi/kPa)

2
2.3 2.7 (32.70 38.40/225.4 264.6)
110
LUBRICATING SYSTEM
GENERAL DESCRIPTION
LUBRICATING OIL FLOW
Battery
Warning Light
Oil pressure switch Cylinder block oil gallery
Oil filter and cooler assembly. Filter cartridge Partial flow oil filter (If so equipped) Main flow oil filter
Idle gear shaft
Crank shaft bearing Oil pipe
Camshaft bearing
Vacuum pump
Rocker arm shaft Oil cooler Relief valve Timing gears Connecting rod bearing Rocker arm
Oil pump (Orifice) Oil strainer
Regulating valve
Oil pan
The A-4J Series engine lubricating system is a full flow type. Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is then delivered to the vital parts of the engine from the cylinder body oil gallery.
111
LUBRICATING SYSTEM
OIL PUMP
A-4J Series engine are equipped with a trochoid type oil pump. The oil filter and the water cooled oil cooler are a single unit to increase the cooling effect.
112
LUBRICATING SYSTEM
MAIN OIL FILTER
OIL FILTER WITH BUILT-IN OIL COOLER
113
LUBRICATING SYSTEM
OIL PUMP
DISASSEMBLY
4 3
051ET001
Disassembly Steps 1. Oil pipe 2. Strainer case 3. Pump cover 4. Vane

L 5. Pump body with rotor and pinion
114
LUBRICATING SYSTEM

Vane, Rotor, and Cover Clearance Use a feeler gauge to measure the clearance between the vane, the rotor, and the cover. If the clearance between the vane, the rotor, and the cover exceeds the specified limit, the rotor set (pin, shaft, rotor, and vane) must be replaced. Vane, Rotor, and Cover Clearance Standard 0.02 0.07 (0.0008 0.0028) Rotor and Vane Clearance Use a feeler gauge to measure the clearance between the rotor and the vane. If the clearance between the rotor and the exceeds the specified limit, the rotor kit (shaft, rotor, and vane) must be replaced. Rotor and Vane Clearance Standard 0.14 (0.006) or less Vane and Pump Body Clearance Use a feeler gauge to measure the clearance between the vane and the pump body. If the clearance between the vane and the pump body exceeds the specified limit, the entire pump assembly must be replaced. Vane and Pump Body Clearance Standard 0.20 0.27 (0.008 0.011) mm(in) Limit 0.40 (0.016) mm(in) Limit 0.20 (0.008) mm(in) Limit 0.15 (0.006)
115
LUBRICATING SYSTEM
REASSEMBLY
2 3
051ET002
Reassembly Steps 1. Pump body with rotor and pinion 2. Vane 3. Pump cover 4. Strainer case 5. Oil pipe
116
LUBRICATING SYSTEM
OIL FILTER WITH BUILT-IN OIL COOLER

DISASSEMBLY
5 4
7 1 6
Disassembly Steps 1. Drain plug 2. Cartridge oil filter 3. Oil cooler 4. O-ring 5. Safety valve 6. Relief valve 7. Oil filter body
117
LUBRICATING SYSTEM

Relief Valve 1. Attach an oil pressure gauge to the oil gallery near the oil filter. 2. Start the engine to check the relief valve opening pressure. Relief Valve Opening Pressure kgf/cm2(psi/kPa) 5.8 6.2 (82.49 88.18/569.0 608.2)
Oil Cooler Water Leakage At Water Passage 1. Plug one side of the oil cooler water passage. 2. Submerge the oil cooler in water. 3. Apply compressed air (2 kgf/cm2 (28.45 psi/196 kPa)) to the other side of the oil cooler water passage. If air bubbles rise to the surface, there is water leakage.
118
LUBRICATING SYSTEM
REASSEMBLY
3 4
1 7 2
Reassembly Steps 1. Oil filter body

L 2. Relief valve L 3. Safety valve L 5. Oil cooler L 6. Oil filter cartridge L 7. Drain plug
4. O-ring
119
LUBRICATING SYSTEM
2. Relief Vale Tighten the relief valve to the specified torque. Relief Valve Torque kgfm(lb.ft/Nm) 2.5 3.5 (18.1 25.3/24.5 34.3)
5. Oil Cooler 1) Align the oil filter holes with the body knock pins at installation. 2) Tighten the oil cooler to the specified torque. Oil Cooler Torque kgfm(lb.ft/Nm) 2.5 3.5 (18.1 25.3/24.5 34.3)
6. Oil Filter Cartridge 1) Apply engine oil to the O-ring. 2) Turn in the cartridge oil filter until the filter sealing face makes contact with the O-ring. 3) Turn in the cartridge oil filter an additional 1 and 1/4 of a turn.
7. Drain Plug Tighten the drain plug to the specified torque. Drain Plug Torque kgfm(lb.ft/Nm) 1.0 2.0 (7.2 14.4/9.8 19.6)
120
COOLING SYSTEM
SECTION 7
COOLING SYSTEM
Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
121
COOLING SYSTEM

Item Water pump type Pump to crankshaft speed ratio (To 1) Delivery volume Lit(qts)/min. Pump speed at 3000 rpm Water temperature at 30C (86F) Pump bearing type Thermostat type Valve initial opening temperature C(F) Valve full opening temperature C(F) Valve lift at fully open position mm(in.) Centrifugal impeller 1.1 100 (105.5)
Double row shaft Wax pellet with jiggle valve 82 (180) 95 (203) 8.0 (0.31)
122
COOLING SYSTEM
GENERAL DESCRIPTION
COOLANT FLOW
The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat. To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the water pump and thermostat through the by-pass hose and back to the cylinder body. The coolant does not circulate through the radiator. When the coolant temperature reaches 82C (180F), the thermostat will begin to open and a gradually increasing amount of coolant will circulate through the radiator. The thermostat will be fully open when the coolant temperature reaches 95C (203F). All of the coolant is now circulating through the radiator for effective engine coolant.
123
COOLING SYSTEM
WATER PUMP
THERMOSTAT
A centrifugal type water pump forcefully circulates the coolant through the cooling system. A wax pellet type thermostat is used. The jiggle valve accelerates engine warm-up.
124
COOLING SYSTEM
WATER PUMP
DISASSEMBLY
4 6 5 3 7 1
Disassembly Steps
L 1.
2. L 3. L 4.
O-ring Set screw Cooling fan center Impeller and seal unit
L 5.
6. 7.
Bearing unit Thrower Water pump body
125
COOLING SYSTEM
3. Cooling Fan Center Remove the fan center with a bench press and a bar.
4. Impeller and Seal Unit Remove the impeller and seal unit with a bench press and bar. Note: Do not drive out the impeller with a hammer. Damage to the impeller will result.
126
COOLING SYSTEM

Bearing Unit Check the bearing for abnormal noise, biding, and other abnormal conditions.
127
COOLING SYSTEM
REASSEMBLY
5 2 3 6 1 7
Reassembly Steps
1. 2. L 3. L 4. Water pump body Thrower Bearing unit Set screw
L 5. L 6.
7.
Impeller and seal unit Cooling fan center O-ring
128
COOLING SYSTEM
3. 4.
Bearing Unit Set Screw 1) Align the bearing set screw hole with the pump body set screw hole. 2) Press the bearing unit into place. 3) Secure the bearing with the set screw.
5.
Impeller and Seal Unit 1) 2) Apply a thin coat of liquid gasket to the seal unit outer periphery. Install the seal unit.
3)
Measure the impeller protection from the water pump body fitting face. mm(in.) 25.0 (0.98)
Impeller Projection
6.
Cooling Fan Center Measure the distance between the cooling fan fitting face and the water pump body fitting face. mm(in.) 79.2 79.8 (3.12 3.14)
Cooling Fan Center Distance
129
COOLING SYSTEM
Note:
1. The fan center and the impeller are installed to the water pump shaft with a press. Never attempt to remove and reinstall the fan center and the impeller a second time. Replace the entire water pump assembly. Removing and reinstalling the fan center and the impeller a second time may result in the breakdown of the water pump during engine operation and subsequent serious overheating problems. 2. The water pump assembly must be replaced whenever the fan center and impeller pressure force falls below 200 kgf (1.96 kN). 3. Do not attempt to strike the bearing into position with a hammer or similar object. Damage to the bearing will result.
130
COOLING SYSTEM
THERMOSTAT
Operating Test 1. Completely submerge the thermostat in water. 2. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat.
1 2
3.
Check the thermostat initial opening temperature. C(F) 82 (180)
Thermostat Initial Opening Temperature
4.
3
Check the thermostat full opening temperature. C(F) 95 (203)
Thermostat Full Opening Temperature
Valve Lift at Fully Open Position 8.0 (0.315) 1 Thermostat 2 Agitating Rod 3 Wooden Piece
mm(in.)
131
MEMO
132
FUEL SYSTEM
SECTION 8
FUEL SYSTEM
Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Injection pump data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
133
FUEL SYSTEM

Item Injection pump type Plunger outside diameter mm(in.) Plunger lift mm(in.) Governor type Fuel feed pump type Injection nozzle type Number of injection nozzle orifices Injection nozzle orifice inside diameter mm(in.) 2 Injection nozzle opening pressure kg/cm (psi/MPa) Main fuel filter type Bosch A type 9.0 (0.35) 3.25 3.35 (0.128 0.132) RSV variable speed mechanical type Single action Hole type 4 1.0 (0.039) 185 (2,630/18.1) Cartridge paper element water separator Water separator (if so equipped)
134
FUEL SYSTEM
GENERAL DESCRIPTION
COOLANT FLOW
Nozzle
Fuel filter
Water separator
Injection pump Fuel tank
The fuel system consists of the fuel tank, the water separator (if so equipped), the fuel filter, the injection pump, and the injection nozzle. The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other foreign material are removed from the fuel. Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum timing for efficient engine operation.
135
FUEL SYSTEM
INJECTION NOZZLE
Nozzle holder
Adjusting shim
Spring Spring seat Injection nozzle Retaing nut
A hole (with 4 orifices) type injection nozzle is used. It consists of the nozzle body and the needle valve assembly. The injection nozzle sprays pressurized fuel from the injection pump into the combustion chamber through the nozzle body injection orifice.
136
FUEL SYSTEM
FUEL FILTER AND WATER SEPARATOR
Drain Level
A cartridge type fuel filter and a water separator are used. As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches the injection pump. The water separator has an internal float. When the float reaches the drain level, remind you to drain the water from the water separator.
137
FUEL SYSTEM
INJECTION NOZZLE DISASSEMBLY
6 5
4 3 2
Disassembly Steps
1.
L 2.
3. 4.
Retaining nut Injection nozzle Spacer Spring seat
5. 6. 7.
Spring Adjusting shim Nozzle holder
138
FUEL SYSTEM
Performance this test before disassembling the injection nozzle. 1) Install the injection nozzle to the nozzle tester. 2) Use the nozzle tester to apply compressed fuel at 185 kgf/cm 2 (2,630 psi/18.1 MPa) to the injection nozzle. 3) Check the area around the nozzle seat for fuel leakage. If there is fuel leakage, the injection nozzle and the injection body must be replaced as a set. 2. 1) Injection Nozzle Remove the injection nozzles from the nozzle holders. The nozzle needle valve and nozzle body combinations must be interchange. Immerse the injection nozzles in a tool tray filled with clean diesel fuel to protect them from dust.
2)
139
FUEL SYSTEM

Injection Nozzle Needle Inspection 1. 2. 3. Remove the nozzle needle from the nozzle body. Carefully wash the nozzle needle and the nozzle body in clean diesel fuel. Check that the nozzle needle moves smoothly inside the injection nozzle body. If the nozzle needle does not moves smoothly, it must be repaired (See Nozzle Lapping Procedure below.) Nozzle Lapping Procedure
3
Lap the nozzle needle 1 and the nozzle body 2 by applying a compound of oxidized chrome and animal oil 3. Note: Do not apply an excessive amount of the oxidized chrome and animal oil compound to the injection needle valve seat area. 1. 2. Carefully wash the needle valve and the nozzle body in clean diesel fuel after lapping.
Nozzle Body and Needle Valve Inspection Check the nozzle body and the needle valve for damage and deformation. The nozzle and body must be replaced if either of these two conditions are discovered during inspection.
140
FUEL SYSTEM
REASSEMBLY
2 3
4 5 6
Reassembly Steps
1.
L 2.
3. 4.
Nozzle holder Adjusting shim Spring Spring seat
5. 6. L 7.
Spacer Injection nozzle Retaining nut
141
FUEL SYSTEM
3.
Adjust Shim mm(in.) 0.50-0.50 (0.02-0.06) 0.025 (0.001) 40 Range Increment
Adjust Shim Availability
Total No. of Shims
7.
Retaining Nut Tighten to the retaining nut to the specified torque. kgfm(lbs.ft./Nm)
Retaining Nut Torque
4.0 5.0 (28.9 36.2/39.2 49.0)
Injection Nozzle Adjustment 1. Attach the injection nozzle holder to the injection nozzle tester. 2. Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure. If the injection nozzle does not open at the specified pressure, install or remove the appropriate number of adjusting shims to adjust it. (Reference) Removing or installing one shim will increase or decrease the nozzle opening pressure approximately 3.77 kgf/cm2 (53.6 psi/369.7 kPa).
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN EASILY PUNCTURE A PERSON S SKIN. KEEP YOUR HANDS AWAY FROM THE INJECTION NOZZLE TESTER AT ALL TIMES.
142
FUEL SYSTEM
INJECTION PUMP DATA

INJECTION PUMP IDENTIFICATION
Refer to the Item INJECTION PUMP IDENTIFICATION on Page 1 of the SERVICING Section of this Workshop Manual.
INJECTION VOLUME ADJUSTMENT

