4HK1 & 6HK1 manual

I n t roduct ion This Manual describes the structure and the troubleshooting of electronic control fuel injection system (common rail type) in 4HK1 and 6HK1 industrial engines. Use this manual sufficiently to perform service work properly and quickly. Hitachi Construction Machinery Co., Ltd

General Contents Disassemble and Assemble Engine General Information Engine Mechanical (4HK1、6HK1) Cooling System Fuel System Engine Electrical Exhaust System and Turbocharger

Engine Manual (1/2) Control System Electronic control fuel injection system (Common rail type)

General Information

GENERAL INFORMATION General Information Contents General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2 Reading the model . . . . . . . . . . . . . . . . . . . . . . . 0A-6 General information . . . . . . . . . . . . . . . . . . . . . . 0A-7

0A-2

General Information

General Information 0A-1

0A-2 General Information

General Information Service Precautions In order to carry out work safely 1. Always use an engine stand when taking the engine down from the vehicle. Do not place the engine directly onto the ground, or place in a manner that interferes with the oil pan. 2. If you are working together with others, always pay attention to each other's safety. 3. If you are repairing any part of the electrical system, always remove the minus side cable from the battery terminal before starting work. If you are removing the battery cover, always remove the cover in a place that is away from sources of fire/ heat. WSHK0190

6. All regular tools, gauges and special tools should be regularly inspected, and prepared before starting work. Do not use bent spanners, hammers with damaged edges, chipped chisels, or any other faulty or damaged tools.

4. Do not perform painting work or leave the engine running for long periods of time in an enclosed or badly ventilated indoor workshop. 5. Always use the correct specialized tool indicated in the instructions. Using the incorrect tool may cause damage to the parts or injury to the person using the tool. 7. Always pay close attention to safety and handling requirements when using grinders, cranes, welders, and other such equipment. Moreover, always wear the correct protective garments and use the necessary safety tools for the job in hand.

General Information 0A-3

WSHK0192

WSHK0191

8. Always check that there are no fuel leaks when performing maintenance work on the fuel system. (It may cause a fire.)

Replacement parts and part numbers. 1. Always replace packing, oil seals, o-rings, caulking lock nuts, folding lock plates, split pins and other such parts with brand new parts. 2. The parts numbers contained in this manual may not represent the supply condition of the parts, and the part numbers may be changed due to revisions. Therefore, parts should always be checked against a parts catalogue before use. Liquid gasket

9. Pay close attention to the risk of ignition if you are handling parts that carry a high voltage. Furthermore, any oil or grease spilt onto rubber parts must be wiped off immediately, as it will cause deterioration of the rubber.

1. Each time you disassemble parts that use liquid gasket, completely remove the old gasket residue from each of the parts and matching sections using a scraper, then clean each of the parts to completely remove oil, water, and dirt etc. from the various surfaces. Using the specified type of liquid gasket, apply new liquid gasket to each of the surfaces before reassembling the parts. 2. In order to make it easier to clean liquid gasket surfaces, apply gasket remover liquid (Pando391D made by Three Bond Co., Ltd.) and leave the part to stand for approximately 10 minutes, after which the old liquid gasket residue will be easier to remove. However, this should not be used on resin components or painted components. 3. Please take care not to apply too much or too little liquid gasket. Also, you should always re-apply the liquid gasket upon itself when you start and finish application. 4. Make sure that there are no gaps when reinstalling the liquid gasket parts to each other. If there are gaps between the two parts, re-apply the liquid gasket. Some parts, especially the oil pan, use the same size studs as a guide to eliminate the need for knock pin positioning etc. 5. Re-install these parts within 7 minutes of applying the liquid gasket.

0A-4 General Information If more than 7 minutes passes, remove the previous liquid gasket and re-apply it. 6. Please wait for at least 30 minutes since the last part is installed before starting the engine. Liquid gasket Seal section

Product name

Manufacturer's name

Between cylinder block and – Flywheel housing

1207B

Three Bond

Between cylinder block and – Flywheel housing and – Crankcase

1207B

Three Bond

Between cylinder block and – Crank case

1207B

Three Bond

Between cylinder block and – Front cover

1207B

Three Bond

262

Loctite

Cylinder block, head plug nipple, unit, switches • Always use the liquid gasket products listed above, or a liquid gasket identical to the ones listed above. • Use the correct quantity of liquid gasket. Always follow the handling instructions for each product. Application procedure 1. Wipe the contact surfaces clean of all water, grease or oil. The contact surfaces should be dry. 2. Apply a regular bead width of liquid gasket to one of the contact surfaces. Make sure that the bead does not break at this point. Notes: If there are special regulations concerning the application procedure in the repair document, please follow those regulations. Work procedure 1. Wipe the joint surfaces of the bolt, bolt hole, and screw thread section clean of water, grease, and oil. The contact surfaces should be dry. 2. Apply Loctite to the top 1/3 of the screw. 3. Tighten the bolt to the correct tightening torque.

Important: After tightening the bolt, do not apply excessive torque or try to rotate the bolt until at least one hour has passed, and the Loctite has hardened. Procedure for using the Plastigauge Type

Measurable range

mm (in)

PG-1 (Green)

0.025 – 0.076 (0.001 – 0.003)

PR-1 (Red)

0.051 – 0.152 (0.002 – 0.006)

PB-1 (Blue)

0.102 – 0.229 (0.004 – 0.009)

Example: Procedure for measuring the clearance between the connecting rod bearing and crank pin. • Clean the connecting rod and bearing, and install the bearing to the rod. • Cut the plastigauge to the same width as the crank pin, and while avoiding the oil pore of the crank pin lay the gauge parallel to the pin.

General Information 0A-5 • Line up the marks on the connecting rod and cap and install the crank pin, apply molybdenum disulfide to the thread section and bearing surface of the fastening bolt, and rotate both cap and bolt to the correct torque. Important: Do not move the connecting rod while using the plastigauge. • Gently remove the cap and connecting rod, and measure the crushed width of the plastigauge (clearance between rod and pin) using the scale printed on the bag.

Example: Measuring the clearance between the crank bearing and crank journal • Clean the clamp face of the cylinder block and crankcase bearing, and also the bearing, and install the cylinder block to the crankcase. • Gently rest the crankshaft on the cylinder block, and rotate it approximately 30 degree to stabilize it.

• Cut the plastigauge to the same size as the journal width, and while avoiding the oil pore of the journal lay the gauge parallel to the journal. • Gently rest the crank case on the cylinder block, apply molybdenum disulfide to the thread section and bearing surface of the fastening bolt, and tighten in sequence to the correct torque. Important: Do not rotate the crankshaft while using the plastigauge. • Gently remove the crankcase, and measure the crushed width of the plastigauge (clearance between bearing and journal) using the scale printed on the bag.

0A-6 General Information Reading the model Engine number stamping position 4HK1

WSHK0185

General Information 0A-7 6HK1

WSHK0186

General information Terminology, description of abbreviations Terminology definitions Term

Explanation

Maintenance standard

The generic name for reference values required for maintenance, such as nominal dimension, selection of a reference point, and limit.

Nominal dimension

Shows the standard value at the point of manufacture that does not include the common difference.

Selection of a reference point Shows the standard value after assembling, repairing, or adjusting. Limit

When this value (dimensions) is reached, it shows that the part has reached its full limit and must be replaced or repaired.

Front ⋅ rear, left ⋅ right, upper ⋅ lower

These show each orientations of parts installed to the vehicle when looking from the vehicle's forward direction.

Unit

Units written to SI conventions (mainly torque, pressure, force) [Example] Length: mm, Torque: N⋅m {kgf⋅m}

Warning

Items that carry the warning mark pose a danger to life or threat of serious injury if not strictly observed.

Caution

Items that carry the caution mark may cause injury or lead to accidents if not strictly observed.

Important

Items that carry the important mark may cause the vehicle to break down, or may prevent the guaranteed normal operation of the system or related parts if not strictly observed.

0A-8 General Information Term

Explanation

Notes

Items that should receive special mention within a work procedure.

Description of abbreviations Abbreviation AC

Abbreviation FWD

Forward Forward

F/C

Fuel Cut Fuel Cut

GND

Ground Earth

Description Alternating Current Alternating Current

ACC

Accessory Accessory

ACG

Alternating Current Generator Alternating current generator

IC

API

American Petrol Institute American Petroleum Institute

ID Plate

ASM (Assy) Assembly Assembly ATDC

After Top Dead Center After Top Dead Center

BAT, BATT

Battery Battery

BRG, Brg

Bearing Bearing

BKT, BRKT

Bracket Bracket

BTDC CO CONN

Before Top Dead Center Before Top Dead Center Carbon Oxide Carbon Monoxide Connector Connector

CPU

Central Processing Unit Central processing unit

C/U

Control Unit Control unit

DC

Direct Current Direct current

DI

Direct Injection Direct injection

ECU

Engine Control Unit / Electronic Control Unit Engine control unit / control unit

Description

IN ISO

I/PUMP JIS

Integrated Circuit Integrated circuit Identification plate Identification plate, ID plate Intake, Intake Intake International Standardization International Standardization

for

Organization

for

Injection Pump Injection Pump Japanese Industrial Standard Japanese Industrial Standard

L/H, LH

Left Hand Left hand side

M/V

Magnetic Valve Magnetic valve

NOx

Nitrogen Oxide Nitrogen Oxide

N-TDC

Organization

Number - Top Dead Center Top dead center rotational frequency

OPT

Option Option

P

Pole(S) Pole

PCV

Pump Control Valve/ Positive Crankcase Ventilation Pump control valve/ Positive crankcase ventilation