TEST CONDITIONS
Injection Nozzle Injection Nozzle Holder Injection Starting Pressure Injection Line Dimensions Inside Diameter Outside Diameter Length Transfer Pump Pressure Testing Diesel Fuel Operating Temperature Pump Rotation Direction kgf/cm2(psi/MPa) mm(in.) ZEXEL No.: 105780-0000 Bosch Type No.: DN12SD12T ZEXEL No.: 105780-2080 Bosch Type No.: EF8511/9 175.0 (2488.5/17.16) 2.0 (0.079) 6.0 (0.236) 600.0 (23.6) 1.6 (22.75/157) ISO4113 or SAE Standard Test Oil (SAEJ967D) 40 45 (104 113) Clockwise (Viewed from the drive side)
kgf/cm2(psi/kPa) C(F)
143
FUEL SYSTEM
INJECTION QUANTITY
Injection Quantity (cc/1000 Strokes) Maximum Variation (%)
Adjusting Point
Rod Position Pump Speed (mm) (rpm)
Fixed
Remarks
8.3 About 6.6
1,500 500 100
64 65 9.5 13.5 (70 85)
2.5 15.0
Lever Basic Rack Lever Adjust max. var. bet. cyl. at R = 6.6. Adjust governor as per. gov. adj. spec. Confirm that the timing of D is advanced 130 from A.
Above 14.0
Pre-Stroke: No.1 Plunger 3.3 0.05 mm Injection Order: 1-3-4-2 (Plunger numbered from the drive side) Tappet Clearance: More than 0.3 mm for all cylinders
* This performance drawing for A-4JB1PAW-01 only.
GOVERNOR ADJUSTMENT
Full Adjustment
Above 14.0 13.0
D Idle-sub spring setting
Governor spring setting 9.3 9.10.1 8.3 7.80.1 500 6.3 4.30.4 C
Rack position (mm)
16030 250
500 (610)
(1535)1545 1610
Pump speed (rpm)
144
FUEL SYSTEM Speed Lever Angle
353 Stop 255
125
145
MEMO
146
ENGINE ELECTRICALS
SECTION 9
ENGINE ELECTRICALS
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
147
ENGINE ELECTRICALS
STARTER
STARTER IDENTIFICATION
3 12V
C A
2 4
HITACHI
MADE IN JAPAN
Hitachi starter are identified by name plate attached to the yoke. (Illustration) 1 Isuzu part number 2 Manufacturers code number
1 2 4 24V
HITACHI
MADE IN JAPAN
3 Rated voltage 4 Manufacturers production mark Note: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number. Use of the wrong service data will result in starter damage.
148
ENGINE ELECTRICALS
MAIN DATA AND SPECIFICATION

Isuzu Part No. Hitachi code No. Rated voltage Rated output Rating Direction of rotation (Viewed from the pinion side) Clutch type Terminal voltage (No. Load) Minimum current (No. Load) Starter motor minimum operating speed (No. Load) Pinion gear Modules Number of teeth Outside diameter Travel distance Yoke outside diameter Number of poles Magnetic switch (at 20C [68F]) Series coil resistance Shut coil resistance Brush length Standard Limit Brush spring standard fitting load Commutator Outside diameter Standard Limit Difference between the largest and smallest diameters Standard Depth of undercut mica Limit Standard Limit V kW Sec 8-97084-877-0 S13-11 12 2.2 30 Clockwise Roller V A rpm 11 160 3900 23 90 3100 8-94423-452-0 S24-07 24 3.5
mm(in.) mm(in.) mm(in.)
2.75 9 33.0 (4.3) 1.51 (0.059) 80.0 (3.15) 4
0.27 1.25
mm(in.) mm(in.) kgf(lb./N)
15.0 (0.59) 9.0 (0.35) (3.52/15.74.4/19.6)
15.0 (0.59) 9.0 (0.35) (2.5/24.57.7/34.3)
mm(in.) mm(in.)
30.0 (1.18) 29.0 (1.14)
36.5 (1.44) 35.5 (1.40)
mm(in.) mm(in.) mm(in.) mm(in.)
0.05 (0.002) 0.10 (0.004) 0.5 0.8 (0.02 0.03) 0.2 (0.008)
149
ENGINE ELECTRICALS
GENERAL DESCRIPTION
This starter is equipped with a reduction gear between the armature shaft and the flywheel ring gear drive pinion. This construction enable the starter to reduce 27% of the armature shaft revolution speed at the pinion contributing to achieve more compact size and higher cold engine starting ability than the non-reduction gear type starter.
150
ENGINE ELECTRICALS
DISASSEMBLY
6 2 19 4 5
18 13 12 17
16
15 14
20 1
8 9 10 11
Disassembly Steps
L 1.
2. L 3. L 4. L 5. L 6. L 7. 8. 9. 10.
Lead wire Bolt Magnetic switch Torsion spring Plunger Shim Through bolt Rear cover Brush holder Yoke
11. 12. L 13. L 14. 15. 16. 17. 18. 19. 20.
Armature Screw Bearing retainer Snap ring Pinion stopper Return spring Pinion shaft Overrunning clutch Dust cover Shift lever
151
ENGINE ELECTRICALS
1. Lead Wire Disconnect lead wire at the magnetic switch.
3. Magnetic Switch Remove the magnetic switch fixing bolts, then remove the switch from the shift lever.
4. Torsion Spring 5. Plunger 6. Shim Remove the torsion spring, plunger and shim from the magnetic switch.
7. Through bolt Remove the yoke, armature and brush holder together from the gear case.
152
ENGINE ELECTRICALS 9. Brush Holder Using long-nose pliers remove the 4 brushes.
13. Bearing retainer Remove the bearing retainer, then remove the pinion from the gear case.
14. Snap Ring Remove the snap ring using a screw driver or equivalent, then disassemble the pinion assembly.
153
ENGINE ELECTRICALS

ARMATURE Armature Short Circuit Test

1
1. Place the armature on a growler tester 1. 2. Hold a hack saw blade 2 against the armature core while slowly rotating the armature. If the armature is short circuited, the hack saw blade will vibrate and will be attracted to the armature core. A short circuited armature must be replaced.
Armature Winding Ground Test

Check for continuity across the commutator segments and the core. If there is continuity, the armature is internally grounded due to insulation failure and must be replaced.
Armature Winding Continuity Test

Check for continuity across the commutator segment. If there is no continuity, the armature coil is open and must be replaced.
154
ENGINE ELECTRICALS
Commutator Run-Out Test

Use a dial indicator and a V-block to measure the commutator runout. If the measure value exceeds the limit, the commutator must be replaced. Commutator Run-Out Standard 0.02 (0.0008) Limit 0.05 (0.002) mm(in.)
Commutator Outside Diameter Measurement

Use a vernier caliper to measure the commutator outside diameter. If the measured value exceeds the limit, the armature must be replaced. Commutator Outside Diameter Standard S13 11 S24 07 30.0 (1.18) 36.5 (1.44) mm(in.) Limit 29.0 (1.14) 35.5 (1.40)
Segment Mica Depth Measurement

Use a depth gauge to measure the segment mica depth. If the measured value exceeds the limit, the segment mica must be undercut. Segment Mica Depth Standard 0.5 0.8 (0.02 0.03) Limit 0.2 (0.008) mm(in.)
Bearing Inspection
Visually inspect the bearing. If the bearing is worn or damaged, it must be replaced.
155
ENGINE ELECTRICALS
YOKE Field Winding Ground Test

Use a circuit tester to check the field winding ground. 1. Touch one probe to the brush field winding end. 2. Touch the other probe to the bare surface of the yoke body. There should be no continuity. If there is continuity, the field windings are grounded. Repair or replace the field windings.
Field Winding Continuity Test

Use a circuit tester to check the field winding continuity. 1. Touch one probe to the field winding lead wire. 2. Touch the other probe to the brush. There should be continuity. If there is no continuity, the field windings are open. Repair or replace the field windings.
BRUSH AND BRUSH HOLDER Brush Length Measurement

Use a vernier caliper to measure the brush length. If the measured value exceeds the limit, the brush and/ or the yoke must be replaced. Brush Length Standard 20.0 (0.79) Limit 13.0 (0.51) mm(in.)
156
ENGINE ELECTRICALS
Brush Spring Inspection

Visually check the brush spring for weakness and rusting. Replace the brush spring if it is weak or rusted. Use a spring balancer to measure the spring tension. If the measured valve exceeds the limit, the brush spring must be replaced.
Brush Holder Insulation Test

Use a circuit tester to check the brush holder insulation. 1. Touch one probe to the field winding lead wire. 2. Touch the other probe to the brush. There should be no continuity. If there is continuity, the brush holder must be repaired or replaced.
PINION CLUTCH Pinion Inspection

Use your hand to turn the pinion in the direction of starter motor rotation. The pinion should turn freely. Try to turn the pinion in the opposite direction. The pinion should lock.
Check the bearing for binding or play by spinning the ball bearing by holding the outer race with fingers.
MAGNETIC SWITCH
Check for continuity across the magnetic switch S terminal and coil case. If no continuity exists, the shunt coil is open and should be replaced.
157
ENGINE ELECTRICALS Check for continuity across magnetic switch S terminal and M terminal. If no continuity exists, series coil are open and should be replaced.
158
ENGINE ELECTRICALS
REASSEMBLY
2 7 6 4 3
8 13 14 9
10
11 12
19
5 20
18 17 16 15
Reassembly Steps
1. 2. 3. L 4. L 5. L 6. 7. 8. L 9. 10. Magnetic switch Shim Plunger Torsion spring Shift lever Dust cover Bolt Overrunning clutch Pinion Return spring 11. 12. 13. 14. 15. 16. L 17. 18. L 19. L 20. Pinion stopper Snap ring Bearing retainer Bolt Armature Yoke Brush holder Rear cover Through bolt Lead wire
159
ENGINE ELECTRICALS
4. Torsion Spring 5. Shift Lever Set the torsion spring to the hole in magnetic switch. Insert the shift lever, via the torsion spring, into plunger hole in the magnetic switch.
6. Dust Cover Install the magnetic switch in gear case. Make sure to install the dust cover. Dust Cover Bolt Torque kgfm(lb.ft./Nm) 0.7 0.8 (5.1 5.8/6.9 7.9)
9. Pinion Install the pinion after applying grease to the reduction gear.
17. Brush Holders When installing brushes, exercise care so as not to cause damage to the commutator face. Install the brush by raising the end of the brush spring. Install the brush holder by aligning it with the yoke.
160
ENGINE ELECTRICALS 19. Through Bolt Tighten the through bolts to the specified torque a little at a time. Through Bolt Torque kgfm(lb.ft./Nm) 0.5 0.7 (3.6 5.1/4.9 6.9)
20. Lead Wire Tighten the lead wire to the specified torque. Lead Wire Torque kgfm(lb.ft./Nm) 0.8 1.0 (5.8 7.2/7.8 9.8)
Inspection After Reassembly The pinion jumps out as the magnetic switch S terminals is connected to the battery positive terminal and negative terminal is connected to the gear case. Check the difference between the point to which the pinion is jumped out and point to which pinion can be pulled out (in direction of arrow) with fingers. Pinion Gap 0.3 1.5 (0.012 0.060) When checking the pinion gap avoid keeping magnetic switch engaged for more than 30 seconds. mm(in.)
When Pinion Gap Deviates From Specified Value Make and adjustment using a shim. Adjusting shims are available in thicknesses of 0.5 mm (0.02 in.) and 0.8 mm (0.03 in.)
161
ENGINE ELECTRICALS
ALTERNATOR
ALTERNATOR IDENTIFICATION
4
Hitachi alternators are identified by name plate attached to the rear cover. (Illustration)
R L
1 Isuzu part number 2 Manufacturers code number 3 Rated output 4 Manufacturers production mark Note: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number. Use of the wrong service data will result alternator damaged.
IC REG BUILT IN Hitachi. Ltd. Japan

3
162
ENGINE ELECTRICALS
MAIN DATA AND SPECIFICATION

Engine Model to be Equipped Manufacturers name Isuzu Part No. Manufacturers Code No. Rated voltage Rated output Operating speed Rated output at rpm No-load output at 0 amperes V A rpm A/V/rpm V/rpm 8-94423-756-0 LR135-127 12 35 100013500 33-37/13.5/5000 13.5/1000 or less A 4J Series HITACHI 8-94431-560-0 LR215-50 24 15 10005000 15/27/5000 27/1000 or less Clockwise Negative 80 (3.15) 5-81200-335-0 LR200-24 24 20 100013500 20/27/5000 27/1000 or less
Direction of rotation (viewed from the pulley side) Polarity grounded Pulley diameter (P.C.D.) mm(in.) Coil resistance at 20C Rotor coil Stator coil Brush length Standard Limit Slip ring diameter: Standard Limit Shaft diameter Front Rear Regulator(s) applicable Isuzu Part No. Manufacturer(s) code No.
3.11 0.13
18.2 0.199
12.72 0.402
mm(in.) mm(in.)
14.5 (0.57) 7.5 (0.30)
16.0 (0.63) 7.0 (0.28)
14.5 (0.57) 7.5 (0.30)
mm(in.) mm(in.)
31.6 (1.24) 30.6 (1.20)
mm(in.) mm(in.)
15.0 (0.59) 12.0 (0.47)
17.0 (0.70) 12.0 (0.47) Built-in 5-81251-016-0 TR2Z-47
15.0 (0.59) 12.0 (0.47)
5-81270-004-0 TR1Z-63
5-81251-016-0 TR2Z-47
163
ENGINE ELECTRICALS
GENERAL DESCRIPTION
The alternator consists of the front cover, the rotor, the stator, the built-in IC regulator (some engines use a Tirrell alternator with separate regulator), and the rear cover. This small size and light weight alternator provides excellent reliability. Its simple construction makes it very easy to service. The built-in IC regulator minimizes circuit wiring.
164
ENGINE ELECTRICALS
DISASSEMBLY
These disassembly steps are based on the built-in IC regulator type. 5 6 3 8 7
4 12 11 1
10
Disassembly Steps
1. 2. L 3. L 4. 5. 6. Through bolt Rear cover and stator Pulley and fan Spacer collar Rotor with bearing Bearing retainer 7. 8. L 9. L 10. 11. 12. Ball bearing Front cover Stator Rectifier with brush holder IC regulator Rear cover
165
ENGINE ELECTRICALS
3. Pulley and Fan (1) Clamp the rotor shaft in a soft jaw vise. (2) Loosen the pulley lock nut 1.
1
(3) Remove the pulley 2 along with the spacer collar.
4. Rotor and Bearing

1
(1) Use a plastic hammer or a press 1 to remove the rotor from the front cover 2. (2) Remove the spacer collar.
8. Front Cover
1
Use screwdrivers to pry the front cover 1 from the stator 2. Note: Do not attempt to pry the coil wires from the stator.
9. Stator 10. Rectifier with Brush Holder Use a soldering iron 1 and a pair of long nose pliers 2 to remove the rectifiers.
2 1
Note: Hold the rectifier leads between the rectifier and the soldering iron with the long nose pliers. This will protect the rectifier from the heat.
166
ENGINE ELECTRICALS

ROTOR AND BEARING

Check the face of the slip rings for contamination and roughness. If found to be roughened, dress with a fine sand paper (#500 600). If found to be contaminated, clean with a cloth saturated with alcohol.
Ball Bearing
Check that the ball bearings rotate smoothly. If the ball bearings are noisy, they must be replaced.
Use a vernier caliper to measure the slip ring outside diameter. If the measured value exceeds the limit, the rotor must be replaced. Slip Ring Outside Diameter Standard 31.6 (1.24) Limit 30.6 (1.20) mm(in.)
167
ENGINE ELECTRICALS
Rotor Coil Continuity Test

Use an circuit tester to test the rotor coil continuity. 1. Touch both circuit tester probes to the rotor coil slip rings. 2. Note the circuit tester reading. The circuit tester should register approximately 9 ohms. 3. If the circuit tester does not show continuity, check the connections between the lead wire and the slip rings. If breaks are founded, repair and repeat the rotor coil continuity test. If there is still no rotor coil continuity, the rotor must be replaced.
Rotor Coil Ground Test

Use an circuit tester to test the rotor coil for grounding. 1. Touch one of the circuit tester probes to the rotor shaft. 2. Touch the other circuit tester probe to one of slip rings. 3. Note the circuit tester reading. 4. Touch the circuit tester probe to the other slip ring. 5. Note the circuit tester reading. The circuit tester should show infinity (no needle movement) at both measuring points. If the circuit tester does not show infinity (the needle moves) at both measuring points, the rotor is grounded and must be replaced.
STATOR COIL Stator Coil Continuity Test

Use an circuit tester to test the stator coil continuity. 1. Touch the circuit tester probes to two of the bare stator wires. 2. Note the circuit tester reading. 3. Move one of the circuit tester probes to a third wire.
168
ENGINE ELECTRICALS 4. Note the circuit tester reading. If the two readings (Steps 2 and 4) are identical, the stator coil has continuity. If the two circuit tester readings are different, there is no stator continuity. 5. Check the neutral junction (arrow mark) for breaks. If breaks are found, repair and repeat the stator coil continuity test. If there is still no stator coil continuity, the stator must be replaced.
Stator Coil Ground Test

Use an circuit tester to test the stator coil for grounding. 1. Touch one circuit tester probe to the bear metal surface of the stator. 2. Touch the other circuit tester probe to a bare stator lead wire. 3. Note the circuit tester reading. The circuit tester should show infinity (no needle movement). If the circuit tester shows a value other than infinity (the needle moves), the stator is grounded and must be replaced.
RECTIFIER
BAD GOOD
Rectifier (Positive Diode) Continuity Test

Use an circuit tester to test rectifier continuity. 1. Touch the circuit tester positive probe to the rectifier holder. 2. Touch the circuit tester negative probe to each of the diode terminals in turns.
169
ENGINE ELECTRICALS 3. Note the meter reading for each diode terminal. All of the diode should show continuity. If a diode shows no continuity, it is open circuit. The rectifier assembly must be replaced.
4. Touch the circuit tester negative probe to the rectifier holder.

GOOD BAD
5. Touch the circuit tester positive probe to each of the diode terminals in turn. 6. Note the meter reading for each diode terminal. None of the diodes should show continuity. If a diode shows continuity, it is shorted. The rectifier assembly must be replaced.
Rectifier (Negative Diode) Continuity Test

BAD GOOD
Use a circuit tester to test the rectifier continuity. 1. Touch the circuit tester negative probe to the rectifier holder. 2. Touch the circuit tester positive probe to each of the diode terminals in turn. 3. Note the meter reading for each diode terminal. All of the diode should show continuity. If a diode shows no continuity, it is open. The rectifier assembly must be replaced.
GOOD
BAD
4. Touch the circuit tester positive probe to the rectifier holder. 5. Touch the circuit tester negative probe to each of the diode terminals in turn. 6. Note the meter reading for each diode terminal. None of the diode should show continuity. If a diode shows continuity, it is shorted. The rectifier assembly must be replaced.
Rectifier Assembly Replacement Procedure

Use the Rectifier Service Kit to replace the rectifier assembly in the following steps. 1. Connect the three inside lead wires to the N terminals 1. 2. Connect the three outside lead wires 2 to the outside terminals.
2
3. Wind the stator lead wires around the rectifier lead wires (included in the Rectifier Service Kit) and solder them.
170
ENGINE ELECTRICALS Note: 1. The stator lead wires must be cut to the proper length before they are connected to the rectifier lead wires. If the stator lead wires are too long or too short, trouble may occur. Stator Lead Wire Length 33.5 (1.32) 2. Take care not to damage the rectifier paint surfaces. mm(in.)
BRUSH
Use a vernier caliper to measure the brush. If the measured value exceeds the limit, the brush must be replaced. Brush Length Standard 8-94423-756-0 8-94431-560-0 5-81200-335-0 14.5 (0.57) 16.0 (0.63) 14.5 (0.57) mm(in.) Limit 7.5 (0.30) 7.0 (0.28) 7.5 (0.30)
Brushes are provided with a line which indicates the limit of usage.
171
ENGINE ELECTRICALS
REASSEMBLY
9 8 11 6 7
10 1 2 12
Reassembly Steps
1. 2. L 3. L 4. 5. 6. Rear cover IC regulator Rectifier with brush holder Stator Rear cover and stator Front cover
L 7.
8. 9. 10. L 11. 12.
Ball bearing Bearing retainer Rotor with bearing Spacer collar Pulley and fan Through bolt
172
ENGINE ELECTRICALS
3. Rectifier with Brush Holder 4. Stator When connecting stator coil leads and diode leads using solder, use long-nose pliers and finish the work as quickly as possible to prevent the heat from being transferred to the diodes.
11. Pulley and Fan Tighten the pulley and fan to the specified torque. Pulley and Fan Nut Torque kgfm(lb.ft./Nm) 5.0 6.5 (36.2 47.7/49.0 63.7)
173
MEMO
174
TROUBLESHOOTING
SECTION 10
TROUBLESHOOTING
Hard starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Unstable idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Insufficient power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Excessive fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Excessive oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 White exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Dark exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Oil pressure does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Abnormal engine noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
175
TROUBLESHOOTING
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair engine problems. Each troubleshooting chart has three headings arranged from left to right. (1) 1. Checkpoint Hard Starting 1) Starter inoperative 2) Starter operates but engine does not turn over 3) Engine turns over but does not start 2. 3. 4. 5. 6. 7. 8. 9. 10. Unstable Idling Insufficient Power Excessive Fuel Consumption Excessive Oil Consumption Overheating White Exhaust Smoke Dark Exhaust Smoke Oil Pressure Does Not Rise Abnormal Engine Noise (2) Trouble Cause (3) Countermeasure This Section is divided into ten sub-sections:
176
TROUBLESHOOTING
1.
1.
Checkpoint
HARD STARTING
STARTER INOPERATIVE
Trouble Cause Countermeasure
Neutral switch (If so equipped)
NG
Defective neutral switch
NG
Replace the neutral switch
Battery
NG
Loose battery cable terminals Poor connections due to rusting
NG
Clean and/or retighten the battery cable terminals
NG
Battery discharged or weak
NG
Recharge or replace the battery
NG
Fan belt loose or broken
NG
Adjust or replace the fan belt
OK
Fusible link
NG
Fusible link shorted
NG
Replace the fusible link
OK
Starter switch
NG
Defective starter switch or starter relay
NG
Replace the starter switch or the starter relay
OK
Starter
NG
Defective magnetic switch or starter relay
NG
Repair or replace the magnetic switch
OK
Starter
NG
Defective starter
NG
Repair or replace the starter motor
177
TROUBLESHOOTING
1.
2.
HARD STARTING
STARTER OPERATES BUT ENGINE DOES NOT TURN OVER

Checkpoint
Battery
NG
Loose battery cable terminals Poor connections due to rusting
NG
Clean and/or retighten the battery cable terminals
NG
Battery discharged or weak
NG
Recharge or replace the battery
NG
Fan belt loose or broken
NG
Adjust or replace the fan belt
OK
Starter
NG
Defective pinion gear
NG
Replace the pinion gear
NG
Defective magnetic switch
NG
Repair or replace the magnetic switch
NG
Brush wear Weak brush spring
NG
Replace the brush and/or the brush spring
OK
Engine
NG
Piston, crank bearing seizure, or other damage
NG
Repair or replace the related parts
178
TROUBLESHOOTING
1.
3.
Checkpoint
HARD STARTING
ENGINE TURNS OVER BUT DOES NOT START

Engine stop mechanism
NG
Defective engine stop mechanism control wire improperly adjusted (In line pump)
NG
Replace the engine stop mechanism Adjust the control wire
NG
Defective fuel cut solenoid valve (VE pump)
NG
Replace the fuel cut solenoid valve
FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP
Fuel
NG
Fuel tank is empty
NG
Fill the fuel tank
OK Repair or replace the fuel lines Retighten the fuel line connections
Fuel piping
NG
Clogged or damaged fuel lines Loose fuel line connections
NG
OK
Fuel filter
NG
Fuel filter overflow valve does not close
NG
Repair or replace the fuel filter overflow valve
NG
Clogged fuel filter element
NG
Replace the fuel filter element or the fuel filter cartridge
OK
Fuel system
NG
Air in the fuel system
NG
Bleed the air from the fuel system
Continued on the next page
179
TROUBLESHOOTING
1.
3.
HARD STARTING
ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP

Checkpoint
Continued from the previous page OK Injection nozzle injection starting pressure too low Improper spray condition
Trouble Cause
Countermeasure
Injection nozzle
NG
NG
Adjust or replace the injection nozzle
OK Defective fuel injection nozzle resulting in fuel drippage after fuel injection
Injection pump
NG
NG
Replace the delivery valve
NG
Defective injection pump control rack operation
NG
Repair or replace the injection pump control rack
NG
Injection pump plunger worn or stuck
NG
Replace the injection pump plunger assembly
OK
Injection pump (VE pump)
NG
Injection pump drive shaft seizure or other damage
NG
Replace the injection pump drive shaft
NG
Injection pump governor spring seizure
NG
Replace the injection pump governor spring
180
TROUBLESHOOTING
2.
Checkpoint
UNSTABLE IDLING
Idling system
NG
Idling improperly adjusted
NG
Adjust the idling
OK
Fast idling speed control device
NG
Defective fast idling speed control device
NG
Repair or replace the fast idling speed control device
OK
Accelerator control system
NG
Accelerator control system improperly adjusted
NG
Adjust the accelerator control system
OK
Fuel system
NG
Fuel system leakage or blockage
NG
Repair or replace the fuel system
NG
Air in the fuel system
NG
Bleed the air from the fuel system
NG
Water particles in the fuel system
NG
Change the fuel
OK
Fuel filter
NG
NG
181
TROUBLESHOOTING
2.
Checkpoint
Continued from the previous page OK
UNSTABLE IDLING
Injection pump
NG
Defective governor lever operation
NG
Repair or replace the governor lever
NG
Regulator valve improperly adjusted (VE pump only)
NG
Adjust or replace the regulator valve
NG
Broken plunger spring
NG
Replace the plunger spring
NG
Worn plunger
NG
Replace the plunger assembly
NG
Worn camshaft (In-line pump only)
NG
Replace the camshaft
NG
Worn roller tappet (In-line pump only)
NG
Replace the roller tappet
NG
Worn cam disc (VE pump only)
NG
Replace the cam disc
182
TROUBLESHOOTING
2.
Checkpoint
UNSTABLE IDLING
Valve clearance
NG
Valve clearance improperly adjusted
NG
Adjust the valve clearance
OK Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat
Compression pressure
NG
NG
Replace the related parts
183
TROUBLESHOOTING
3.
Checkpoint
INSUFFICIENT POWER
Air cleaner
NG
Clogged air cleaner element
NG
Clean or replace the air cleaner element
OK
Fuel
NG
Water particles in the fuel
NG
Replace the fuel
OK
Fuel filter
NG
NG
OK
Fuel feed pump
NG
Defective fuel feed pump
NG
Repair or replace the fuel feed pump
OK
Injection nozzle
NG
Injection nozzle sticking
NG
Replace the injection nozzle
NG
Injection nozzle injection starting pressure too low Improper spray condition
NG
OK
Fuel injection pipes
NG
Fuel injection pipes damaged or obstructed
NG
Replace the fuel injection pipes
184
TROUBLESHOOTING
3.
Checkpoint
INSUFFICIENT POWER
Injection pump
NG
Defective regulating valve (VE pump only)
NG
Repair or replace the regulating valve
NG
Defective delivery valve
NG
NG
Defective timer
NG
Repair or replace the timer
NG
NG
NG
Improper control lever operation
NG
Adjust or replace the control lever
NG
Defective injection timing
NG
Adjust the injection timing Repair or replace the injection pump timer
NG
Weak governor spring
NG
Replace the governor spring
185
TROUBLESHOOTING
3.
Checkpoint
INSUFFICIENT POWER
Injection pump
NG
Worn plunger
NG
Replace the plunger assembly
NG
Worn camshaft (In-line pump only)
NG
Replace the camshaft
NG
Worn roller tappet (In-line pump only)
NG
Replace the roller tappet
NG
NG
OK
Turbocharger
NG
Booster compensator pipe broken or cracked
NG
Replace the booster compensator pipe
NG
Exhaust gas leakage from the exhaust system Air leakage from the intake system
NG
Repair or replace the related parts
NG
Defective power echo gate
NG
Repair or replace the power echo gate
186
TROUBLESHOOTING
3.
Checkpoint
INSUFFICIENT POWER
Turbocharger
NG
Defective turbocharger assembly
NG
Replace the turbocharger assembly
NG
NG
OK
Valve clearance
NG
NG
OK
Valve spring
NG
Valve spring weak or broken
NG
Replace the valve spring
OK
Exhaust system
NG
Exhaust pipe clogged
NG
Clean the exhaust pipe
OK
Full load adjusting screw seal
NG
Open and improperly set adjusting screw seal
NG
Adjust and reseal the adjusting screw
187
TROUBLESHOOTING
4.
Checkpoint
EXCESSIVE FUEL CONSUMPTION

Fuel system
NG
Fuel leakage
NG
Repair or replace the fuel system related parts
OK
Air cleaner
NG
NG
OK
Idling speed
NG
Poorly adjusted idling speed
NG
Adjust the idling speed
OK Injection nozzle injection starting pressure too low Improper spray condition
Injection nozzle
NG
NG
OK
Fuel injection timing
NG
Fuel injection timing improperly adjusted
NG
Adjust the fuel injection timing
OK Defective delivery valve resulting is fuel drippage after fuel injection
Injection pump
NG
NG
OK
Turbocharger
NG
Air leakage from the turbocharger intake side
NG
Repair the turbocharger intake side
188
TROUBLESHOOTING
4.
Checkpoint
EXCESSIVE FUEL CONSUMPTION