PM

Particulate Matter Particulate matter

PS

Pre-Stroke Pre-stroke

ECM

Engine Control Module Engine control module

EGR

Exhaust Gas Recirculation Exhaust gas recirculation

PTO

Exhaust Exhaust

Power Take Off Power take off

QOS

Quick On System Rapid preheating system

Exh, EXH Ft, FRT

Front Front

Rr, RR

Rear Rear

General Information 0A-9 Abbreviation R/H, RH

SI (International System of Units)

Description

With regards the conversion to SI (International System of Units)

Right Hand Right hand side

R/L

Relay Relay

STD

Standard Standard

SW

Switch Switch

TICS

Timing & Injection rate Control System A type of injection system

VGS Turbo

Variable Geometry turbocharger System Adjustable turbo, VGS turbo

W/L

The introduction of the SI systems aims to internationally unify the metric system and the various units used by different countries (traditional weights and measures, the foot pound method etc.), and to curb the confusion that occurs between the different units (conversion calculations etc.). The new calculating method which adopted SI units was completely adopted in Japan in 1992, and is standardized by JIS-Z-8203. All of the units in this manual are written in line with the International System of Units SI units, and conventional units are written in { } brackets. SI French) Abbreviated name of Le Systeme International d’Unites

Warning Lamp Warning lamp

Connection between main SI units and conventional units SI

Conventional Unit

Length

m

m

Same as the conventional unit

Weight (Mass)

kg

kg

Same as the conventional unit

Force

N

* kg, kgf

Torque

N⋅m

* kg⋅m, gf⋅m

Pressure

Pa

*kg/cm2, mmHg

Dynamic force, horsepower

W

PS

Capacity, air volume displacement

m3

Litle, L, cc

g/(kW⋅h)

g/(PS⋅h)

Fuel consumption

*1 Published service data may conveniently use kg for force and mass (weight) instead of kgf. *2 Some conversion results may be rounded off to 1 or 2 decimal places. Converting expressions of quantity When converting, prefixes such as k (kilo) or m (mili) are used. M

Mega

106

1,000,000

k

Kilo

103

1,000

2

100 0.1

h

Hecto

10

d

Deci

10-1

c

Centi

-2

m

Milli

µ

Micro

10

0.01

10-3

0.001

-6

10

0.000001

• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa • 40 mmHg = 5,332 Pa = 5.3 kPa

Item, unit conversion

1 kgf = 9.80665 N 1 kgf⋅m = 9.80665 N⋅m 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa 1 PS = 0.74 kW 1 Litle = 1 dm3, 1 cc = 1mLitle = 1cm3 1 g/(PS⋅h) = 1.360 g/(kW⋅h)

Conversion formula Length • km × 0.6214 = mile • m × 3.281 = ft • mm × 0.03937 = in Pressure • kPa × 0.0101972 = kg/cm2 • kPa × 0.145038 = psi • MPa × 10.197162 = kg/cm2 • MPa × 145.03774 = psi Tightening torque • N⋅m × 0.101972 = kg⋅m • N⋅m × 0.737562 = lb ft Speed • kg/h × 0.6214 = MPH Temperature • °C × 1.8 + 32 = °F

0A-10 General Information Table of tightening torque The tightening torque values in the table below apply to all situations unless a special tightening torque is specified. bolts, nuts N⋅m {kgf⋅m} Strength classification

4.8 4T

Bolt head Hexagon head bolt section shape * M10 × 1.5 M12 × 1.25 * M12 × 1.75

7T

Flange bolt

Hexagon head bolt

Flange bolt

19.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1} 49.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}

68.1 ~ 102.1 {6.9 ~ 10.4}

45.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6} 76.5 ~ 114.7 {7.8 ~ 11.7}

83.0 ~ 124.5 {8.5 ~ 12.7}

93.2 ~ 139.3 {9.5 ~ 14.2}

100.8 ~ 151.1 {10.3 ~ 15.4}

71.6 ~ 106.9 {7.3 ~ 10.9}

77.2 ~ 115.8 {7.9 ~ 11.8}

88.3 ~ 131.4 {9.0 ~ 13.4}

94.9 ~ 142.3 {9.7 ~ 14.5}

104.0 ~ 157.0 {10.6 ~ 16.0}

115.6 ~ 173.3 {11.8 ~ 17.7}

135.3 ~ 204.0 {13.8 ~ 20.8}

150.1 ~ 225.2 {15.3 ~ 23.0}

100.0 ~ 149.1 {10.2 ~ 15.2}

109.4 ~ 164.2 {11.2 ~ 16.7}

129.4 ~ 194.2 {13.2 ~ 19.8}

142.5 ~ 213.8 {14.5 ~ 21.8}

M18 × 1.5

151.0 ~ 225.6 {15.4 ~ 23.0}

—

195.2 ~ 293.2 {19.9 ~ 29.9}

—

* M18 × 2.5

151.0 ~ 225.6 {15.4 ~ 23.0}

—

196.1 ~ 294.2 {20.0 ~ 30.0}

—

M20 × 1.5

206.0 – 310.0 {21.0 ~ 31.6}

—

269.7 ~ 405.0 {27.5 ~ 41.3}

—

* M20 × 2.5

190.2 ~ 286.4 {19.4 – 29.2}

—

249.1 ~ 374.6 {25.4 ~ 38.2}

—

M22 × 1.5

251.1 – 413.8 {25.6 ~ 42.2}

—

362.8 ~ 544.3 {37.0 ~ 55.5}

—

* M22 × 2.5

217.7 ~ 327.5 {22.2 ~ 33.4}

—

338.3 ~ 507.0 {34.5 ~ 51.7}

—

M24 × 2

358.9 ~ 539.4 {36.6 ~ 55.0}

—

430.5 ~ 711.0 {43.9 ~ 72.5}

—

* M24 × 3

338.3 ~ 507.0 {34.5 ~ 51.7}

—

406.0 ~ 608.0 {41.4 ~ 62.0}

—

M14 × 1.5 * M14 × 2 M16 × 1.5 * M16 × 2

The * mark indicates where soft materials have been used for internal thread sections, such as castings.

General Information 0A-11 N⋅m {kgf⋅m} Strength classification Bolt head shape

section

9.8 9T

8.8 Hexagon head bolt

Flange bolt

Hexagon head bolt

Flange bolt

5.6 ~ 11.2 {0.6 ~ 1.1}

6.6 ~ 12.2 {0.6 ~ 1.2}

—

—

M8 × 1.25

13.4 ~ 25.7 {1.4 ~ 2.6}

15.3 ~ 28.4 {1.6 ~ 2.9}

16.7 ~ 30.4 {1.7 ~ 3.1}

18.1 ~ 33.6 {1.9 ~ 3.4}

M10 × 1.25

31.3 ~ 52.5 {3.2 ~ 5.4}

35.4 ~ 58.9 {3.6 ~ 6.1}

37.3 ~ 62.8 {3.8 ~ 6.4}

42.3 ~ 70.5 {4.3 ~ 7.2}

31.3 ~ 51.4 {3.2 ~ 5.2}

34.5 ~ 57.5 {3.5 ~ 5.8}

36.3 ~ 59.8 {3.7 ~ 6.1}

40.1 ~ 66.9 {4.1 ~ 6.8}

M12 × 1.25

69.3 ~ 104.0 {7.1 ~ 10.6}

77.7 ~ 116.5 {7.9 ~ 11.9}

75.5 ~ 113.8 {7.7 ~ 11.6}

85.0 ~ 127.5 {8.7 ~ 13.0}

* M12 × 1.75

64.8 ~ 96.1 {6.6 ~ 9.8}

71.4 ~ 107.2 {7.3 ~ 10.9}

71.6 ~ 106.9 {7.3 ~ 10.9}

79.5 ~ 119.2 {8.1 ~ 12.2}

M14 × 1.5

106.2 ~ 158.8 {10.8 ~ 16.2}

114.9 ~ 172.3 {11.7 ~ 17.6}

113.8 ~ 170.6 {11.6 ~ 17.4}

123.4 ~ 185.1 {12.6 ~ 18.9}

100.6 ~ 149.8 {10.3 ~ 15.3}

108.2 ~ 162.2 {11.1 ~ 16.6}

106.9 ~ 160.0 {10.9 ~ 16.3}

115.5 ~ 173.3 {11.8 ~ 17.7}

154.3 ~ 232.5 {15.7 ~ 23.7}

171.1 ~ 256.7 {17.4 ~ 26.2}

160.0 ~ 240.3 {16.3 ~ 24.5}

176.9 ~ 265.3 {18.0 ~ 27.1}

147.6 ~ 221.4 {15.0 ~ 22.6}

162.5 ~ 243.8 {16.6 ~ 24.9}

153.0 ~ 229.5 {15.6 ~ 23.4}

168.5 ~ 252.7 {17.2 ~ 25.8}

M18 × 1.5

222.5 ~ 334.3 {22.7 ~ 34.1}

—

229.5 ~ 345.2 {23.4 ~ 35.2}

—

* M18 × 2.5

223.6 ~ 335.4 {22.8 ~ 34.2}

—

230.5 ~ 346.2 {23.6 ~ 35.3}

—

M20 × 1.5

307.4 ~ 461.7 {31.4 ~ 47.1}

—

316.8 ~ 475.6 {32.3 ~ 48.5}

—

* M20 × 2.5

284.0 ~ 472.1 {29.0 ~ 43.5}

—

293.2 ~ 440.3 {29.2 ~ 44.9}

—

M22 × 1.5

413.6 ~ 620.5 {42.2 ~ 63.3}

—

424.6 ~ 636.5 {43.3 ~ 64.9}

—

* M22 × 2.5

385.7 ~ 578.0 {39.3 ~ 58.9}

—

394.2 ~ 592.3 {40.0 ~ 60.4}

—

M24 × 2

490.8 ~ 810.5 {50.0 ~ 82.7}

—

554.1 ~ 830.6 {56.5 ~ 84.7}

—

* M24 × 3

462.8 ~ 693.1 {47.2 ~ 70.7}

—

520.7 ~ 781.6 {53.1 ~ 79.7}

—

M6 × 1

* M10 × 1.5

* M14 × 2 M16 × 1.5 * M16 × 2

The * mark indicates where soft materials have been used for internal thread sections, such as castings.