Turbocharger
NG
Defective turbocharger assembly
NG
Replace the turbocharger assembly
OK
Valve clearance
NG
NG
NG
NG
OK
Valve spring
NG
Valve spring weak or broken
NG
Replace the valve spring
189
TROUBLESHOOTING
5.
Checkpoint
EXCESSIVE OIL CONSUMPTION

Engine oil
NG
Engine oil unsuitable Too much engine oil
NG
Replace the engine oil Correct the engine oil volume
OK
Oil seal and gasket
NG
Oil leakage from the oil seal and/or the gasket
NG
Replace the oil seal and/or the gasket
OK
Air breather
NG
Clogged air breather
NG
Clean the air breather
OK Defective valve seals Worn valves stems and valve guides
Inlet and exhaust valves Valve seals
NG
NG
Replace the valve seals, the valves, and the valve guides
OK
Piston rings
NG
Piston rings worn, broken or improperly installed
NG
Replace the piston rings or properly install
OK
Cylinder liners
NG
Cylinder lines scored or worn
NG
Replace the cylinder liners
190
TROUBLESHOOTING
6.
Checkpoint
OVERHEATING
Cooling water
NG
Insufficient cooling water
NG
Replenish the cooling water
OK
Fan coupling (if so equipped)
NG
Oil leakage from the fan coupling
NG
Replace the fan coupling
OK
Fan belt
NG
Fan belt loose or cracked causing slippage
NG
Replace the fan belt
OK
Radiator
NG
Defective radiator cap or clogged radiator core
NG
Replace the radiator cap or clean the radiator core
OK
Water pump
NG
Defective water pump
NG
Repair or replace the water pump
OK
Cylinder head and cylinder body sealing cap
NG
Defective sealing cap resulting in water leakage
NG
Replace the sealing cap
OK
Thermostat
NG
Defective thermostat
NG
Replace the thermostat
191
TROUBLESHOOTING
6.
Checkpoint
OVERHEATING
Cooling system
NG
Cooling system clogged by foreign material
NG
Clean the foreign material from the cooling system
OK
NG
NG
192
TROUBLESHOOTING
7.
Checkpoint
WHITE EXHAUST SMOKE

Fuel
NG
Water particles in the fuel
NG
Replace the fuel
OK
NG
Delayed fuel injection timing
NG
NG
NG
OK
Turbocharger
NG
Defective turbocharger
NG
Replace the turbocharger
OK Defective valve seals Worn valves stems and valve guides
Inlet and exhaust valves Valve seals
NG
NG
Replace the valve seals, the valves, and the valve guides
OK
Piston rings
NG
Piston rings worn, broken or improperly installed
NG
Replace the piston rings or properly install
OK
Cylinder liners
NG
Cylinder lines scored or worn
NG
Replace the cylinder liners
193
TROUBLESHOOTING
8.
Checkpoint
DARK EXHAUST SMOKE

Air cleaner
NG
NG
OK Injection nozzle injection starting pressure too low Improper spray condition
Injection nozzle
NG
NG
OK
NG
NG
OK Defective delivery valve resulting in fuel drippage after fuel injection
Injection pump
NG
NG
NG
Excessive injection volume
NG
Adjust the injection volume
194
TROUBLESHOOTING
9.
Checkpoint
OIL PRESSURE DOES NOT RISE

Engine oil
NG
Improper viscosity engine oil Too much engine oil
NG
Replace the engine oil Correct the engine oil volume
OK Defective oil pressure gauge or unit Defective indicator light Repair or replace the oil pressure gauge or unit Replace the indicator light
Oil pressure gauge or unit Oil pressure indicator light
NG
NG
OK
Oil filter
NG
Clogged oil filter element
NG
Replace the oil filter element or the oil filter cartridge
OK
Relief valve and by-pass valve
NG
Relief valve sticking and/or weak by-pass valve spring
NG
Replace the relief valve and/or the by-pass valve spring
OK
Oil pump
NG
Clogged oil pump strainer
NG
Clean the oil pump strainer
NG
Worn oil pump related parts
NG
Replace the oil pump related parts
OK
Rocker arm shaft
NG
Worn rocker arm bushing
NG
Replace the rocker arm bushing
195
TROUBLESHOOTING
9.
Checkpoint
OIL PRESSURE DOES NOT RISE

Camshaft
NG
Worn camshaft and camshaft bearing
NG
Replace the camshaft and the camshaft bearings
OK
Crankshaft and bearings
NG
Worn crankshaft and bearings
NG
Replace the crankshaft and/or the bearings
196
TROUBLESHOOTING
10.
ABNORMAL ENGINE NOISE

1. Engine Knocking Trouble Cause Countermeasure
Checkpoint
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.
Fuel
NG
Fuel unsuitable
NG
Replace the fuel
OK
NG
NG
OK
Injection nozzle
NG
Improper injection nozzle starting pressure and spray condition
NG
OK
NG
Blown out head gasket Broken piston ring
NG
Replace the head gasket or the piston ring
2.
Gas Leakage Noise

Tighten the exhaust pipe connections Replace the exhaust pipes
Exhaust pipes
NG
Loosely connected exhaust pipes Broken exhaust pipes
NG
OK Replace the washers Tighten the injection nozzles and/or the glow plugs
Injection nozzles and/or glow plugs
NG
Loose injection nozzles and/or glow plugs
NG
197
TROUBLESHOOTING
10.

2. Gas Leakage Noise Trouble Cause Countermeasure
Checkpoint
Exhaust manifold
NG
Loosely connected exhaust manifold and/or glow plugs
NG
Tighten the exhaust manifold connections
OK
Cylinder head gasket
NG
Damaged cylinder head gasket
NG
Replace the cylinder head gasket
3.
Continuous Noise
Fan belt
NG
Loose fan belt
NG
Readjust the fan belt tension
OK
Cooling fan
NG
Loose cooling fan
NG
Retighten the cooling fan
OK
Water pump bearing
NG
Worn or damaged water pump bearing
NG
Replace the water pump bearing
OK
Alternator or vacuum pump
NG
Defective alternator or vacuum pump
NG
Repair or replace the alternator or the vacuum pump
OK
Valve clearance
NG
NG
198
TROUBLESHOOTING
10.

4. Slapping Noise Trouble Cause Countermeasure
Checkpoint
Valve clearance
NG
NG
OK
Rocker arm
NG
Damaged rocker arm
NG
Replace the rocker arm
OK
Flywheel
NG
Loose flywheel bolts
NG
Retighten the flywheel bolts
OK
Crankshaft and thrust bearings
NG
Worn or damaged crankshaft and/or thrust bearings
NG
Replace the crankshaft and/or the thrust bearings
OK
Crankshaft and connecting rod bearings
NG
Worn or damaged crankshaft and/or connecting rod bearings
NG
Replace the crankshaft and/or the connecting rod bearings
OK
Connecting rod bushing and piston pin
NG
Worn or damaged connecting rod bushing and piston pin
NG
Replace the connecting rod bushing and/or the piston pin
OK Worn or damaged piston and cylinder liner Foreign material in the cylinder
Piston and cylinder liner
NG
NG
Replace the piston and the cylinder liner
199
MEMO
200
SPECIAL TOOL LIST
SECTION 11
SPECIAL TOOL LIST
201
SPECIAL TOOL LIST
SPECIAL TOOL LIST