0A-12 General Information Designations for bolt heads

Legend 1. Hexagon head bolt(4.8, 4T) 2. Hexagon head bolt(4.8, 4T) 3. Flange bolt(4.8, 4T) 4. Flange bolt(4.8, 4T) 5. Hexagon head bolt(7T) 6. Flange bolt(7T) 7. Hexagon head bolt (refined 8.8) 8. Hexagon head bolt (refined 8.8)

9. 10. 11. 12. 13. 14. 15. 16.

Hexagon head bolt(Un-refined 8.8) Hexagon head bolt(Un-refined 8.8) Flange bolt(8.8) Flange bolt(8.8) Hexagon head bolt(9.8, 9T) Hexagon head bolt(9.8, 9T) Flange bolt(9.8, 9T) Flange bolt(9.8, 9T)

Flare nut Pipe diameter

Flare nut tightening torque (service standard value) N⋅m {kgf⋅m}

tightening torque (for medium and large size vehicles)

Flare nut 2 side width (mm) Old

New

φ4.76 mm

12.8 ~ 18.6 {1.3 ~ 1.9}

14

14

φ6.35 mm

23.5 ~ 49 {2.4 ~ 5.0}

17

17

φ8.0 mm

23.5 ~ 49 {2.4 ~ 5.0}

19

17

φ10.0 mm

44.1 ~ 93.2 {4.5 ~ 9.5}

22

19

φ12.0 mm

58.8 ~ 137.3 {6.0 ~ 14.0}

27

24

φ15.0 mm

78.5 ~ 156.9 {8.0 ~ 16.0}

30

30

General Information 0A-13 Taper screw from connectors (brass) N⋅m {kgf⋅m} Screw size

PT(R) 1/8

PT(R) 1/4

PT(R) 3/8

PT(R) 1/12

—

2.0 ~ 14.7 (0.2 ~ 1.5)

4.9 ~ 15.7 (0.5 ~ 1.6)

9.8 ~ 16.7 (1.0 ~ 1.7)

9.8 ~ 17.7 (1.0 ~ 1.8)

Special Tool Classification A; Essential tool Servicing operation cannot be done with any other tools than the essential tool. B; Recommended tool Servicing work can be done with a general-purpose tool commercially available. However, it is advisable to use the recommended tool as much as possible for a reduced work time and an improved safety in work operations. C; Available tool Although it takes a more working time, servicing operations can be made with a tool commercially available as substitute for the available tool.

0A-14 General Information

ENGINE MECHANICAL (4HK1, 6HK1)

ENGINE ENGINE MECHANICAL (4HK1, 6HK1) TABLE OF CONTENTS DIESEL ENGINE (4HK1, 6HK1) . . . . . . . . . . . . . . 1A-3 Precautions on Service Work. . . . . . . . . . . . . . . 1A-3 Main Data and Specifications. . . . . . . . . . . . . . 1A-11 Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 1A-14 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-16 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-18 Inlet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-24 Turbocharger and Exhaust Manifold . . . . . . . . . . 1A-25 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-28 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-31 Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 1A-34 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-39 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-50 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-51 Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-52 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-52 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-56 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-58 Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-59 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-60 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-61 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-63 Fixing torque . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-65 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-65 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-66 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-68 Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-69 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-69 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-69 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-70 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-71 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-73 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-74 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-78

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-81 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-87 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-94 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-101 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-101 Piston, Connecting Rod . . . . . . . . . . . . . . . . . . 1A-103 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-104 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-110 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-112 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-114 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-115 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-119 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-121 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-124 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1A-126 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-126 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-126 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-128 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-133 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-133 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . . 1A-134 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-134 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-134 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-135 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-138 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-146 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-150 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-150 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-153 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-154 Lubrication System . . . . . . . . . . . . . . . . . . . . . . 1A-157 Precautions on Service Work . . . . . . . . . . . . . 1A-157

ENGINE MECHANICAL (4HK1, 6HK1) Function Check . . . . . . . . . . . . . . . . . . . . . . . 1A-158 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-159 Oil Port Cover ASM. . . . . . . . . . . . . . . . . . . . . . 1A-160 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-160 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-163 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-165 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-168 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-169 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171 Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-174 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 1A-178 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-178


1A-3

DIESEL ENGINE (4HK1, 6HK1) Precautions on Service Work Matters that maintenance

require

attention

in

terms

of

To prevent damage to the engine and ensure reliability of its performance, pay attention to the following in maintaining the engine: When taking down the engine on the ground, do not make the bearing surface of the oil pan touch directly the ground. Use a wood frame, for example, to support the engine with the engine foot and the flywheel housing. Because there is only a small clearance between the oil pan and the oil pump strainer, it can damage the oil pan and the oil strainer. • When the air duct or air cleaner is removed, cover the air intake opening to prevent foreign matter from getting into the cylinder. If it gets into it, it can considerably damage the cylinder and others while the engine is operating. • When maintaining the engine, never fail to remove the battery ground cable. If not, it may damage the wire harness or electrical parts. If you need electricity on for the purpose of inspection, for instance, watch out for short circuits and others. • Apply engine oil to the sliding contact surfaces of the engine before reassembling it. This ensures adequate lubrication when the engine is first started. • When valve train parts, pistons, piston rings, connecting rods, connecting rod bearings or crankshaft journal bearings are removed, put them in order and keep them. • When installing them, put them back to the same location as they were removed. • Gaskets, oil seals, O-rings, etc. must be replaced with new ones when the engine is reassembled. • As for parts where a liquid gasket is used, remove an old liquid gasket completely and clean it up thoroughly so that no oil, water or dust may be clung to them. Then, apply the designated liquid gasket to each place anew before assembly. • Surfaces covered with liquid gasket must be assembled within 7 minutes of gasket application. If more than 7 minutes have elapsed, remove the existing liquid gasket and apply new liquid gasket. • When assembling or installing parts, fasten them with the specified tightening torque so that they may be installed properly.

Matters that require attention in specifically dealing with this engine. Holes or clearances in the fuel system, which serve as a passage of fuel, including the inside of the injector, are made with extreme precision. For this reason, they are highly sensitive to foreign matter and if it gets in, it can lead to an accident on the road, for instance; thus, make sure that foreign matter will be prevented from getting in. When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system. • Before beginning the service procedure, wash the fuel line and the surrounding area. • Perform the service procedures with clean hands. Do not wear work gloves. • Immediately after removing the fuel hose and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe. • Always replace the high-pressure pipe in fuel system with new one if it has been removed. Reuse of it causes damage the seal surface, resulting in fuel leakage. • If parts are to be replaced (fuel hose, fuel pipe, etc.) do not open the new part packaging until installation. Work procedure • The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and common rail. • The eyebolts and gasket must be stored in a clean parts box with a lid to prevent adhesion of foreign matter. • Fuel leakage could cause fires. Therefore, after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.

1A-4 ENGINE MECHANICAL (4HK1, 6HK1) How to read the model 4HK1

Name 1. Cast The Engine Model

2. Stamp An Engine Number


1A-5

6HK1

1

WSHK0001

Name 1. Stamp An Engine Number Explanations on functions and operation Electronic engine control With the control unit, the range from injection to air intake/exhaust, including fuel injection quantity, injection timing, intake air restriction, EGR, and idling rpm, is controlled. Cylinder block The cylinder block is cast-iron with the center distance of each bore being equal and is of the highly rigid, symmetrical structure with the crankshaft center being the center. The bearing cap is of the ladder frame structure and tightened up under the plastic range rotation angle method.

Cylinder liner The cylinder liner is selected to match an internal diameter of a bore of the cylinder block and built, which is imprinted on the left side of the cylinder. Piston The piston is aluminum-alloy and an autothermatic piston with a strut cast, while the combustion chamber is a round reentrant type. Cylinder head The cylinder head is cast-iron and there are 4 valves per cylinder. The angular tightening method of the cylinder head bolt further increases reliability and durability.

1A-6 ENGINE MECHANICAL (4HK1, 6HK1) Crankshaft Tuftriding is given, while on the No. 1 balance weight imprinted is the grade of each journal diameter.

• Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC). 4HK1

EGR system Based upon data, including water temperature, engine speeds or engine loads, it is controlled via Engine Control Module (ECM) to purify exhaust by recycling part of it. Its main components include an EGR valve, an EGR cooler and various sensors. Connecting rod cap bolt The angular tightening method of the connecting rod cap bolt further increases reliability and durability. Common rail-type electronic control injection system The common rail-type electronic control injection system is composed of a fuel supply pump that sets the target pressure of high-pressure fuel and supply it, a common rail that measures such high-pressure fuel and a fuel injector that turns it into a fine spray and injects it. Each is controlled via ECM based upon various signals, while injection timing or fuel injection quantity is controlled under every possible driving condition.

6HK1

Fuel injector The fuel injector is a 7-hole nozzle that adjusts fuel injection quantity or injection timing by opening or closing an electromagnetic valve on the head of the fuel injector. ECM corrects the dispersion of fuel injection quantity between fuel injectors according to ID code data in memory. At the replacement of fuel injectors, ID code data should be stored in ECM. Fuel filter with sedimenter It is a fuel filter with sedimenter that gets rid of water by making use of the difference in specific gravity between light oil and water, which comes with an indicator that notifies you that it is filled with water. Preheating system The preheating system consists the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and make the engine easy to start. Lubrication system It is an oil filter with full-flow bypass, which uses a water-cool oil cooler and oil jet to cool the piston. Function check Inspection/adjustment of valve clearance 1. • • • •

Inspection of valve clearance Remove the cylinder head cover. Remove the fuel injector harness ASM. Loosen the terminal nuts alternately to remove. Remove the leak off pipe.