ITEM NO. ILLUSTRATION PART NO. PARTS NAME PAGE
5-8840-0145-0
Measuring Device
25
5-8840-2675-0
Compression Gauge
26
5-8840-9029-0
Compression Gauge Adapter
26
5-8840-0019-0
Sliding Hammer
35 71
5-8840-2034-0
Nozzle Holder Remover
35
5-8840-2363-0
Oil Seal Remover (Axial Type)
38
9-8523-1423-0
Valve Spring Compressor
42 85
5-8840-0086-0
Camshaft Timing Gear Universal Puller
46 64
9-8523-1212-0
Valve Guide Replacer
49 50
10
5-8840-2039-0
Cylinder Liner Remover
57
202
SPECIAL TOOL LIST
ITEM NO.
ILLUSTRATION
PART NO.
PARTS NAME
PAGE
11
5-8840-2040-0
Cylinder Liner Installer
58
12
5-8840-2038-0
Camshaft Bearing Replacer
63 64
13
9-8840-2057-0
Crankshaft Timing Gear Remover
70
14
9-8522-0020-0
Crankshaft Timing Gear Installer
70
15
5-8840-2000-0
Crankshaft Pilot Bearing Remover
71
16
5-8522-0024-0
Crankshaft Pilot Bearing Installer
71
17
5-8840-2061-0
Crankshaft Front Oil Seal Installer
79
18
5-8840-2033-0
Valve Stem Oil Seal Installer
85
19
5-8840-0141-0
Crankshaft Rear Oil Seal Installer
98
20
5-8840-9057-0
Oil Seal Installer (Axial Type)
98
203
MEMO
204
REPAIR STANDARDS
SECTION 12
REPAIR STANDARDS
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Repair standards chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
General Rules
1. These tables provide standards relating the repair of the following diesel engine; Model A-4JA1, A-4JB1 2. These Repair Standards are based on inspection items, together with dimensions, assembly standards, limit values, and repair procedures. (1) Nominal dimensions are the standard production values. (2) Assembly standards considered to be the values used as objectives during the assembly procedures which follow repairs; as a result, they may be somewhat at variance with the assembly dimensions of a new engine. (3) Limit values refer to the measured values resulting from wear, etc., beyond which a part must not be used. If a measured value falls beyond the limit value, the part involved must be repaired or replaced. (4) Repair Procedures indicates normal repair methods. (5) Unless otherwise stated, the unit of numerical values in tables should be taken to refer to millimeters, mm (in). Explanation of Terms Used in Tables (1) The dimension of wear refers to the difference between the dimensions of a part which is not worn (or the nominal dimension of a part without wear) and the dimension of the part suffering from the most wear (the dimension of the worn part). (2) Uneven wear means the difference between the maximum and minimum wear values. When repairs are requested on the overall engine, first perform bench tests to determine what parts require repairs, then perform the minimum disassembly and repairs required to correct the problems. When repairs on a specific engine part are requested, repairs to be made in reference to the relevant items in accordance with the repair standards listed in this manual.
3.
4.
205
Engine Body
Cylinder Body
206
Nominal Dimension Limit Repair Procedure Comments Assembly Standard Value 31 (441/3.04) Disassemble and repair engine L/h L/h 100% 200% 100% 140% 22 (313/2.157) Warm engine engine speed 200 rpm (varies depending on altitude) New engine performance is assumed 100%
20.0
Major Category
Name of Part
Inspection Item
REPAIR STANDARDS
Time for engine disassembly and repair
Cylinder compression pressure kgf/cm2 (psi/MPa)
Fuel consumption
Lubricating oil consumption
Wear on liner bore Measured at AA
Dia. 93 (3.661)
A
Dia 93.1 (3.665)
Upper step wear must (Ref) be repaired, or replace Cylinder & liner with standard dimen- clearance sion liner 0.017 0.055 (0.0007 0.0022)
Liner projection
0 0.10 (0 0.0039)
Some projection must be present
Difference in liner projection between neighboring cylinders not to exceed 0.02
Cylinder block upper face warpage
0.05 (0.002) or less 5 (71.1/490)
0.20 (0.008)
Not repairable; must be replaced Leaks require repair or replacement
Pressure test: 3 minutes kgf/cm2 (psi/kPa)
Major Category Limit Repair Procedure Comments
Name of Part
Inspection Item
Nominal Dimension
Assembly Standard Value
Valve seat depression: B (both inlet and exhaust) Inlet side 0.73 (0.029) Replace insert
(Valve) Same for
(Insert)
1.28 (0.050)
(Cylinder head)
Valve seat angle: Inlet side 30 Exhaust side 45
45
( inlet & exhaust )
Exhaust side 0.70 (0.028)
1.20 (0.047)
Bottom surface to cylinder
Must not protrude from lower surface of cylinder head
Inlet side 1.7 (0.067) 2.2 (0.087) 2.5 (0.098) 0.2 (0.008) Exhaust side 2.0 (0.079) 0.05 (0.002) or less
Contact width with valve seat: A
Repair with valve seat cutter
After repair, be sure to lap contact surfaces
Engine Body
Cylinder Head
Warpage and flatness of cylinder head lower face (mounting surface) 0.05 (0.002) or less 5 (71.1 490)
Maximum Allowable Griding stock 0.3 (0.012) 0.2 (0.008) repair Leaks require repair or replacement
Warpage of manifold mounting surface
Water-pressure test, 3 minutes kgf/cm2 (psi/kPa)
1st Step New bolt Reused bolt 3.0 5.0 (21.7 36.1/ 29.4 49.0) 8.0 9.0 (57.9 65.1/ 78.4 88.2)
2nd Step 8.2 9.2 (59.4 66.5/ 80.4 90.2) 10.0 11.0 (72.4 79.6/ 98.1 107.9)
Cylinder head bolts tightening torque kgfm(lbft/Nm)
Apply engine oil to the cylinder need fixing bolt threads and setting faces.
REPAIR STANDARDS
207
Pistons
Main Operating Parts
Piston Ring
208
Nominal Dimension Limit Repair Procedure Comments Clearance with major axis 0.017 0.055 (0.0007 0.0022) 0.002 0.015 (0.00008 0.0006) Dia. 31.0 (1.2205) Replace piston pin 1st compression ring 2nd compression ring Oil ring 1st compression ring 2nd compression ring Oil ring 1st compression ring 2nd compression ring Oil ring 4.0 6.0 (8.82 13.2/ 39.2 58.8) 0.090 0.125 (0.0035 0.0049) 0.050 0.075 (0.002 0.003) 0.030 0.070 (0.0012 0.0028) 0.15 (0.006) 0.15 (0.006) 0.15 (0.006) At 120 intervals Replace rings or piston 1.11 1.59 (2.45 3.50/ 10.9 16.0) 0.10 0.30 (0.004 0.012) 0.20 0.40 (0.008 0.016) 1.5 (0.059) Replace rings or piston 30.992 30.98 (1.2202 1.2197) Dia. 30.95 (1.2185) Replace piston or piston pin Assembly Standard Value Replace Replace Measure with expander attached
When assembling compression rings on piston, be sure rings marked surface is up. Backwards installation will result in excessive oil consumption. No top/bottom to oil ring.
Major Category
Name of Part
Inspection Item
REPAIR STANDARDS
Clearance with cylinder: grade position from upper face 70 mm (2.76 in)
Piston pin and piston pin hole clearance
Pin wear
Piston Ring Gap
Tension kgf (lb/N)
Clearance between piston ring and ring groove
Ring gap orientation
Major Category Limit 0.09 (0.0035) Replace 0.094 (0.0037) Use those with projection and proper arc; take care with back side fit 0.035 0.080 (0.0014 0.0031) Replace bearing Undersize bearings cannot be used 0.10 (0.0039) 0.05 (0.002) or less 0.08 (0.0031) Replace crankshaft 0.30 (0.0118) Replace thrust bearings Measure at crankshafts No. 1 bearing thrust surface 0.11 (0.0043) Do not attempt to grind: always replace with new parts Repair Procedure Comments
Name of Part
Inspection Item
Nominal Dimension
A-4JA1 Dia.60(2.362) Uneven Journal A-4JB1 Dia.70(2.756) wear on journal Dia. 53 and pins Pin (2.087)
Journal and bearing spread
Clearance between journal and bearing
Crankshaft
Journal bearing undersize
Crankshaft end play
Crankshaft runout
Ring gear
Perform lapping on gears with burrs; in cases of severe damage, replace. 16.0 18.0 (115.7 130.2/ 156.9 176.5) Apply engine oil to threads and seating areas of bolts before tightening Use those with projection and proper arc; take care work back side fit 0.029 0.066 (0.0011 0.0026) 0.10 (0.0039) Replace bearing Do not catch foreign matter in bolts
Bearing cup bolt tightening torque kgfm (lbft/Nm)
Connecting rod bearing runout
Connecting Rods
Clearance between connecting rod bearing and crankpin
REPAIR STANDARDS
209
Connecting Rods
Camshaft
210
Nominal Dimension Limit Replace parts with poor contact or abrasions Take special care with crankpin precision Repair Procedure Comments Assembly Standard Value 0.008 0.020 (0.0003 0.0008) Replace bushing or pin Dia. 53 (2.087) 0.175 0.290 (0.007 0.0114) Replace connecting rod Repair or replace 0.05 (0.002) or less 0.05 (0.002) or less 0.15 (0.006) Repair or replace 0.20 (0.008) 0.35 (0.0138) 0.05 (0.002) Sufficient gap to allow smooth rotation when holding big end Crank must not be ground (no undersizes available) 8.0 9.0 (57.9 65.1/ 78.4 88.2) Apply engine oil to bolts before tightening Dia. 50 (1.969) 0.025 0.085 (0.001 0.0033) Dia. 50 (1.969) 49.945 49.975 (1.9663 1.9675) 0.05 (0.002) 0.12 (0.0047) Dia. 49.60 (1.953) Replace camshaft Replace bearing Replace camshaft
Major Category
Name of Part
Inspection Item
REPAIR STANDARDS
Contact between connecting rod bearing and crankpin
Clearance between smallend bushing and piston pin
Connecting rod bearing undersize
Connecting rod and crankpin end play
Big end to small end hole twist (per 100 mm)
Big end to small end hole parallelism (per 100 mm)
Bearing cap bolt tightening torque (angular tightening method) kgfm (lbft/Nm)
Journal uneven wear
Clearance between journal and bearing
Journal wear
Major Category Limit Repair Procedure Comments
Name of Part
Inspection Item
Nominal Dimension
Cam height: Replace camshaft
Camshaft
42.08 (1.65)
41.65 (1.64)
Minor step wear on cams can be repaired
Camshaft runout 0.05 0.114 (0.002 0.0045) 0.20 (0.008) Replace thrust plate
0.02 (0.0008) or less Replace camshaft
0.10 (0.004)
Camshaft end play
REPAIR STANDARDS
211
Valve System
Valves
Valve spring
212
Nominal Dimension Limit Repair Procedure Comments Dia. 7.949 7.961 (0.3129 0.3134) Dia. 7.921 7.936 (0.3118 0.3124) 0.039 0.069 (0.0015 0.0027) 0.064 0.096 (0.0025 0.0038) 0.02 (0.0008) 1.8 (0.071) Inlet Exhaust 13.0 (0.512) 32.6 (71.9/319.6) mm mm 1.5 (0.06) or less 0.40 (0.016) 0.01 0.05 (0.0004 0.002) Dia. 18.98 19.00 (0.747 0.748) 49.7 (1.96) 29.0 (63.9/284.4) 48.2 (1.90) 2.5 (0.098) 13.0 (0.512) Reference value 1.5 (0.059) Replace valve and valve guide together 0.25 (0.0098) Replace valve and valve guide together 0.2 (0.008) Dia. 7.88 (0.3102) Replace valve Assembly Standard Value Dia. 8 (0.315) Measure valve stem at three positions Apply oil to valve guide and press in Adjust 0.2 (0.008) Dia. 18.85 (0.742) Replace bushing or shaft Replace rocker arm shaft
Major Category
Name of Part
Inspection Item
Inlet valve stem wear
REPAIR STANDARDS
Exhaust valve stem wear
Clearance between inlet valve stem and valve guide
Clearance between exhaust valve stem and guide
Interference between valve guide and cylinder head
Valve thickness
Thickness
Height of valve guide above cylinder head
Tension kgf (lb/N) (When compressed to Installed length) 38.9 mm (1.53 in)
Free length
Inclination
Valve clearance (inlet & exhaust) (cold)
Clearance between rocker arm shaft and bushing
Rocker arm shaft wear
Major Category Limit Repair Procedure Comments 0.03 (0.0012) Replace tappet Replace tappet 12.97 12.99 (0.5106 0.5114) 12.95 (0.5098) 0.10 (0.0039)
Name of Part
Inspection Item
Nominal Dimension
Valve System
Tappet
Clearance between tappet and cyl. body
Tappet wear
Out diameter
Intake System
Air cleaner
Air cleaner element condition
Special order item from manufacturer
REPAIR STANDARDS
213
Oil pressure
Lubricating System
Oil lpump and Relief valve
Oil filter
214
Nominal Dimension Limit 2.0 (28.4/196) 0.15 (0.006) 0.20 (0.008) Replace rotor set Repair or replace 0.40 (0.016) Replace vane, rotor or cover Repair Procedure Comments 4.0 4.5 (56.89 64.00 /392 441) 0.02 0.07 (0.0008 0.0026) 0.14 (0.006) or less 0.20 0.27 (0.008 0.011) Assembly Standard Value
Major Category
Name of Part
Inspection Item
Lubricating oil pressure (1400 rpm) kgf/cm2 (psi/kPa)
REPAIR STANDARDS
Vane, rotor and cover clearance
Rotor and vane clearance
Clearance between pump body and vane
Pumping rate L/min 1000 rpm, SAE #30, pumping pressure 4 kgf/cm2 (56.9 psi/392 kPa) oil temp. 50C (122F)
(
13 Replace 5.8 6.2 (82.49 88.18 /569 608.2)
Clogging and damage to oil filter
Initial operating pressure of main oil filter relief valve kgf/cm2 (psi/kPa)
Major Category Limit Repair Procedure Comments 0.2 (0.0079) Replace
Name of Part
Inspection Item
Nominal Dimension
Water pump ball bearing chatter (radial direction) L/min
Pumping rate
( )
100 0.3 1.3 (0.0118 0.0512) Repair or replace if impeller and pump body are touching 8 12 (0.31 0.47) mm(in) 82C (180F) 95C (203F) 80 84C (176 183F) Temperature at whic thermostat lift reaches 8mm(0.315in) or more. Repair or replace Adjust
Press with finger A
pumping speed 3000 rpm, water temp 30C (86F) Total head 14.5 m or more
Clearance between pump impeller and pump body mm
Cooling System
Water pump
Fan belt deflection
(Reference) 10 kgf (22.0 lb/98N) each
Initial thermostat operating temperature (at sea level)
Replace thermostat if operation is incorrect.
Thermostat full-open temperature (at sea level)
Piping, etc.
Clogged, cracked, loose fuel pipes, injection pipes, nozzle holders; defective seals.
Fuel System
Fuel filter element clogging or damage
Replace
Cartridge type
REPAIR STANDARDS
215
Charge/ Discharge indication
Wiring
Rotor
Electrical
Alternator 12V, 35A (Hitachi 1-81200-756-0)
Brush
Starter 12V, 2.2 kW (Hitachi 8-97084-879-0)
216
Nominal Dimension Limit Repair Procedure Comments Assembly Standard Value If warning indicator lights when engine is operating at normal speeds, check and repair electrical system. Repair 0.1 (0.0039) Replace rotor or ress Replace bearings 0.3 (0.012) Repair 31.6 (1.24) 14.5 (0.57) 7.5 (0.3) Repair 15.0 (0.59) 9.0 (0.35) Replace If coil resistance value is severely abnormal, replace switch. 0.27 Dia. 30.0 (1.18) 0.5 0.8 (0.02 0.03) Dia. 29.0 (1.14) 0.2 (0.008) Replace armature Repair 30.6 (1.20) Replace Rotate by hand and check for smooth rotation: no abnormal sound or resistance should be felt.
Major Category
Name of Part
Inspection Item
REPAIR STANDARDS
Warning lamp indication
Check for looseness, cuts or damaged insulation to wiring.
Shaft runout
Bearing chatter
Thrust side chatter
Slip ring dia waler
Length
Loose mount
Brush length
Jeries coil Magnetic resistance () switch (at 20C [68F]) Shut coil resistance ()
O.D.
Commutator
Undercut depth
Major Category Limit 6200 Z 6204 DDU 6006 DDU Repair Procedure Comments Dia. 10 (0.3937) Dia. 20 (0.7874) Dia. 30 (1.811) 3900 rpm or more Replace if cut wiring or shorts are found 30 minutes or more
Name of Part
Inspection Item
Nominal Dimension
Rear side (armature)
Ball bearings
Front (armature)
Replace if rotation is not smooth or if abnormal sounds are heard.
Electrical
Pinion shaft (shaft)
Starter 12V, 2.2 kW (Hitachi 8-97084-879-0)
Performance
Unloaded characteristics (11V, 160A or less)
Smooth pinion operation without noise
Preheater
Glow plug
Engine run-in operation
Cylinder compression pressure kgf/ cm2 (psi/MPa) about 200 rpm 31 (441/3.04) 22 (313/2.157)
Inspect
Warm engine
Final Inspection
Difference in compression between cylinders kgf/ cm2 (psi/MPa) about 200 rpm 4.0 4.5 (392 441) 90% or more 110% or less
5% or less
Inspect
Warm engine
Lubricating oil pressure kgf/ cm2 (psi/KPa)
Adjust
1400 rpm Oil Temp About 80C (176F) When new engine output is 100%
Output check
Fuel consumption check
REPAIR STANDARDS
217
MEMO
218
CONVERSION TABLE
SECTION 13
CONVERSION TABLES
INDEX CONTENTS PAGE
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
LENGTH
MILLIMETERS TO INCHES
mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 101 102 103 104 105 106 107 108 109 in. 0.0394 0.0787 0.1181 0.1575 0.1969 0.2362 0.2756 0.3150 0.3543 0.3937 0.4331 0.4724 0.5118 0.5512 0.5906 0.6299 0.6693 0.7087 0.7480 0.7874 0.8268 0.8661 0.9055 0.9449 0.9843 3.9764 4.0157 4.0551 4.0945 4.1339 4.1732 4.2126 4.2520 4.2913 mm 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 111 112 113 114 115 116 117 118 119 in. 1.0236 1.0630 1.1024 1.1417 1.1811 1.2205 1.2598 1.2992 1.3386 1.3780 1.4173 1.4567 1.4961 1.5354 1.5748 1.6142 1.6535 1.6929 1.7323 1.7717 1.8110 1.8504 1.8898 1.9291 1.9685 4.3701 4.4094 4.4488 4.4882 4.5276 4.5669 4.6063 4.6457 4.6850 mm 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 121 122 123 124 125 126 127 128 129 in. 2.0079 2.0472 2.0866 2.1260 2.1654 2.2047 2.2441 2.2835 2.3228 2.3622 2.4016 2.4409 2.4803 2.5197 2.5591 2.5984 2.6378 2.6772 2.7165 2.7559 2.7953 2.8346 2.8740 2.9134 2.9528 4.7638 4.8031 4.8425 4.8819 4.9213 4.9606 5.0000 5.0394 5.0787 mm 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 131 132 133 134 135 136 137 138 139 in. 2.9921 3.0315 3.0709 3.1102 3.1496 3.1890 3.2283 3.2677 3.3071 3.3465 3.3858 3.4252 3.4646 3.5039 3.5433 3.5827 3.6220 3.6614 3.7008 3.7402 3.7795 3.8189 3.8583 3.8976 3.9370 5.1575 5.1968 5.2362 5.2756 5.3150 5.3543 5.3937 5.4331 5.4724 in. 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2
INCHES TO MILLIMETERS
mm 0.3969 0.7938 1.1906 1.5875 1.9844 2.3813 2.7781 3.1750 3.5719 3.9688 4.3656 4.7625 5.1594 5.5563 5.9531 6.3500 6.7469 7.1438 7.5406 7.9375 8.3344 8.7313 9.1281 9.5250 9.9219 10.3188 10.7156 11.1125 11.5094 11.9063 12.3031 12.7000 in. 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 mm 13.0969 13.4938 13.8906 14.2875 14.6844 15.0813 15.4781 15.8750 16.2719 16.6688 17.0656 17.4625 17.8594 18.2563 18.6531 19.0500 19.4469 19.8438 20.2406 20.6375 21.0344 21.4313 21.8281 22.2250 22.6219 23.0188 23.4156 23.8125 24.2094 24.6063 25.0031 25.4000
219
CONVERSION TABLE LENGTH