WSHK0049 • Insert a 0.4 mm (0.016 in) thickness gauge into a clearance between the rocker arm and the bridge to check it and adjust it if needed. Valve clearance

mm (in)

Intake valve

0.4 (0.016)

Exhaust valve

0.4 (0.016)

Caution: Adjust while being cold. 2. Adjustment of valve clearance Caution: Adjust valve clearance carefully so that the bridge may become level (hit the end of the 2 valve axes).

ENGINE MECHANICAL (4HK1, 6HK1) a. Completely loosen all of the bridge and rocker arm adjusting nuts and adjusting screws (4HK1: 8 nuts and 8 screws, 6HK1: 12 nuts and 12 screws). b. Place a 0.4 mm (0.016 in) thickness gauge between the No. 1 cylinder rocker arm end and the bridge cap. c. Tighten the rocker arm adjusting screw until the thickness gauge is snug (not tight) between the rocker arm end and the bridge cap. d. Tighten the rocker arm lock nut. e. Tighten the bridge adjusting screw until the bridge contacts the valve head. f. Tighten the bridge lock nut. g. Check that the thickness gauge is still held snugly between the rocker arm end and the bridge cap. If it is too tight, slightly loosen the bridge adjusting screw and lock nut to restore snugness. h. Remove the thickness gauge. i. Repeat the above procedure for the remaining cylinders. Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb ft)

Name 1. Rocker Arm 2. Bridge Cap 3. Bridge

1A-7

• With a thickness gauge kept inserted, tighten an adjusting screw of the bridge lightly and make sure that the tip of the adjusting screw touches the end of valve axis and the movement of the thickness gauge has become tight. • Then, check if the end of the valve axis on the opposite side is unstable or hits diagonally. If so, loosen the bridge adjusting screw a little so that the end of the valves on both sides may touch properly. Valve bridge clearance: ± 0.1 mm (0.0039 in) or less • After making an adjustment so that the end of the valves on both sides may touch properly, tighten up an adjusting screw nut of the bridge with a flathead screwdriver so that the bridge adjusting screw may not rotate. Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb ft) Caution: If the adjusting screw of the bridge is poorly adjusted, the bridge would tilt and be pushed down and seized, which may damage the bridge guide, for example. Thus, adjust it accurately.

Tightening torque: Rocker arm adjustment 22 N⋅m (2.2 kg⋅m/16 lb ft) screw nut Bridge adjustment screw 22 N⋅m (2.2 kg⋅m/16 lb ft) nut

1A-8 ENGINE MECHANICAL (4HK1, 6HK1) Adjustment table (4HK1) Cylinder No.

1

2

3

4

Valve arrangement

IN EX IN EX IN EX IN EX

No. 1 cylinder Compression top dead center position

{

{

{

{


×

×

×

×

Adjustment table (6HK1) Cylinder No.

1

2

3

4

5

6

Valve arrangement

IN EX IN EX IN EX IN EX IN EX IN EX


{

{

{


{ ×

×

{

{ ×

×

×

×

• If the No. 1 cylinder is the compression TDC, adjust a valve clearance with { mark given on the table and if the No. 4 (4HK1) or No. 6 (6HK1) cylinder is the compression TDC, that with × mark. 4HK1

6HK1

WSHK0002


1A-9

4HK1

WSHK0003

• Attach the harness ASM to the fuel injector. Tighten the harness bracket with the designated torque. Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb ft) • Install the terminal nuts on the fuel injector.

Name 1. Fuel Injector Harness Connector 6HK1

Tightening torque: 2 N⋅m (0.2 kg⋅m/18 lb in) Note: • Tighten the terminal nuts alternately in order to prevent imbalance in tightening because they are unified. • Do not tighten the nuts too tightly because it leads to damage to the terminal stud. • Install the cylinder head cover. Refer to the “Cylinder Head Cover”. Compression pressure inspection • Warm-up the engine. • Remove a negative terminal of the battery and remove all the glow plugs. • Remove the harness connector for the fuel injector built on the lower head cover (no fuel will be injected). Caution: When the harness connector is removed, ECM judges that it broke down and DTC is recorded. Upon completion of measurement, never fail to clear memory of ECM. (For how to clear memory of ECM, refer to the Engine Control System Section)

1

WSHK0004

Name 1. Fuel Injection Harness Connector • Install the negative terminal of the battery. • Turn on the starter to emit foreign matter within the cylinders. • Install an adapter and a gauge of a compression gauge of the special tool.

1A-10 ENGINE MECHANICAL (4HK1, 6HK1)

Compression gauge: 5-8840-2675-0 (J-26999-12) Compression gauge adapter 4HK1: EN-46722 6HK1: 5-8840-2622-0 • Turn on the starter to inspect compression pressure. 4HK1 Compression pressure Standard Limit Differences among the cylinders

MPa (psi) / 200 rpm 2.84 – 3.24 (412 – 469) 1.96 (284) 294 kPa (43)

6HK1 Compression pressure

MPa (psi) / 200 rpm

Standard

3.24 (469)

Limit

2.26 (327)

Differences among the cylinders

294 kPa (43)

• Measure each cylinder one by one. Caution: To keep engine speed at 200 rpm or more, use fully charged batteries. • Remove a compression gauge of the special tool. • Remove a negative terminal of the batteries. • Install a harness connector for the fuel injector built on the lower head cover. • Install all the glow plugs. Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft) • Install the negative terminal of the battery.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-11 Main Data and Specifications Item

Engine model 4HK1

Type

Diesel/4-cycle/water cooled-type, inline four-cylinder OHC

Combustion chamber form

Direct injection type

Cylinder liner type

Dry type

Number of cylinders - cylinder bore × strokes Displacement

mm (in) cc (cu.in)

Compression ratio

4-115 (4.53) × 125 (4.92) 5193 (317) 17.5

Compression pressure

MPa (psi)/rpm

Idle speed

rpm

Valve clearance

Intake

3.23 (468)/200 800 0.4 (0.016) (cold)

mm (in) Exhaust

0.4 (0.016) (cold)

Ignition type

Compressed ignition

Injection order

1-3-4-2

Lubricating system Lubricating type

Pressure type

Oil pump type Volume of lubricating oil

Gear type L (qts)

Oil filter type

13.0 (13.7) — 20.5 (21.7) Full flow filter (cartridge type)

Oil cooling type

Built-in, water-cooling

Cooling system Cooling type

Water cooling type

Radiator type

Corrugated fin (pressure type)

Water pump type

Centrifugal, belt type

Thermostat type

2 wax-type units

Thermostat valve-opening temperature

°C (°F)

85 (185)

Volume of coolant

L (qts)

14 (14.8) (incl. radiator)

Fuel system Injection pump type

Electronic control common rail type

Governor type

Electronic type

Timer type

Electronic type

Injection nozzle type

Multi-hole type 7-hole and φ 0.16 mm (0.0063 in) inside diameter

Charging system Generator type Power output Regulator type

AC type V/A

24 - 50 IC

1A-12 ENGINE MECHANICAL (4HK1, 6HK1) Item

Engine model 4HK1

Starting system Starter type

Reduction type

Power output

V-kw

Preheat system type

24 - 5.0 Glow plug

Glow plug standard voltage/electric current

V/A

Item

23 - 3.5 Engine model 6HK1

Type

Diesel/4-cycle/water cooled-type, inline four-cylinder OHC

Combustion chamber form

Direct injection type

Cylinder liner type

Dry type

Number of cylinders - cylinder bore × strokes Displacement

mm (in) cc (cu.in)

Compression ratio

6-115 (4.53) × 125 (4.92) 7790 (475) 17.5

Compression pressure

MPa (psi)/rpm

Idle speed

rpm

Valve clearance

Intake

3.04 (441)/200 For Hitachi products: 800, For JCB and Sumitomo products: 900 0.4 (0.016) (cold)

mm (in) Exhaust Ignition type

0.4 (0.016) (cold) Compressed ignition

Injection order

1-5-3-6-2-4

Lubricating system Lubricating type

Pressure type

Oil pump type Volume of lubricating oil

Gear type L (qts)

Oil filter type

28 (29.6) — 38 (40.2) Full flow filter (cartridge type)

Oil cooling type

Built-in, water-cooling

Cooling system Cooling type

Water cooling type

Radiator type

Corrugated fin (pressure type)

Water pump type

Centrifugal, belt type

Thermostat type

2 wax-type units

Thermostat valve-opening temperature

°C (°F)

82 (180)

Volume of coolant

L (qts)

14.5 (15.3)

Fuel system Injection pump type

Electronic control common rail type

Governor type

Electronic type

Timer type

Electronic type

ENGINE MECHANICAL (4HK1, 6HK1) Item

Engine model 6HK1

Injection nozzle type

Multi-hole type 7-hole and φ0.16 mm (0.0063 in) inside diameter

Charging system Generator type

AC type

Power output

V/A

Regulator type

24 - 90/50 IC

Starting system Starter type

Reduction type

Power output

V-kw

Preheat system type

24 - 5.0 Glow plug

Glow plug standard voltage/electric current Special tool Illustration

1A-13

Tool Number/Description

5-8840-26750-0 J-26999-12 Compression gauge

EN-46722 Compression gauge adapter (4HK1)

5-8840-2622-0 Compression gauge adapter (6HK1)

V/A

23 - 3.5


Cylinder Head Cover Components 4HK1

Name 1. Head Cover 2. Gasket

3. Head Cover Case 4. Gasket


1A-15

6HK1

1

2

3

4

WSHK0005

Name 1. Head Cover 2. Gasket

Removal 1. Remove the head cover. 2. Remove the gasket.

3. Head Cover Case 4. Gasket

1A-16 ENGINE MECHANICAL (4HK1, 6HK1) 4HK1

4HK1

Name 1. Head Cover

Name 1. Head Cover Case 2. Fuel Injector Harness Connector

6HK1 6HK1

1 1

2

WSHK0006

Name 1. Head Cover 3. Remove the fuel injector harness connector. 4. Remove the head cover case. 5. Remove the gasket.

WSHK0007

Name 1. Head Cover Case 2. Fuel Injector Harness Connector

Installation 1. Install the gasket on the lower cover. 2. Install the head cover case. Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft), 6HK1: 13 N⋅m (1.3 kg⋅m/9.6 lb ft) 3. Install the fuel injector harness connector.

ENGINE MECHANICAL (4HK1, 6HK1) Caution: Push it in thoroughly until the claws of the lock raise.

1A-17

4HK1

4HK1

6HK1 Name 1. Head Cover Case 2. Fuel Injector Harness Connector 6HK1

1

WSHK0008

2

WSHK0007

Name 1. Head Cover Case 2. Fuel Injector Harness Connector 4. Install the gasket on the head cover. 5. Install the head cover and tighten up according to the orders given on the figure. Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft), 6HK1: 13 N⋅m (1.3 kg⋅m/9.6 lb ft)

1A-18 ENGINE MECHANICAL (4HK1, 6HK1) Torque Specifications 4HK1


1A-19

6HK1 N m{kg m/lb ft}

13 {1.3 / 9.6}

13 {1.3 / 9.6}

WSHK0009


Inlet Cover Components 4HK1

Name 1. Case ASM 2. Inlet Cover 3. Inlet Pipe Gasket

4. Inlet Pipe 5. Reed Valve


1A-21

6HK1

5 4 6

1 3

2

WSHK0177

Name 1. Case ASM 2. Inlet Cover 3. Inlet Pipe Gasket

Removal 1. Remove the common rail. Refer to the “Common Rail” in the fuel system section. 2. Remove the inlet pipe. 3. Remove the case ASM. • Remove the reed valve from the case ASM. • Inspect the valve whether the carbon has not come in contact around the valve.

4. Inlet Pipe 5. Reed Valve 4. Bolt

4HK1


WSHK0048

* 4HK1 is shown for illustration.

4. Remove the boost pressure sensor and bracket.

Installation

1

2

1. Install the inlet cover. • Apply the liquid gasket (ThreeBond 1207C or equivalent) by using a bead diameter of 2.5 – 5.5 mm (0.1 – 0.2 in) along a groove of the inlet cover. • Install within seven minutes after applying liquid gasket. Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb ft) Caution: • Be careful not to forget to fasten the bolt indicated with an arrow. • Tighten up the stud part together with the common rail.

WSHK0236

Name 1. Boost Pressure Sensor 2. Bracket 5. Remove the inlet cover. • On the place where the case ASM is to be installed inside the inlet cover (arrowed) is a bolt. Be careful not to forget to remove it. • Peel the liquid gasket off carefully.


ENGINE MECHANICAL (4HK1, 6HK1) 2. Install the boost pressure sensor and bracket. Apply Loctite to the bolt shown on the illustration and install it. Tightening torque: 21.6 N⋅m (2.2 kg⋅m/16 lb ft)

1A-23

Name 1. Case ASM 2. Reed Valve 3. Bolt 6HK1

1

2

1

2

3

WSHK0236 WSHK0179

Name 1. Boost Pressure Sensor 2. Bracket 3. Install the reed valve to the case ASM • Apply the liquid gasket (Loctite 262) on the mounting bolt and tighten it to the specified torque. Tightening torque: 9.8 N⋅m (1.0 kg⋅m/7.2 lb ft) 4. Install the case ASM. • Apply the liquid gasket and mount within 7 minutes. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 4HK1

Name 1. Case ASM 2. Reed Valve 3. Bolt 5. Install the gasket on the inlet pipe and tighten up with the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 6. Install the common rail. Refer to the “Common Rail” in the fuel system section.

1A-24 ENGINE MECHANICAL (4HK1, 6HK1) Torque Specifications 4HK1

6HK1

N m(kg m/lb ft)

39 (3 / 29)

20 (2 / 15)

24.5 (2.5 / 18)

WSHK0063


Turbocharger and Exhaust Manifold Components 4HK1

Name 1. Oil Feed Pipe 2. Water Return Pipe 3. Exhaust Manifold 4. Water Feed Pipe

5. Turbo Charger ASM 6. Exhaust Adapter 7. Oil Return Pipe

1A-25


4

3

2

1

5

WSHK0012

Name 1. Oil Feed Pipe 2. Exhaust Manifold 3. Turbo Charger ASM

Removal 1. Loosen the radiator drain cock to drain coolant. (4HK1 only) 2. Remove the air intake duct from the turbocharger and the air cleaner. 3. Remove the charge air pipe from the turbocharger and the charge air cooler. 4. Disconnect the exhaust pipe. 5. Remove the EGR pipe. 6. Remove the oil feed pipe. 7. Remove the oil return pipe. 8. Remove the water feed pipe. (4HK1 only)

4. Exhaust Adapter 5. Oil Return Pipe

ENGINE MECHANICAL (4HK1, 6HK1) • Remove the water return pipe. (4HK1 only)

1A-27

6HK1

1

3

2

WSHK0013

Name 1. Water Return Pipe 9. 10. 11. 12.

Remove the heat protector on the turbocharger. Remove the exhaust adapter bolts. Remove the four turbocharger clamping nuts. Remove the turbocharger from the exhaust manifold. 13. Remove the exhaust manifold. 4HK1

Name 1. Exhaust Manifold 2. Turbocharger 3. Exhaust Adapter

Inspection • Inspection of exhaust manifold Inspect the plane surface of the plane on which the manifold and the cylinder head are to be installed. Manifold installation plane surface Standard Limit

mm (in) 0.3 (0.01) or less 0.5 (0.02)

Caution: If the plane surface exceeds the limit, replace it.



1A-28 ENGINE MECHANICAL (4HK1, 6HK1) • Check a crack in the exhaust manifold visually. Carefully inspect the turbocharger for abrasion and/or excessive wear. Make any necessary adjustments, repairs, and/or part replacements. Inspecting the turbocharger is refered to the “Turbo chager” in the exhaust system section.

6HK1

Installation 1. Put the gasket in to install the exhaust manifold. • 4HK1: Tighten up with the 2 nuts and 6 bolts according to the order given on the figure. Tightening torque: 34 N⋅m (3.5 kg⋅m/25 lb ft) • 6HK1: Tighten up with the 12 nuts according to the order given on the figure. Tightening torque: 55 N⋅m (5.6 kg⋅m/41 lb ft) 34 N⋅m (3.5 kg⋅m/25 lb ft) for (7) only Caution: Do not tighten up too much because it hampers expansion and contraction due to the heat from the manifold. 4HK1

WSHK0014

2. Install the gasket and turbocharger to the exhaust manifold. Tighten the nuts to the specified torque. Tightening torque: 52 N⋅m (5.3 kg⋅m/38 lb ft) 3. Tighten the adapter bolts (exhaust manifold side) to the specified torque. Tightening torque: 32.4 N⋅m (3.3 kg⋅m/24 lb ft) 4HK1



1A-29

Tightening torque: 41 N⋅m (4.2 kg⋅m/30 lb ft)

6HK1

6. Install the water return pipe bracket. Tighten the bolts to the specified torque. (4HK1 only) 1

3

2

Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) • Install the rubber hose between the water return pipe and the thermostat housing. 4HK1

WSHK0013

Name 1. Exhaust Manifold 2. Turbocharger 3. Exhaust Adapter 4. Install the water feed pipe to the turbocharger. (4HK1 only) • Tighten the joint bolts to the specified torque. Tightening torque: 41 N⋅m (4.2 kg⋅m/30 lb ft) • Install the pipe bracket and tighten the bolts to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 4HK1

Name 1. Water Return Pipe 7. Install the turbocharger oil feed pipe to the top of the turbocharger. Tighten the joint bolts to the specified torque. Tightening torque: 4HK1: 41 N⋅m (4.2 kg⋅m/30 lb ft), 6HK1: 34.5 N⋅m (3.5 kg⋅m/25 lb ft) • Install the pipe bracket and tighten the bolts to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 8. Tighten the oil return pipe bolts to the specified torque. Tightening torque (Turbocharger side): 4HK1: 9 N⋅m (0.9 kg⋅m/80 lb in), 6HK1: 17.6 N⋅m (1.8 kg⋅m/13 lb ft) Tightening torque (Cylinder block): 4HK1: 22 N⋅m (2.2 kg⋅m/16 lb ft), 6HK1: 17.6 N⋅m (1.8 kg⋅m/13 lb ft)

Name 1. Water Feed Pipe 5. Install the water return pipe. Tighten the joint bolts to the specified torque. (4HK1 only)


* 4HK1 is shown for illustration. Name 1. Oil Return Pipe 9. Install the air intake duct and tighten the bolts to the specified torque. Tightening torque: 10 N⋅m (1.0 kg⋅m/89 lb in) 10. Install the charge air pipe in the turbo charger and the charge air cooler. Tightening torque: Duct bolt 21 N⋅m (2.1 kg⋅m/15 lb ft) Duct clip 6 N⋅m (0.6 kg⋅m/53 lb in) 11. 12. 13. •

Connect the exhaust pipe. Add cooling water to the radiator. (4HK1 only) Install the EGR pipe. Put the gasket between both ends of the EGR pipe and install to the specified torque.

Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 14. Replenish the coolant. (4HK1 only)

ENGINE MECHANICAL (4HK1, 6HK1) Torque Specifications 4HK1

1A-31


N m(kg m/lb ft)

17.6 (1.8 / 13)

34.5 (3.5 / 25)

23.5 (2.4 / 17)

50.5 (5.1 / 37)

32.4 (3.3 / 24)

17.6 (1.8 / 13)

WSHK0015


1A-33

N m{kg m/lb ft}

WSHK0232



Timing Gear Train Components 4HK1

Name 1. Idle Gear B Shaft 2. Idle Gear A 3. Idle Gear B 4. PTO Idle Gear 5. PTO Idle Gear Cover 6. Flywheel

7. 8. 9. 10. 11. 12.

Rear Oil Seal Flywheel Housing Slinger Crankshaft Position Sensor Oil Pan Fuel Supply Pump


1A-35

6HK1

2

10

1 3

5

8 12

9

11

4

7

6

WSHK0017

Name 1. Idle Gear B Shaft 2. Idle Gear A 3. Idle Gear B 4. PTO Idle Gear 5. PTO Idle Gear Cover 6. Flywheel

Removal 1. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 2. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 3. Remove the camshaft ASM. Refer to “Camshaft ASM”. 4. Remove the cylinder head ASM. Refer to the “Cylinder Head”. 5. Remove the fuel supply pump ASM.

7. 8. 9. 10. 11. 12.

Rear Oil Seal Flywheel Housing Slinger Idle Gear A Shaft PTO Idle Gear Shaft Oil Pump

1A-36 ENGINE MECHANICAL (4HK1, 6HK1) Refer to “Fuel Supply Pump” in the fuel system section.

6HK1

WSHK0064 * 4HK1 is shown for illustration. 6. Remove the crankshaft position sensor. • Remove the crankshaft position sensor before remove flywheel. 4HK1

7. Remove the flywheel. • Install the crankshaft stopper on the starter part of the flywheel housing to stop the crankshaft from rotating. Caution: Check if the stopper meshes with the ring gear without fail and is installed properly. Special tool Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx)

• Loosen the fastening bolts of the flywheel little by little according to the order given on the figure. • After loosening all the bolts, remove the stopper to remove the flywheel. 8. Remove the rear oil seal. Refer to the “Crankshaft Rear Oil Seal”. 9. Use the slinger remover to remove the slinger.

ENGINE MECHANICAL (4HK1, 6HK1) Caution: If the oil seal has been removed, both the oil seal and slinger must be replaced as a set.

1A-37

• Never fail to remove the bolt(s) given on the figure.

Special tool Slinger remover: 1-8521-0027-0 (For 4HK1 and 6HK1) x-xxxx-xxxx-x (For 4HK1) 8-9439-6858-0 (For 6HK1)

* 4HK1 is shown for illustration. 14. 15. 16. 17. 18.

Remove the idle gear A. Remove the idle gear A shaft. (6HK1) Remove the oil pump. (6HK1) Remove the idle gear B. Remove the idle gear B shaft.

10. Remove the oil pan. 11. Remove the PTO idle gear cover. 12. Remove the PTO idle gear.


Inspection * 4HK1 is shown for illustration. 13. Remove the flywheel housing.

1. Measurement of idle gear backlash • Apply a dial gauge on the teeth of the idle gear to be measured and move the gear to right and left lightly to read how much the dial gauge shook (never fail to fix the gear). • If the measurement exceeds the limit, replace the idle gear.

1A-38 ENGINE MECHANICAL (4HK1, 6HK1) Backlash of the timing gear Standard Limit

mm (in)

0.10 – 0.17 (0.004 – 0.006) 0.30 (0.01)

• Measure backlash of the idle gear before removing the idle gear A.

3. Outside diameter of idle gear shaft • Use a micrometer to measure an external diameter of each idle gear shaft. • If the measurement exceeds the limit, replace the shaft. 4HK1 2. Measurement of end clearance of the idle gear. • Insert a thickness gauge between the idle gear and the thrust collar to measure a clearance. • If the measurement exceeds the limit, replace either the idle gear or the thrust collar.

Outside diameter of idle gear shaft Standard Limit

29.959 – 29.980 (1.179 – 1.180) 29.80 (1.173)

External diameter of the idle gear A shaft Axial play of idle gear Standard Limit

mm (in) 0.080 – 0.140 (0.003 – 0.006) 0.20 (0.008)

• Measure an end clearance of the idle gear before removing the idle gear B.

Standard Limit

mm (in)

mm (in)

39.959 – 39.975 (1.573 – 1.574) 39.80 (1.567)

ENGINE MECHANICAL (4HK1, 6HK1) 6HK1

6HK1

Outside diameter of idle gear shaft Standard Limit

mm (in)

29.959 – 29.980 (1.179 – 1.180)

Clearance between the idle gear and the shaft Standard

29.9 (1.177)

Limit External diameter of the idle gear A shaft Standard Limit

49.950 – 49.975 (1.967 – 1.968) 49.9 (1.965)

• If the measurement exceeds the limit, replace either the idle gear or the shaft. 4HK1 mm (in)

0.020 – 0.062 (0.0007 – 0.0024) 0.200 (0.0079)

Clearance between the idle gear A and the shaft Limit

0.200 (0.0079) mm (in)

0.025 – 0.075 (0.0010 – 0.0030) 0.200 (0.0079)

Installation 1. Install the idle gear B shaft. • Tighten the idle gear B shaft to the specified torque. Tightening torque: 31 N⋅m (3.2 kg⋅m/23 lb ft)

Clearance between the idle gear and the shaft

Standard

0.020 – 0.062 (0.0007 – 0.0024)

Clearance between the idle gear A and the shaft Standard

4. Clearance between the idle gear and the idle gear shaft • Measure an inside diameter of the idle gear bushing to calculate a clearance between the idle gear and the idle gear shaft.

Limit

mm (in)

mm (in)

Limit

Standard

1A-39

mm (in)

0.025 – 0.066 (0.0009 – 0.0026) 0.200 (0.0079)

• After installation, apply engine oil to the shaft.


WSHK0193

* 4HK1 is shown for illustration. 2. Install the idle gear B. • Install the idle gear B in the direction given on the figure and tighten up the fastening bolts with the specified torque. Tightening torque: 4HK1: 110 N⋅m (11.2 kg⋅m/81 lb ft), 6HK1: 95 N⋅m (9.7 kg⋅m/70 lb ft)

Name 1. Crank Gear 2. Idle Gear A • Align the crankshaft gear (2) L mark and idle gear A (1) 0 marks. • Tighten the installing bolt to the specified torque. Tightening torque: 133 N⋅m (13.6 kg⋅m/98 lb ft)

* 4HK1 is shown for illustration. Name 1. Idle Gear 2. Thrust Collar 3. Bolt 3. 4. 5. •

Install the oil pump. Install the idle gear A shaft. (6HK1) Install the idling gear A. Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC).


Name 1. Idle Gear C 2. Camshaft Gear 3. Idle Gear B 4. PTO Gear 5. PTO Idle Gear 6. Install the flywheel housing. • Clean the rear side of the cylinder block. In particular, remove overflow liquid gasket thoroughly when the crankcase is installed. • As the figure shows, apply the liquid gasket (ThreeBond 1207B or equivalent) inside a hole of the bolt (except the bolt holes indicated with an arrow) evenly.

6. 7. 8. 9. 4HK1

Crankshaft Gear Oil pump Drive Gear Fuel Supply Pump Gear Idle Gear A

1A-41


• Align with the knock pin of the cylinder block and install the flywheel housing. Tightening torque of the flywheel housing (4HK1): N⋅m (kg⋅m/lb ft) 1 = 96 (9.8/71) 2 = 77 (7.9/57) 3 = 38 (3.9/28) • Tighten up the Mark 3 from the cylinder block side.

WSHK0043 4HK1


1A-43

Tightening torque of the flywheel housing (6HK1): N⋅m (kg⋅m/lb ft) 1 = 96 (9.8/71) 2 = 86 (8.8/63) 3 = 119 (12.1/88) 4 = 53 (5.4/39) 5 = 73 (7.4/54) 6 = 26 (2.7/19) 6HK1

1 1

2

5

1 3

6 1

3

4

1 1

WSHK0044 7. Install the PTO idle gear. • Apply engine oil over the part where the gear of the idle gear shaft is to be put together. • Put the idle gear and the shaft together and install it on the location given on the figure and tighten up with the specified torque. Tightening torque: 4HK1: 133 N⋅m (13.6 kg⋅m/98 lb ft) 6HK1: 119 N⋅m (12.1 kg⋅m/88 lb ft)


8. Install the PTO idle gear cover. • Install the O-ring on the cover and install it on the flywheel housing and tighten up the tightening bolts with the specified torque. Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb ft) 4HK1

WSHK0194

9. Install the oil pan. • Apply the liquid gasket (ThreeBond 1207B or equivalent) on a joint between the cylinder block, the front cover and the flywheel housing with a beat diameter of 3 mm (0.12 in). • Install the oil pan within 7 minutes after applying the liquid gasket. 4HK1


1A-45

6HK1

WSHK0195

• With the flywheel housing, the front cover and the stud of the crankcase as a guide, put together the gasket and put the oil pan on it. Then, put the rubber ASM on the oil pan and fix it by fastening bolts and nuts. 4HK1

Name 1. Oil Pan 2. Gasket Tightening 4HK1 • After fastening the oil pan at the respective points of (1), (2), (3), and (4), fasten other parts. Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft)

1A-46 ENGINE MECHANICAL (4HK1, 6HK1) 6HK1 • Fastening the oil pan from the part of A or B in clock wise order. • It tightens again by specified torque. Tightening torque: 24.5 N⋅m (2.5 kg⋅m/18 lb ft)

WSHK0197

• After pressing in the slinger, make sure that the distance between crankshaft end surface and the slinger is A as specified. 4HK1

WSHK0196

10. Install the rear slinger using installer, setting tool. Special tool 4HK1 Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx) 6HK1 Oil seal setting tool: 8-94396-856-0 • Install the slinger (1) to the end of adapter (2). Install the adapter to the crankshaft (3). • Install the slinger sleeve (4) to the adapter. Tighten the center bolt (5) until the sleeve comes in contact with the adapter stopper.