FEET TO METERS
ft. 0 m 10 20 30 40 50 60 70 80 90 100 0 3.048 6.096 9.144 12.192 15.240 18.288 21.336 24.384 27.432 30.480 1 m 0.305 3.353 6.401 9.449 12.497 15.545 18.593 21.641 24.689 27.737 30.785 2 m 0.610 3.658 6.706 9.754 12.802 15.850 18.898 21.946 24.994 28.042 31.090 3 m 0.914 3.962 7.010 10.058 13.106 16.154 19.202 22.250 25.298 28.346 31.394 4 m 1.219 4.267 7.315 10.363 13.411 16.459 19.507 22.555 25.603 28.651 31.699 5 m 1.524 4.572 7.620 10.668 13.716 16.764 19.812 22.860 25.908 28.956 32.004 6 m 1.829 4.877 7.925 10.973 14.021 17.069 20.117 23.165 26.213 29.261 32.309 7 m 2.134 5.182 8.230 11.278 14.326 17.374 20.422 23.470 26.518 29.566 32.614 8 m 2.438 5.486 8.534 11.582 14.630 17.678 20.726 23.774 26.822 29.870 32.918 9 m 2.743 5.791 8.839 11.887 14.935 17.983 21.031 24.079 27.127 30.175 33.223 10 20 30 40 50 60 70 80 90 100 ft.
METERS TO FEET
m 0 ft. 10 20 30 40 50 60 70 80 90 100 00 32.8084 65.6168 98.4252 131.2336 164.0420 196.8504 229.6588 262.4672 295.2756 328.0840 1 ft. 3.2808 36.0892 68.8976 101.7060 134.5144 167.3228 200.1312 232.9396 265.7480 298.5564 331.3648 2 ft. 6.5617 39.3701 72.1785 104.9869 137.7953 170.6037 203.4121 236.2205 269.0289 301.8373 334.6457 3 ft. 9.8425 42.6509 75.4593 108.2677 141.0761 173.8845 206.6929 239.5013 272.3097 305.1181 337.9265 4 ft. 13.1234 45.9318 78.7402 111.5486 144.3570 177.1654 209.9738 242.7822 275.5906 308.3990 341.2074 5 ft. 16.4042 49.2126 82.0210 114.8294 147.6378 180.4462 213.2546 246.0630 278.8714 311.6798 344.4882 6 ft. 19.6850 52.4934 85.3018 118.1102 150.9186 183.7270 216.5354 249.3438 282.1522 314.9606 347.7690 7 ft. 22.9659 55.7743 88.5827 121.3911 154.1995 187.0079 219.8163 252.6247 285.4331 318.2415 351.0499 8 ft. 26.2467 59.0551 91.8635 124.6719 157.4803 190.2887 223.0971 255.9055 288.7139 321.5223 354.3307 9 ft. 29.5276 62.3360 95.1444 127.9528 160.7612 193.5696 226.3780 259.1864 291.9948 324.8032 357.6116 10 20 30 40 50 60 70 80 90 100
MILES TO KILOMETERS
miles 0 km 10 20 30 40 50 60 70 80 90 100 00 16.093 32.187 48.280 64.374 80.467 96.561 112.654 128.748 144.841 160.934 1 km 1.609 17.703 33.796 49.890 65.983 82.077 98.170 114.263 130.357 146.450 162.544 2 km 3.219 19.312 35.406 51.499 67.592 83.686 99.779 115.873 131.966 148.060 164.153 3 km 4.828 20.921 37.015 53.108 69.202 85.295 101.389 117.482 133.576 149.669 165.762 4 km 6.437 22.531 38.624 54.718 70.811 86.905 102.998 119.091 135.185 151.278 167.372 5 km 8.047 24.140 40.234 56.327 72.420 88.514 104.607 120.701 136.794 152.888 168.981 6 km 9.656 25.750 41.843 57.936 74.030 90.123 106.217 122.310 138.404 154.497 170.590 7 km 11.265 27.359 43.452 59.546 75.639 91.733 107.826 123.919 140.013 156.106 172.200 8 km 12.875 28.968 45.062 61.155 77.249 93.342 109.435 125.529 141.622 157.716 173.809 9 km 14.484 30.578 46.671 62.764 78.858 94.951 111.045 127.138 143.232 159.325 175.418 10 20 30 40 50 60 70 80 90 100
KILOMETERS TO MILES
km 0 miles 10 20 30 40 50 60 70 80 90 100 0 6.214 12.427 18.641 24.855 31.069 37.282 43.496 49.710 55.923 62.137 1 miles 0.621 6.835 13.049 19.262 25.476 31.690 37.904 44.117 50.331 56.545 62.758 2 miles 1.243 7.456 13.670 19.884 26.098 32.311 38.525 44.739 50.952 57.166 63.380 3 miles 1.864 8.078 14.292 20.505 26.719 32.933 39.146 45.360 51.574 57.787 64.001 4 miles 2.485 8.699 14.913 21.127 27.340 33.554 39.768 45.981 52.195 58.409 64.622 5 miles 3.107 9.321 15.534 21.748 27.962 34.175 40.389 46.603 52.816 59.030 65.244 6 miles 3.728 9.942 16.156 22.369 28.583 34.797 41.010 47.224 53.438 59.652 65.865 7 miles 4.350 10.563 16.777 22.991 29.204 35.418 41.632 47.845 54.059 60.273 66.487 8 miles 4.971 11.185 17.398 23.612 29.826 36.039 42.253 48.467 54.681 60.894 67.108 9 miles 5.592 11.806 18.020 24.233 30.447 36.661 42.875 49.088 55.302 61.516 67.729 10 20 30 40 50 60 70 80 90 100
220
CONVERSION TABLE AREA

SQUARE INCHES TO SQUARE CENTIMETERS
in2 0 cm2 10 20 30 40 50 60 70 80 90 100 00 64.516 129.032 193.548 258.064 322.580 387.096 451.612 516.128 580.644 645.160 1 cm2 6.452 70.968 135.484 200.000 264.516 329.032 393.548 458.064 522.580 587.096 651.612 2 cm2 12.903 77.419 141.935 206.451 270.967 335.483 399.999 464.515 529.031 593.547 658.063 3 cm2 19.355 83.871 148.387 212.903 277.419 341.935 406.451 470.967 535.483 599.999 664.515 4 cm2 25.806 90.322 154.838 219.354 283.870 348.386 412.902 477.418 541.934 606.450 670.966 5 cm2 32.258 96.774 161.290 225.806 290.322 354.838 419.354 483.870 548.386 612.902 677.418 6 cm2 38.710 103.226 167.742 232.258 296.774 361.290 425.806 490.322 554.838 619.354 683.870 7 cm2 45.161 109.677 174.193 238.709 303.225 367.741 432.257 496.773 561.289 625.805 690.321 8 cm2 51.613 116.129 180.645 245.161 309.677 374.193 438.709 503.225 567.741 632.257 696.773 9 cm2 58.064 122.580 187.096 251.612 316.128 380.644 445.160 509.676 574.192 638.708 703.224 10 20 30 40 50 60 70 80 90 100 in2
SQUARE CENTIMETERS TO SQUARE INCHES

cm2 0 in2 10 20 30 40 50 60 70 80 90 100 0 1.550 3.100 4.650 6.200 7.750 9.300 10.850 12.400 13.950 15.500 1 in2 0.155 1.705 3.255 4.805 6.355 7.905 9.455 11.005 12.555 14.105 15.655 2 in2 0.310 1.860 3.410 4.960 6.510 8.060 9.610 11.160 12.710 14.260 15.810 3 in2 0.465 2.015 3.565 5.115 6.665 8.215 9.765 11.315 12.865 14.415 15.965 4 in2 0.620 2.170 3.720 5.270 6.820 8.370 9.920 11.470 13.020 14.570 16.120 5 in2 0.775 2.325 3.875 5.425 6.975 8.525 10.075 11.625 13.175 14.725 16.275 6 in2 0.930 2.480 4.030 5.580 7.130 8.680 10.230 11.780 13.330 14.880 16.430 7 in2 1.085 2.635 4.185 5.735 7.285 8.835 10.385 11.935 13.485 15.035 16.585 8 in2 1.240 2.790 4.340 5.890 7.440 8.990 10.540 12.090 13.640 15.190 16.740 9 in2 1.395 2.945 4.495 6.045 7.595 9.145 10.695 12.245 13.795 15.345 16.895 10 20 30 40 50 60 70 80 90 100 cm2
VOLUME
CUBIC INCHES TO CUBIC CENTIMETERS
in3 0 cm3(cc) 10 20 30 40 50 60 70 80 90 100 00 163.871 327.741 491.612 655.483 819.353 983.224 1147.094 1310.965 1474.836 1638.706 1 cm3(cc) 16.387 180.258 344.128 507.999 671.870 835.740 999.611 1163.482 1327.352 1491.223 1655.093 2 cm3(cc) 32.774 196.645 360.515 524.386 688.257 852.127 1015.998 1179.869 1343.739 1507.610 1671.481 3 cm3(cc) 49.161 213.032 376.902 540.773 704.644 868.514 1032.385 1196.256 1360.126 1523.997 1687.868 4 cm3(cc) 65.548 229.419 393.290 557.160 721.031 884.901 1048.772 1212.643 1376.513 1540.384 1704.255 5 cm3(cc) 81.935 245.806 409.677 573.547 737.418 901.289 1065.159 1229.030 1392.900 1556.771 1720.642 6 cm3(cc) 98.322 262.193 426.064 589.934 753.805 917.676 1081.546 1245.417 1409.288 1573.158 1737.029 7 cm3(cc) 114.709 278.580 442.451 606.321 770.192 934.063 1097.933 1261.804 1425.675 1589.545 1753.416 8 cm3(cc) 131.097 294.967 458.838 622.708 786.579 950.450 1114.320 1278.191 1442.062 1605.932 1769.803 9 cm3(cc) 147.484 311.354 475.225 639.095 802.966 966.837 1130.707 1294.578 1458.449 1622.319 1786.190 10 20 30 40 50 60 70 80 90 100 in3
CUBIC CENTIMETERS TO CUBIC INCHES

cm3(cc) 0 in3 10 20 30 40 50 60 70 80 90 100 0 0.6102 1.2205 1.8307 2.4409 3.0512 3.6614 4.2716 4.8818 5.4921 6.1023 1 in3 0.0610 0.6713 1.2815 1.8917 2.5020 3.1122 3.7224 4.3326 4.9429 5.5531 6.1633 2 in3 0.1220 0.7323 1.3425 1.9527 2.5630 3.1732 3.7834 4.3937 5.0039 5.6141 6.2243 3 in3 0.1831 0.7933 1.4035 2.0138 2.6240 3.2342 3.8444 4.4547 5.0649 5.6751 6.2854 4 in3 0.2441 0.8543 1.4646 2.0748 2.6850 3.2952 3.9055 4.5157 5.1259 5.7362 6.3464 5 in3 0.3051 0.9153 1.5256 2.1358 2.7460 3.3563 3.9665 4.5767 5.1870 5.7972 6.4074 6 in3 0.3661 0.9764 1.5866 2.1968 2.8071 3.4173 4.0275 4.6377 5.2480 5.8582 6.4684 7 in3 0.4272 1.0374 1.6476 2.2579 2.8681 3.4783 4.0885 4.6988 5.3090 5.9192 6.5295 8 in3 0.4882 1.0984 1.7086 2.3190 2.9291 3.5393 4.1496 4.7598 5.3700 5.9803 6.5905 9 in3 0.5492 1.1594 1.7697 2.3799 2.9901 3.6004 4.2106 4.8208 5.4310 6.0413 6.6515 10 20 30 40 50 60 70 80 90 100 cm3(cc)
221
CONVERSION TABLE VOLUME

GALLONS (U.S.) TO LITERS
U.S. gal. 0 liters 10 20 30 40 50 60 70 80 90 100 00 37.8543 75.7085 113.5628 151.4171 189.2713 227.1256 264.9799 302.8342 340.6884 378.5427 1 liters 3.7854 41.6397 79.4940 117.3482 155.2025 193.0568 230.9110 268.7653 306.6196 344.4738 382.3281 2 liters 7.5709 45.4251 83.2794 121.1337 158.9879 196.8422 234.6965 272.5507 310.4050 348.2593 386.1135 3 liters 11.3563 49.2105 87.0648 124.9191 162.7734 200.6276 238.4819 276.3362 314.1904 352.0447 389.8990 4 liters 15.1417 52.9960 90.8502 128.7045 166.5588 204.4131 242.2673 280.1216 317.9759 355.8301 393.6844 5 liters 18.9271 56.7814 94.6357 132.4899 170.3442 208.1985 246.0527 283.9070 321.7613 359.6156 397.4698 6 liters 22.7126 60.5668 98.4211 136.2754 174.1296 211.9839 249.8382 287.6924 325.5467 363.4010 401.2553 7 liters 26.4980 64.3523 102.2065 140.0608 177.9151 215.7693 253.6236 291.4779 329.3321 367.1864 405.0407 8 liters 30.2834 68.1377 105.9920 143.8462 181.7005 219.5548 257.4090 295.2633 333.1176 370.9718 408.8261 9 liters 34.0688 71.9231 109.7774 147.6316 185.4859 223.3402 261.1945 299.0487 336.9030 374.7573 412.6115 10 20 30 40 50 60 70 80 90 100 U.S.gal.
LITERS TO GALLONS (U.S.)

liters 0 gal. 10 20 30 40 50 60 70 80 90 100 00 2.6417 5.2834 7.9252 10.5669 13.2086 15.8503 18.4920 21.1338 23.7755 26.4172 1 gal. 0.2642 2.9059 5.5476 8.1893 10.8311 13.4728 16.1145 18.7562 21.3979 24.0397 26.6814 2 gal. 0.5283 3.1701 5.8118 8.4535 11.0952 13.7369 16.3787 19.0204 21.6621 24.3038 26.9455 3 gal. 0.7925 3.4342 6.0760 8.7177 11.3594 14.0011 16.6428 19.2846 21.9263 24.5680 27.2097 4 gal. 1.0567 3.6984 6.3401 8.9818 11.6236 14.2653 16.9070 19.5487 22.1904 24.8322 27.4739 5 gal. 1.3209 3.9626 6.6043 9.2460 11.8877 14.5295 17.1712 19.8129 22.4546 25.0963 27.7381 6 gal. 1.5850 4.2268 6.8685 9.5102 12.1519 14.7936 17.4354 20.0771 22.7188 25.3605 28.0022 7 gal. 1.8492 4.4909 7.1326 9.7744 12.4161 15.0578 17.6995 20.3412 22.9830 25.6247 28.2664 8 gal. 2.1134 4.7551 7.3968 10.0385 12.6803 15.3220 17.9637 20.6054 23.2471 25.8889 28.5306 9 gal. 2.3775 5.0193 7.6610 10.3027 12.9444 15.5861 18.2279 20.8696 23.5113 26.1530 28.7947 10 20 30 40 50 60 70 80 90 100 liters
GALLONS (IMP.) TO LITERS