WSHK0198

Distance (A): 17.3±0.3 mm Distance (B): 10.8±0.1 mm

(0.7±0.01 in) (0.4±0.004 in)


1A-47

•

WSHK0201 WSHK0199

Distance (A): 17±0.3 mm

(0.7±0.01 in)

Caution: Be sure to replace the slinger and oil seal as a set. 11. Install the rear oil seal using installer, setting tool.

• After pressing the oil seal, make sure that the distance between crankshaft end surface and the oil seal as specified. 4HK1

WSHK0202

Distance (A): 7.8±0.3 mm WSHK0200

Special tool 4HK1 Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx) 6HK1 Oil seal setting tool: 8-94396-856-0 • Apply engine oil to the oil seal lip. Caution: Do not allow engine oil to come in contact with the outside oil seal and felt ring. • Insert the oil seal (1) into the adapter (2). • Insert the oil seal sleeve (3) to the adapter. • Tighten the center bolt until the sleeve comes into contact with the adapter stopper.

(0.3±0.01 in)


13. Rotate the crankshaft to make the No. 1 cylinder meet the compression TDC. 14. Remove the oil drain adapter. 15. Install the O-ring on the fuel supply pump and make the slits with an arrow meet and with the stud bolt as a guide, install the fuel supply pump tentatively. Caution: • When removing the fuel supply pump, if the stud bolt on the cylinder block side loosens, or the stud bolt is replaced, apply the Loctite No. 262 on the side where the stud bolt is to be buried before assembly.

WSHK0203

Distance (B): 7.5±0.15 mm

(0.3±0.006 in)

12. Install the flywheel. • Along with the knock pin of the crankshaft, install the flywheel and tighten up with the specified torque according to the order given on the figure. Tightening torque: 1st step = 78 N⋅m (8.0 kg⋅m/58 lb ft) 2nd step = 60° 3rd step = 60°

* 4HK1 is shown for illustration. • Check if the alignment mark of the gear painted white is at the location given on the figure when viewed from the plug hole and tighten up with the specified torque. Nut tightening torque:

50 N⋅m (5.1 kg⋅m/37 lb ft)

Bolt tightening torque:

76 N⋅m (7.7 kg⋅m/56 lb ft)

• If the location of the teeth of the painted gear is not in the right place, put it together all over again.

ENGINE MECHANICAL (4HK1, 6HK1) 17. Install the cylinder head ASM. Refer to the “Cylinder Head”. 18. Install the camshaft ASM. Refer to “Camshaft ASM”. 19. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 20. Install the cylinder head cover. Refer to “Cylinder Head Cover”.

* 4HK1 is shown for illustration. Name 1. Plug Hole 2. Alignment Mark 16. Install the oil drain adapter ASM on the plug hole and tighten with the specified torque. Tightening torque: 6 N⋅m (0.6 kg⋅m/53 lb in) • Apply engine oil over the O-ring nice and thin and install it.

Name 1. Adapter 2. O-Ring

1A-49

1A-50 ENGINE MECHANICAL (4HK1, 6HK1) Torque Specifications N m{kg m/lb ft} 31 {3.2 / 23}

110 {11.2 / 81}

50 {5.1 / 37}

134 {13.7 / 99} 134 {13.7 / 99}

76 {7.7 / 56} 19 {1.9 / 14}

78 {8 / 58}

60

60

6 {0.6 / 4}

30 {3.1 / 22}

8 {0.8 / 6}

WSHK0065

ENGINE MECHANICAL (4HK1, 6HK1) Special Tool Illustration

Tool Number/Description/ Special Tool Rank

x-xxxx-xxxx-x xx-xxxxx Crankshaft stopper Rank B

1-8521-0027-0 Slinger remover Rank B

x-xxxx-xxxx-x x-xxxxx Oil seal installer kit (4HK1) Rank A

8-9439-6856-0 Oil seal setting tool (6HK1) Rank A

1A-51


Rocker Arm Shaft ASM Components

* 4HK1 is shown for illustration. Name 1. Camshaft Bracket 2. Rocker Arm 3. Wave Washer 4. Rocker Arm

Removal 1. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 2. Remove the rocker arm shaft ASM. • Along with the camshaft bracket, remove the rocker arm shaft ASM.

5. Rocker Arm Bracket 6. Camshaft Bracket 7. Rocker Arm Shaft

ENGINE MECHANICAL (4HK1, 6HK1) • Because the bolt(s) shown on the figure is are designed to fix the rocker arm shaft, do not remove it for now.

1A-53

6. Remove the camshaft bracket to take the shaft out.

* 4HK1 is shown for illustration. Caution: Pay full attention so as not to drop the bridge cap in the gear case of the rear part of the cylinder head or the hole into which oil pours back in the front.

Disassembly 1. 2. 3. 4. 5. •

Remove the camshaft bracket. Remove the rocker arm. Remove the wave washer. Remove the rocker arm. Remove the rocker arm bracket. Disassemble according to the order (2) – (4) thereafter.

Name 1. Camshaft Bracket 2. Rocker Arm 3. Wave Washer 4. Rocker Arm 5. Rocker Arm Bracket 6. Camshaft Bracket 7. Rocker Arm Shaft 7. Check if the oil hole is clogged of the camshaft bracket (on the rear side).

8. Check if the rocker arm shaft is bent. • Place the rocker arm shaft on a V block. • Check if it is bent by rotating the shaft with a dial gauge on the center of the shaft. • As a result of measurement, if its bend is slight, press it to rectify it (while cold).

1A-54 ENGINE MECHANICAL (4HK1, 6HK1) • If the bend of the shaft exceeds the limit, replace the shaft. Bend of the rocker arm shaft Limit

mm (in) 0.3 (0.012)

10. Inspect a clearance between the rocker arm and the rocker arm shaft. • Use a cylinder gauge to measure an inside diameter of the bushing of the rocker arm to measure a clearance between the external diameter of the shaft. • If the measurement exceeds the limit, replace the rocker arm and the shaft. Clearance between the rocker arm and rocker arm shaft Standard Limit

mm (in)

0.010 – 0.056 (0.0004 – 0.0022) 0.2 (0.0079)

9. Check if the rocker arm shaft is worn. • Use a micrometer to measure 8 places of the vibrating part of the rocker arm. • If the measurement falls is the limit or less, replace the shaft. External diameter of the rocker arm shaft Standard

22.0 (0.866)

Limit

21.85 (0.860)

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

mm (in)

0.068 – 0.099 (0.0026 – 0.0038) 0.2 (0.0079)


Reassembly 1. Install the camshaft bracket to one side of the rocker arm shaft tentatively first. When the rocker arm shaft ASM is installed on the cylinder head, tighten them up fast. • Assemble in the reverse order of disassembly.

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

1A-55

3. Install the wave washer between the rocker arm. 4. Install the rocker arm bracket. • Pay attention to the direction in which the bracket is put together and put it together with the rocker arm shaft. 5. Install the camshaft bracket. • Install the camshaft bracket on the rocker arm shaft with the bolts indicated with an arrow tightened tentatively. When the rocker arm shaft ASM is installed on the cylinder head, tighten them up fast.


* 4HK1 is shown for illustration. Name 1. Camshaft Bracket 2. Rocker Arm 3. Wave Washer 4. Rocker Arm 5. Rocker Arm Bracket 6. Camshaft Bracket 7. Rocker Arm Shaft

Name 1. Bridge Cap 2. Bridge • Loosen an adjusting screw of the rocker arm, apply engine oil over the roller part of the rocker arm and install it on the cylinder head. • Loosen the bolts indicated with an arrow a little, it will become easier to install it.

Installation 1. Install the rocker arm shaft ASM. • If the bridge cap comes off, apply engine oil over the inside of the bridge cap and put it together with the bridge. Caution: Pay full attention so as not to drop the bridge cap in the gear case of the rear part of the cylinder head or the hole into which oil pours back in the front.

• Apply engine oil on a screw of the bolts and nuts. • Tighten up the tightening bolts of the rocker arm ASM tentatively, and gradually tighten up the entire rocker arm ASM horizontally according to the order of the nut on the rocker arm side. Tightening torque: 4HK1 Bolt (3) = 56 N⋅m (5.7 kg⋅m/41 lb ft) Nut (1), Bolt (2), (4) = 27 N⋅m (2.8 kg⋅m/20 lb ft)


Name 1. Camshaft Bracket Fixing Nut 2. Camshaft Bracket Fixing Bolt 3. Rocker Arm Bracket Fixing Bolt 4. Rocker Arm Shaft Set Bolt 6HK1 Nut (1) – (4) and Bolt (10) – (13) = 27 N⋅m (2.8 kg⋅m/20 lb ft) Bolt (5) – (9) = 56 N⋅m (5.7 kg⋅m/41 lb ft)

WSHK0204

• Adjustment of valve clearance Refer to “Function Check”. 2. Install the cylinder head cover. Refer to “Cylinder Head Cover”.

1A-57

1A-58 ENGINE MECHANICAL (4HK1, 6HK1) Torque Specifications



Camshaft ASM Components 4HK1

Name 1. Bearing Cap 2. Bearing

3. Knock Pin 4. Camshaft Gear

1A-59


11

WSHK0055

Name 1. Bolt 2. Washer 3. Gear 4. Pin 5. Spring 6. Pin

Removal 1. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 2. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 3. Remove the camshaft bearing cap. 4. Remove the bearing upper. 5. Remove the camshaft ASM. 6. Remove the bearing lower.

7. 8. 9. 10. 11.

Sub Gear Dish Spring Snap Ring Pin Camshaft

Caution: Put the removed bearings in order with a tag, for example, by cylinder.