Imp gal. 0 liters 10 20 30 40 50 60 70 80 90 100 00 45.4590 90.9180 136.3770 181.8360 227.2950 272.7540 318.2130 363.6720 409.1310 454.5900 1 liters 4.5459 50.0049 95.4639 140.9229 186.3819 231.8409 277.2999 322.7589 368.2179 413.6769 459.1359 2 liters 9.0918 54.5508 100.0098 145.4688 190.9278 236.3868 281.8458 327.3048 372.7638 418.2228 463.6818 3 liters 13.6377 59.0967 104.5557 150.0147 195.4737 240.9327 286.3917 331.8507 377.3097 422.7687 468.2277 4 liters 18.1836 63.6426 109.1016 154.5606 200.0196 245.4786 290.9376 336.3966 381.8556 427.3146 472.7736 5 liters 22.7295 68.1885 113.6475 159.1065 204.5655 250.0245 295.4835 340.9425 386.4015 431.8605 477.3195 6 liters 27.2754 72.7344 118.1934 163.6524 209.1114 254.5704 300.0294 345.4884 390.9474 436.4064 481.8654 7 liters 31.8213 77.2803 122.7393 168.1983 213.6573 259.1163 304.5753 350.0343 395.4933 440.9523 486.4113 8 liters 36.3672 81.8262 127.2852 172.7442 218.2032 263.6622 309.1212 354.5802 400.0392 445.4982 490.9572 9 liters 40.9131 86.3721 131.8311 177.2901 222.7491 268.2081 313.6671 359.1261 404.5851 450.0441 495.5031 10 20 30 40 50 60 70 80 90 100 Imp gal.
LITERS TO GALLONS (IMP.)

liters 0 gal. 10 20 30 40 50 60 70 80 90 100 00 2.1998 4.3996 6.5994 8.7992 10.9990 13.1988 15.3986 17.5984 19.7982 21.9980 1 gal. 0.2200 2.4198 4.6196 6.8194 9.0192 11.2190 13.4188 15.6186 17.8184 20.0182 22.2180 2 gal. 0.4400 2.6398 4.8396 7.0394 9.2392 11.4390 13.6388 15.8386 18.0384 20.2382 22.4380 3 gal. 0.6599 2.8597 5.0595 7.2593 9.4591 11.6589 13.8587 16.0585 18.2583 20.4581 22.6579 4 gal. 0.8799 3.0797 5.2795 7.4793 9.6791 11.8789 14.0787 16.2785 18.4783 20.6781 22.8779 5 gal. 1.0999 3.2997 5.4995 7.6993 9.8991 12.0989 14.2987 16.4985 18.6983 20.8981 23.0979 6 gal. 1.3199 3.5197 5.7195 7.9193 10.1191 12.3189 14.5187 16.7185 18.9183 21.1181 23.3179 7 gal. 1.5399 3.7397 5.9395 8.1393 10.3391 12.5389 14.7387 16.9385 19.1383 21.3381 23.5379 8 gal. 1.7598 3.9596 6.1594 8.3592 10.5590 12.7588 14.9586 17.1584 19.3582 21.5580 23.7578 9 gal. 1.9798 4.1796 6.3794 8.5792 10.7790 12.9788 15.1786 17.3784 19.5782 21.7780 23.9778 10 20 30 40 50 60 70 80 90 100 liters
222
CONVERSION TABLE MASS

POUNDS TO KILOGRAMS
lbs. 0 kg 10 20 30 40 50 60 70 80 90 100 0 4.536 9.072 13.608 18.144 22.680 27.216 31.751 36.287 40.823 45.359 1 kg 0.454 4.990 9.525 14.061 18.597 23.133 27.669 32.205 36.741 41.277 45.813 2 kg 0.907 5.443 9.979 14.515 19.051 23.587 28.123 32.659 37.195 41.731 46.267 3 kg 1.361 5.897 10.433 14.970 19.504 24.040 28.576 33.112 37.648 42.184 46.720 4 kg 1.814 6.350 10.886 15.422 19.958 24.494 29.030 33.566 38.102 42.638 47.174 5 kg 2.268 6.804 11.340 15.876 20.412 24.948 29.484 34.019 38.555 43.091 47.627 6 kg 2.722 7.257 11.793 16.329 20.865 25.401 29.937 34.473 39.009 43.545 48.081 7 kg 3.175 7.711 12.247 16.783 21.319 25.855 30.391 34.927 39.463 43.998 48.534 8 kg 3.629 8.165 12.701 17.237 21.772 26.308 30.844 35.380 39.916 44.452 48.988 9 kg 4.082 8.618 13.154 17.690 22.226 26.762 31.298 35.834 40.370 44.905 49.442 10 20 30 40 50 60 70 80 90 100 lbs.
KILOGRAMS TO POUNDS
kg 0 lbs. 10 20 30 40 50 60 70 80 90 100 00 22.046 44.092 66.139 88.185 110.231 132.277 154.324 176.370 198.416 220.462 1 lbs. 2.205 24.251 46.297 68.343 90.390 112.436 134.482 156.528 178.574 200.621 222.667 2 lbs. 4.409 26.455 48.502 70.548 92.594 114.640 136.687 158.733 180.779 202.825 224.871 3 lbs. 6.614 28.660 50.706 72.753 94.799 116.845 138.891 160.937 182.984 205.030 227.076 4 lbs. 8.818 30.865 52.911 74.957 97.003 119.050 141.096 163.142 185.188 207.234 229.281 5 lbs. 11.023 33.069 55.116 77.162 99.208 121.254 143.300 165.347 187.393 209.439 231.485 6 lbs. 13.228 35.274 57.320 79.366 101.413 123.459 145.505 167.551 189.597 211.644 233.690 7 lbs. 15.432 37.479 59.525 81.571 103.617 125.663 147.710 169.756 191.802 213.848 235.895 8 lbs. 17.637 39.683 61.729 83.776 105.822 127.868 149.914 171.960 194.007 216.053 238.099 9 lbs. 19.842 41.888 63.934 85.980 108.026 130.073 152.119 174.165 196.211 218.258 240.304 10 20 30 40 50 60 70 80 90 100 kg
KILOGRAMS TO NEWTON
kgf 0 N 10 20 30 40 50 60 70 80 90 100 0 98.07 196.13 294.20 392.27 490.33 588.40 686.47 784.53 882.60 980.67 1 N 9.81 107.87 205.94 304.01 402.07 500.14 598.21 696.27 794.34 892.41 990.47 2 N 19.61 117.68 215.75 313.81 411.88 509.95 608.01 706.08 804.15 902.21 1000.28 3 N 29.42 127.49 225.55 323.62 421.69 519.75 617.82 715.89 813.95 912.02 1010.08 4 N 39.23 137.29 235.36 333.43 431.49 529.56 627.63 725.69 823.76 921.83 1019.89 5 N 49.03 147.10 245.17 343.23 441.30 539.37 637.43 735.50 833.57 931.63 1029.70 6 N 58.84 156.91 254.97 353.04 451.11 549.17 647.24 745.31 843.37 941.44 1039.50 7 N 68.65 166.71 264.78 362.85 460.91 558.98 657.05 755.11 853.18 951.25 1049.31 8 N 78.45 176.52 274.59 372.65 470.72 568.79 666.85 764.92 862.99 961.05 1059.12 9 N 88.26 186.33 284.39 382.46 480.53 578.59 676.66 774.73 872.79 970.86 1068.92 10 20 30 40 50 60 70 80 90 100 kgf
NEWTON TO KILOGRAMS
N 0 kgf 100 200 300 400 500 600 700 800 900 1000 00 10.197 20.394 30.592 40.789 50.986 61.183 71.380 81.578 91.775 101.972 10 kgf 1.020 11.217 21.414 31.611 41.809 52.006 62.203 72.400 82.597 92.795 102.992 20 kgf 2.039 12.237 22.434 32.631 42.828 53.025 63.223 73.420 83.617 93.814 104.011 30 kgf 3.059 13.256 23.454 33.651 43.848 54.045 64.242 74.440 84.637 94.834 105.031 40 kgf 4.079 14.276 24.473 34.670 44.868 55.065 65.262 75.459 85.656 95.854 106.051 50 kgf 5.099 15.296 25.493 35.690 45.887 56.085 66.282 76.479 86.676 96.873 107.071 60 kgf 6.118 16.316 26.513 36.710 46.907 57.104 67.302 77.499 87.696 97.893 108.090 70 kgf 7.138 17.335 27.532 37.730 47.927 58.124 68.321 78.518 88.716 98.913 109.110 80 kgf 8.158 18.355 28.552 38.749 48.947 59.144 69.341 79.538 89.735 99.933 110.130 90 kgf 9.177 19.375 29.572 39.769 49.966 60.163 70.361 80.558 90.755 100.952 111.149 100 200 300 400 500 600 700 800 900 1000 N
223
CONVERSION TABLE PRESSURE

POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS
lb/in2 (psi) 10 20 30 40 50 60 70 80 90 100 0 kgf/cm2 0 0.7031 1.4061 2.1092 2.8123 3.5154 4.2184 4.9215 5.6246 6.3276 7.0307 1 kgf/cm2 0.0703 0.7734 1.4764 2.1795 2.8826 3.5857 4.2887 4.9918 5.6949 6.3979 7.1010 2 kgf/cm2 0.1406 0.8437 1.5468 2.2498 2.9529 3.6560 4.3590 5.0621 5.7652 6.4682 7.1713 3 kgf/cm2 0.2109 0.9140 1.6171 2.3201 3.0232 3.7263 4.4293 5.1324 5.8355 6.5386 7.2416 4 kgf/cm2 0.2812 0.9843 1.6874 2.3904 3.0935 3.7966 4.4996 5.2027 5.9058 6.6089 7.3119 5 kgf/cm2 0.3515 1.0546 1.7577 2.4607 3.1638 3.8669 4.5700 5.2730 5.9761 6.6792 7.3822 6 kgf/cm2 0.4218 1.1249 1.8280 2.5311 3.2341 3.9372 4.6403 5.3433 6.0464 6.7495 7.4525 7 kgf/cm2 0.4921 1.1952 1.8983 2.6014 3.3044 4.0075 4.7106 5.4136 6.1167 6.8198 7.5228 8 kgf/cm2 0.5625 1.2655 1.9686 2.6717 3.3747 4.0778 4.7809 5.4839 6.1870 6.8901 7.5932 9 kgf/cm2 0.6328 1.3358 2.0389 2.7420 3.4450 4.1481 4.8512 5.5543 6.2573 6.9604 7.6635 lb/in2 (psi) 10 20 30 40 50 60 70 80 90 100
KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES

kgf/cm2 0 lb/in2(psi) 10 20 30 40 50 60 70 80 90 100 00 142.23 284.46 426.69 568.92 711.15 853.38 995.61 1137.84 1280.07 1422.30 1 lb/in2(psi) 14.22 156.45 298.68 440.91 583.14 725.37 867.60 1009.83 1152.06 1294.29 1436.52 2 lb/in2(psi) 28.45 170.68 312.91 455.14 597.37 739.60 881.83 1024.06 1166.29 1308.52 1450.75 3 lb/in2(psi) 42.67 184.90 327.13 469.36 611.59 753.82 896.05 1038.28 1180.51 1322.74 1464.97 4 lb/in2(psi) 56.89 199.12 341.35 483.58 625.81 768.04 910.27 1052.50 1194.73 1336.96 1479.19 5 lb/in2(psi) 71.12 213.35 355.58 497.81 640.04 782.27 924.50 1066.73 1208.96 1351.19 1493.42 6 lb/in2(psi) 85.34 227.57 369.80 512.03 654.26 796.49 938.72 1080.95 1223.18 1365.41 1507.64 7 lb/in2(psi) 99.56 241.79 384.02 526.25 668.48 810.71 952.94 1095.17 1237.40 1379.63 1521.86 8 lb/in2(psi) 113.78 256.01 398.24 540.47 682.70 824.93 967.16 1109.39 1251.62 1393.85 1536.08 9 lb/in2(psi) 128.01 270.24 412.47 554.70 696.93 839.16 981.39 1123.62 1265.85 1408.08 1550.31 10 20 30 40 50 60 70 80 90 100 kgf/cm2
KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL

kgf/cm2 0 KPa 10 20 30 40 50 60 70 80 90 100 00 980.7 1961.3 2942.0 3922.7 4903.4 5884.0 6864.7 7845.3 8826.0 9806.7 1 KPa 98.1 1078.7 2059.4 3040.1 4020.7 5001.4 5982.1 6962.7 7943.4 8924.1 9904.7 2 KPa 196.1 1176.8 2157.5 3138.1 4118.8 5099.5 6080.1 7060.8 8041.5 9022.1 10002.8 3 KPa 294.2 1274.9 2255.5 3236.2 4216.9 5197.5 6178.2 7158.9 8139.5 9120.2 10100.8 4 KPa 392.3 1372.9 2353.6 3334.3 4314.9 5295.6 6276.3 7256.9 8237.6 9218.3 10198.9 5 KPa 490.3 1471.0 2451.7 3432.3 4413.0 5393.7 6374.4 7355.0 8335.7 9316.3 10297.0 6 KPa 588.4 1569.1 2549.7 3530.4 4511.1 5491.8 6472.4 7453.1 8433.7 9414.4 10395.1 7 KPa 686.5 1667.1 2647.8 3628.5 4609.1 5589.8 6570.5 7551.1 8531.8 9512.5 10493.1 8 KPa 784.5 1765.2 2745.9 3726.5 4707.2 5687.9 6668.6 7649.2 8629.9 9610.5 10591.2 9 KPa 882.6 1863.3 2843.9 3824.6 4805.3 5785.9 6766.6 7747.3 8727.9 9708.6 10689.2 10 20 30 40 50 60 70 80 90 100 kgf/cm2
KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

KPa 0 kgf/cm2 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 00 10.197 20.394 30.592 40.789 50.986 61.183 71.380 81.578 91.775 101.972 100 kgf/cm2 1.020 11.217 21.414 31.611 41.809 52.006 62.203 72.400 82.597 92.795 102.992 200 kgf/cm2 2.039 12.237 22.434 32.631 42.828 53.025 63.223 73.420 83.617 93.814 104.011 300 kgf/cm2 3.059 13.256 23.454 33.651 43.848 54.045 64.242 74.440 84.637 94.834 105.031 400 kgf/cm2 4.079 14.276 24.473 34.670 44.868 55.065 65.262 75.459 85.656 95.854 106.051 500 kgf/cm2 5.099 15.296 25.493 35.690 45.887 56.085 66.282 76.479 86.676 96.873 107.071 600 kgf/cm2 6.118 16.316 26.513 36.710 46.907 57.104 67.302 77.499 87.696 97.893 108.090 700 kgf/cm2 7.138 17.335 27.532 37.730 47.927 58.124 68.321 78.518 88.716 98.913 109.110 800 kgf/cm2 8.158 18.355 28.552 38.749 48.947 59.144 69.341 79.538 89.735 99.933 110.130 900 kgf/cm2 9.177 19.375 29.572 39.769 49.966 60.163 70.361 80.558 90.755 100.952 111.149 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 KPa
224
CONVERSION TABLE TORQUE

FOOT POUNDS TO KILOGRAMMETERS
ft. lbs. 0 kgf-m 10 20 30 40 50 60 70 80 90 100 0 1.383 2.765 4.148 5.530 6.913 8.295 9.678 11.060 12.443 13.826 1 kgf-m 0.138 1.521 2.903 4.286 5.668 7.051 8.434 9.816 11.199 12.581 13.964 2 kgf-m 0.277 1.659 3.042 4.424 5.807 7.189 8.572 9.954 11.337 12.719 14.102 3 kgf-m 0.415 1.797 3.180 4.562 5.945 7.328 8.710 10.093 11.475 12.858 14.240 4 kgf-m 0.553 1.936 3.318 4.701 6.083 7.466 8.848 10.231 11.613 12.996 14.379 5 kgf-m 0.691 2.074 3.456 4.839 6.221 7.604 8.987 10.369 11.752 13.134 14.517 6 kgf-m 0.830 2.212 3.595 4.977 6.360 7.742 9.125 10.507 11.890 13.272 14.655 7 kgf-m 0.968 2.350 3.733 5.115 6.498 7.881 9.263 10.646 12.028 13.411 14.793 8 kgf-m 1.106 2.489 3.871 5.254 6.636 8.019 9.401 10.784 12.166 13.549 14.932 9 kgf-m 1.244 2.627 4.009 5.392 6.774 8.157 9.540 10.922 12.305 13.687 15.070 10 20 30 40 50 60 70 80 90 100 ft lbs.
KILOGRAMMETERS TO FOOT POUNDS

kgf-m 0 ft. lbs. 10 20 30 40 50 60 70 80 90 100 0 72.33 144.66 216.99 289.32 361.65 433.98 506.31 578.64 650.97 723.30 1 ft. lbs. 7.23 79.56 151.89 224.22 296.55 368.88 441.21 513.54 585.87 658.20 730.53 2 ft. lbs. 14.47 86.80 159.13 231.46 303.79 376.12 448.45 520.78 593.11 665.44 737.77 3 ft. lbs. 21.70 94.03 166.36 238.69 311.02 383.35 455.68 528.01 600.34 672.67 745.00 4 ft. lbs. 28.93 101.26 173.59 245.92 318.25 390.58 462.91 535.24 607.57 679.90 752.23 5 ft. lbs. 36.17 108.50 180.83 253.16 325.49 397.82 470.15 542.48 614.81 687.14 759.47 6 ft. lbs. 43.40 115.73 188.06 260.39 332.72 405.05 477.38 549.71 622.04 694.37 766.70 7 ft. lbs. 50.63 122.96 195.29 267.62 339.95 412.28 484.61 556.94 629.27 701.60 773.93 8 ft. lbs. 57.86 130.19 202.52 274.85 347.18 419.51 491.84 564.17 636.50 708.83 781.16 9 ft. lbs. 65.10 137.43 209.76 282.09 354.42 426.75 499.08 571.41 643.74 716.07 788.40 10 20 30 40 50 60 70 80 90 100 kgf-m
KILOGRAMMETERS TO NEWTONMETERS
kgf-m 0 N-m 10 20 30 40 50 60 70 80 90 100 00 98.07 196.13 294.20 392.27 490.33 588.40 686.47 784.53 882.60 980.67 1 N-m 9.81 107.87 205.94 304.01 402.07 500.14 598.21 696.27 794.34 892.41 990.47 2 N-m 19.61 117.68 215.75 313.81 411.88 509.95 608.01 706.08 804.15 902.21 1000.28 3 N-m 29.42 127.49 225.55 323.62 421.69 519.75 617.82 715.89 813.95 912.02 1010.08 4 N-m 39.23 137.29 235.36 333.43 431.49 529.56 627.63 725.69 823.76 921.83 1019.89 5 N-m 49.03 147.10 245.17 343.23 441.30 539.37 637.43 735.50 833.57 931.63 1029.70 6 N-m 58.84 156.91 254.97 353.04 451.11 549.17 647.24 745.31 843.37 941.44 1039.51 7 N-m 68.65 166.71 264.78 362.85 460.91 558.98 657.05 755.11 853.18 951.25 1049.31 8 N-m 78.45 176.52 274.59 372.65 470.72 568.79 666.85 764.92 862.99 961.05 1059.12 9 N-m 88.26 186.33 284.39 382.46 480.53 578.59 676.66 774.73 872.79 970.86 1068.93 10 20 30 40 50 60 70 80 90 100 kgf-m
NEWTONMETERS TO KILOGRAMMETERS
N-m 0 kgf-m 100 200 300 400 500 600 700 800 900 1000 00 10.197 20.394 30.591 40.788 50.985 61.182 71.379 81.576 91.773 101.970 10 kgf-m 1.020 11.217 21.414 31.611 41.808 52.005 62.202 72.399 82.596 92.793 102.990 20 kgf-m 2.039 12.236 22.433 32.630 42.827 53.024 63.221 73.418 83.615 93.812 104.009 30 kgf-m 3.059 13.256 23.453 33.650 43.847 54.044 64.241 74.438 84.635 94.832 105.029 40 kgf-m 4.079 14.276 24.473 34.670 44.867 55.064 65.261 75.458 85.655 95.852 106.049 50 kgf-m 5.099 15.296 25.493 35.690 45.887 56.084 66.281 76.478 86.675 96.872 107.069 60 kgf-m 6.118 16.315 26.512 36.709 46.906 57.103 67.300 77.497 87.694 97.891 108.088 70 kgf-m 7.138 17.335 27.532 37.729 47.926 58.123 68.320 78.517 88.714 98.911 109.108 80 kgf-m 8.158 18.355 28.552 38.749 48.946 59.143 69.340 79.537 89.734 99.931 110.128 90 kgf-m 9.177 19.374 29.571 39.768 49.965 60.162 70.359 80.556 90.753 100.950 111.147 100 200 300 400 500 600 700 800 900 1000 N-m
225
CONVERSION TABLE TEMPERATURE

FAHRENHEIT TO CENTIGRADE
F -60 -58 -56 -54 -52 -50 -48 -46 -44 -42 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 C -51.1 -50.0 -48.9 -47.8 -46.7 -45.6 -44.4 -43.3 -42.2 -41.1 -40.0 -38.9 -37.8 -36.7 -35.6 -34.4 -33.3 -32.2 -31.1 -30.0 -28.9 -27.8 -26.7 -25.6 -24.4 -23.3 -22.2 -21.1 -20.0 F -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 C -18.9 -17.8 -16.7 -15.6 -14.4 -13.3 -12.2 -11.1 -10.0 -8.9 -7.8 -6.7 -5.6 -4.4 -3.3 -2.2 -1.1 0.0 1.1 2.2 3.3 4.4 5.6 6.7 7.8 8.9 10.0 11.1 12.2 F 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 C 13.3 14.4 15.6 16.7 17.8 18.9 20.0 21.1 22.2 23.3 24.4 25.6 26.7 27.8 28.9 30.0 31.1 32.2 33.3 34.4 35.6 36.7 37.8 38.9 40.0 41.1 42.2 43.3 44.4 F 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 C 45.6 46.7 47.8 48.9 50.0 51.1 52.2 53.3 54.4 55.6 56.7 57.8 58.9 60.0 61.1 62.2 63.3 64.4 65.6 66.7 67.8 68.9 70.0 71.1 72.2 73.3 74.4 75.6 76.7 F 172 174 176 178 180 182 184 186 188 190 192 194 196 198 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228 C 77.8 78.9 80.0 81.1 82.2 83.3 84.4 85.6 86.7 87.8 88.9 90.0 91.1 92.2 93.3 94.4 95.6 96.7 97.8 98.9 100.0 101.1 102.2 103.3 104.4 105.6 106.7 107.8 108.9 F 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 C 110.0 111.1 112.2 113.3 114.4 115.6 116.7 117.8 118.9 120.0 121.1 122.2 123.3 124.4 125.6 126.7 127.8 128.9 130.0 131.1 132.2 133.3 134.4 135.6 136.7 137.8 138.9 140.0 141.1 F 288 290 292 294 296 298 300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332 334 336 338 340 342 344 C 142.2 143.3 144.4 145.6 146.7 147.8 148.9 150.0 151.1 152.2 153.3 154.4 155.6 156.7 157.8 158.9 160.0 161.1 162.2 163.3 164.4 165.6 166.7 167.8 168.9 170.0 171.1 172.2 173.3 F 346 348 350 352 354 356 358 360 362 364 366 368 370 372 374 376 378 380 382 384 386 388 390 392 400 410 420 430 440 C 174.4 175.6 176.7 177.8 178.9 180.0 181.1 182.2 183.3 184.4 185.6 186.7 187.8 188.9 190.0 191.1 192.2 193.3 194.4 195.6 196.7 197.8 198.9 200.0 204.4 210.0 215.6 221.1 226.7
CENTIGRADE TO FAHRENHEIT
C -50 -49 -48 -47 -46 -45 -44 -43 -42 -41 -40 -39 -38 -37 -36 -35 -34 -33 -32 -31 -30 -29 -28 -27 -26 -25 -24 -23 -22 -21 -20 -19 F -58.0 -56.2 -54.4 -52.6 -50.8 -49.0 -47.2 -45.4 -43.6 -41.8 -40.0 -38.2 -36.4 -34.6 -32.8 -31.0 -29.2 -27.4 -25.6 -23.8 -22.0 -20.2 -18.4 -16.6 -14.8 -13.0 -11.2 -9.4 -7.6 -5.8 -4.0 -2.2 C -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 F -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 C 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 F 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 C 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 C 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 F 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 213.8 215.6 217.4 219.2 221.0 222.8 224.6 226.4 228.2 C 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 F 230.0 231.8 233.6 235.4 237.2 239.0 240.8 242.6 244.4 246.2 248.0 249.8 251.6 253.4 255.2 257.0 258.8 260.6 262.4 264.2 266.0 267.8 269.6 271.4 273.2 275.0 276.8 278.6 280.4 282.2 284.0 285.8 C 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 F 287.6 289.4 291.2 293.0 294.8 296.6 298.4 300.2 302.0 303.8 305.6 307.4 309.2 311.0 312.8 314.6 316.4 318.2 320.0 321.8 323.6 325.4 327.2 329.0 330.8 332.6 334.4 336.2 338.0 339.8 341.6 343.4 C 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 210 220 230 240 250 F 345.2 347.0 348.8 350.6 352.4 354.2 356.0 357.8 359.6 361.4 363.2 365.0 366.8 368.6 370.4 372.2 374.0 375.8 377.6 379.4 381.2 383.0 384.8 386.6 388.4 390.2 392.0 410.0 428.0 446.0 464.0 482.0
226
Copyright reserved for this manual may not be reproduced or copied, in whole or in part, without the written consent of ISUZU MOTORS LIMITED.
WORKSHOP MANUAL (INDUSTRIAL) A-4JA1, A-4JB1 (IDE-2310)
Issued by
ISUZU MOTORS LIMITED

POWERTRAIN SERVICE & PARTS POWERTRAIN OPERATIONS 6-26-1, Minami-oi, Shinagawa-ku,Tokyo, 140-8722, Japan TEL 03-5471-1111 First edition Jul., 1998 107-03K
IDE-2310
PRINTED IN JAPAN

Isuzu Diesel Engine 4JA1 and 4JB1

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INDUSTRIAL DIESEL ENGINE A-4JA1, A-4JB1 MODELS

2003 ISUZU MOTORS LIMITED

GENERAL REPAIR INSTRUCTIONS

NOTES ON THE FORMAT OF THIS MANUAL

11.0 1.0 (79.5 7.2/107.8 9.8)

14. Flywheel Housing

5.61.0 (40.57.2/ 54.99.8) 10.51.0 (76.07.2/103.09.8) 9.81.0 (71.07.2/ 96.09.8)

M12x1.25 (0.47x0.05) Bolt M12x1.75 (0.47x0.07) Bolt

Important operation requiring extra care

Specified torque (tighten)

MAIN DATA AND SPECIFICATIONS

(31.7 x 24.6 x 28.7) (29.1 x 24.6 x 29.4) (22.8 x 30.4 x 22.7)

TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE SPECIFICATIONS

FLANGED HEAD BOLT

SPECIAL PARTS FIXING NUTS AND BOLTS

5.0 6.0 (36.2 43.4/49.0 58.8)

1.0 2.0 (7.2 14.4/9.8 19.6)

1st Step New bolt Reused bolt

16.0 18.0 (115.7 130.2/159.6 176.5)

20.1 24.5 (145.4 177.2/197.1 240.3)

14 24 (1.4 2.4/4.4 7.2)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.4 2.4 (10.1 17.3/13.7 23.5)

10.0 12.0 (72.4 86.8/98.1 117.7)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.0 1.5 (7.2 10.9/9.8 14.7)

6.6 8.7 (48 63/66 85)

Cooling and Lubricating System kgfm(lb.ft./Nm)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.4 2.4 (10.1 17.3/13.7 23.5)

Intake and Exhaust Manifold kgfm(lb.ft./Nm)

1.4 2.4 (10.1 17.3/13.7 23.5)

1.4 2.4 (10.1 17.3/13.7 23.5)

Engine Electrical kgfm(lb.ft./Nm)

1.4 2.4 (10.1 17.3/13.7 23.5)

2.0 2.5 (14.4 18.1/19.6 24.5)

3.6 4.6 (26.0 33.3/35.3 45.1)

6.0 8.0 (43.4 57.9/58.8 78.4)

Fuel Injection System kgfm(lb.ft./Nm)

20 4.0 (14.4 28.9/19.6 39.2)

INJECTION PUMP IDENTIFICATION

Water Separator (Water Sedimentor) (Optional Equipment)

0.9 1.5 (6.5 10.9/8.8 14.7)

For the engine equipped with distributor type injection pump

mm(in.) 0.50 1.50 (0.02 0.06)

VALVE CLEARANCE ADJUSTMENT

5.0 6.0 (36.2 43.4/49.0 58.8)

7) Remove the delivery valve holder.

MAINTENANCE 2. Distributor type injection pump

COMPRESSION PRESSURE MEASUREMENT

ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE

25C 30C (77F) (86F)

ENGINE REPAIR KIT