1A-61

WSHK0057

Disassembly 1. Remove the scissors gear ASM. (6HK1) • Fix the hexagon portion of the camshaft in a vise using a mouth ring. Use snap ring pliers to remove the sub gear. Caution: Take care not to damage to the cam portion and the journal portion of the camshaft.

Name 1. Snap Ring 2. Dish Spring 3. Sub Gear 4. Spring 5. Camshaft Gear 2. Remove the camshaft gear. • Remove the fastening bolts of the camshaft gear and put the block of wood in a puller to remove the camshaft gear.

WSHK0056 Name 1. Wood 3. Remove the knock pin. 4. Inspect the camshaft visually. • Check if the journal and cam parts of the camshaft are worn or damaged, if so, replace it.

1A-62 ENGINE MECHANICAL (4HK1, 6HK1) • If the height of the cam lobe is the limit or less, replace the camshaft. Height of the cam lobe

mm (in)

Intake air

Exhaust

Standard

52.8 (2.08)

54.5 (2.15)

Limit

51.8 (2.04)

53.5 (2.11)

H

5. Check the axial play of the camshaft. • Use a thickness gauge to measure an end clearance of the camshaft gear and the camshaft bracket. • If the measurement exceeds the limit, replace the camshaft gear or the camshaft. End clearance of the camshaft Standard Limit

mm (in)

0.085 – 0.205 (0.033 – 0.008) 0.25 (0.009)

Caution: Measure an end clearance of the camshaft before disassembling.

WSHK0228

7. Check if the camshaft journal is worn. • Use a micrometer to measure wear which is not even with a diameter of the camshaft journal. • If the measured uneven wear exceeds the limit, replace the camshaft. External diameter of the camshaft journal part Standard Limit

39.950 – 39.975 (1.5728 – 1.5738) 39.850 (1.5688)

Partial wear of the camshaft journal part Limit

6. Check if the cam lobe is worn. • Use a micrometer to measure the height of the cam lobe.

mm (in)

0.05 (0.0019)

mm (in)

ENGINE MECHANICAL (4HK1, 6HK1) Clearance of the journal part Standard Limit

1A-63 mm (in)

0.020 – 0.087 (0.0008 – 0.0034) 0.15 (0.0059)

8. Check for bent of the camshaft. • Place the camshaft on a V block to measure a bend with a dial gauge. • Rotate the camshaft slowly to measure how much the dial indicator shook. If it exceeds the limit, replace the camshaft.

Reassembly Bent of the camshaft Limit

mm (in) 0.05 (0.0019)

1. Install the knock pin. 2. Install the camshaft gear. • With the side of the camshaft gear center boss part stuck out being on the camshaft side, install the camshaft gear along with the knock pin. Tightening torque: 142 N⋅m (14.5 kg⋅m/105 lb ft) Caution: Be careful not to damage the cam and journal parts when tightening up the gear.

9. Measure a camshaft journal oil clearance. a. Measure an inside diameter of the camshaft bearing with a dial gauge. b. Read the difference between the inside diameter of the camshaft bearing and the diameter of the camshaft journal. If the measured oil clearance exceeds the limit, replace the camshaft bearing.

3. Install the scissors gear ASM. (6HK1)

1A-64 ENGINE MECHANICAL (4HK1, 6HK1) • Fix the hexagon portion of the camshaft in a vise using a mouth ring. Assemble the spring with its left end contacting the pin of camshaft main gear to make a gap on the right. • Assemble the sub gear so that its pin is inserted into the gap between the right side of pin of the camshaft main gear and the right end of the spring.

• Before installing the camshaft to the cylinder head, rotate the sub gear using the special tool to prevent the spring force which acts on the sub gear from affecting. Align the hole of the sub gear with the camshaft main gear and install the phase alignment pin from the sub gear side to match the teeth. Special tool Scissors gear spring wrench: 5-8840-2674-1

WSHK0057 Name 1. Snap Ring 2. Dish Washer 3. Sub Gear 4. Spring 5. Camshaft Gear

WSHK0244

• Assemble onto the cylinder head.

• Use snap ring pliers to assemble the snap ring and the dish washer securely.

WSHK0056


1A-65

Fixing torque

N m(kg m/lb ft)

142 (14.5 / 105)

WSHK0060

Special Tool Tool Number/Description/ Special Tool Rank

Illustration

5-8840-2674-1 Scissors gear spring wrench Rank A WSHK0245

1A-66 ENGINE MECHANICAL (4HK1, 6HK1) Installation

4HK1

1. Rotate the crankshaft to make the No. 1 cylinder meet the compression TDC. 4HK1

WSHK0066 6HK1

6HK1

WSHK0049 2. Install the camshaft bearing lower. • Apply engine oil over the camshaft bearing lower and install it on the cylinder head. 3. Install the camshaft ASM. • Put together the camshaft ASM so as to make the “B” (4HK1) or “•” (6HK1) mark meets the upper face of the cylinder head.

4. Install the baring upper to the bearing cap. 5. Install the bearing cap. • Apply engine oil on the bearing upper. • Direct the front mark of the bearing cap toward the front of the engine and put it together with the cylinder head in numerical order.


• Apply engine oil over the screw part and tighten up the bearing cap with the specified torque. Tightening torque: 27 N⋅m (2.8 kg⋅m/20 lb ft)

* 4HK1 is shown for illustration. 6. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 7. Install the cylinder head cover. Refer to “Cylinder Head Cover”.

1A-67




1A-69

Valve Stem Seal, Valve Spring Components

* 4HK1 is shown for illustration. Name 1. Camshaft Bearing Cap 2. Camshaft Bearing 3. Camshaft 4. Rocker Arm Shaft ASM 5. Valve Stem Oil Seal

6. 7. 8. 9. 10.

Removal

5. Remove the bridge (2).

1. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 2. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 3. Remove the camshaft ASM. Refer to “Camshaft ASM”. 4. Remove the bridge cap (1).

Valve Spring Spring Upper Seat Split Collar Bridge Valve Spring Seat

Caution: Keep the removed bridge and bridge cap properly so that they may be put back to the original place.

1A-70 ENGINE MECHANICAL (4HK1, 6HK1) 8. Remove the valve spring. Put the removed valve springs in order by cylinder number. 9. Remove the valve stem oil seal. • Use pliers to remove the oil seal. 10. Remove the valve spring seat.

Name 1. Bridge Cap 2. Bridge Caution: Pay full attention so as not to drop the bridge cap in the gear case of the rear part of the cylinder head or the hole into which oil pours back in the front. 6. Remove the split collar. • Apply compressed air over the cylinder from the glow plug holes to keep the valve at the home position. • Use a replacer to compress the valve spring to remove the split collar. Special tool Valve spring replacer: 5-8840-2621-0 (J-43263) Pivot: 8-9439-6862-0 (EN-46721)

Caution: Do not reuse the removed oil seal.

Inspection Check the valve spring. Caution: Check the valve spring visually and if there is clear damage or wear-out, replace it. 1. Free length • Measure free length of the spring and if it is shorter than the specified limit, replace the spring. 4HK1 Free length of the valve spring

mm (in)

Intake air

Exhaust

Standard

65.9 (2.59)

68.1 (2.68)

Limit

62.9 (2.48)

65.1 (2.56)

6HK1 Free length of the valve spring

7. Remove the spring upper seat. • Remove the special tool to remove the upper seat.

mm (in)

Intake air

Exhaust

Standard

59.9 (2.36)

68.1 (2.68)

Limit

58.7 (2.31)

66.7 (2.63)


1A-71

4HK1 Tension of the valve spring

N (lb)

Intake air

Exhaust

Installation length mm (in)

46.0 (1.81)

46.0 (1.81)

Standard

348 (78)

383 (86)

Limit

330 (74)

356 (80)

6HK1 Tension of the valve spring

2. Valve spring squareness • Use a surface plate and a square to measure the valve spring squareness. If the measured value exceeds the specified limit, the valve spring must be replaced.

N (lb)

Intake air

Exhaust

Installation length mm (in)

46.0 (1.81)

46.0 (1.81)

Standard

348 (78)

378 (85)

Limit

309 (69)

329 (74)

4HK1 Valve spring squareness Limit

mm (in) 3.0 (0.12)

6HK1 Valve spring squareness Limit

mm (in) 3.4 (0.13)

Installation 1. Install the valve stem oil seal. • Apply engine oil over the peripheral part of the valve guide and install the oil seal by using a valve stem seal installer. Caution: After installing the valve stem oil seal, check if it is inserted nice and deep and the oil seal is not tilted or the garter spring has not come off. 3. Tension • Use a spring tester to compress the spring to the installation height. Measure tension of the compressed spring. If the measurement is lower than the limit, replace the spring.

1A-72 ENGINE MECHANICAL (4HK1, 6HK1) Special tool 4HK1 Valve stem seal installer: 8-9439-6815-0 (EN-47685) 6HK1 Valve guide oil seal installer: 5-8840-2625-0 (J43267)

3. Install the spring upper seat. 4. Install the split collar. • Apply compressed air over the cylinder from the glow plug holes to keep the valve at the home position. • Use a replacer to compress the valve spring and install the split collar. Special tool Valve spring replacer: 5-8840-2621-0 (J-43263) Pivot: 8-9439-6862-0 (EN-46721)

2. Install the valve spring. • Install it with the paint mark or the narrow side of the spring pitch being the lower side (cylinder head side). Paint mark Intake air

Light blue

Exhaust

Yellow

5. Apply engine oil over the bridge and install it. Caution: Move it up and down to check if it moves smoothly. 6. Apply engine oil over the bridge cap and install it. Caution: Pay full attention so as not to drop the bridge cap in the gear case of the rear part of the cylinder head or the hole into which oil pours back in the front.

Name 1. Spring Pitch 2. Paint Mark


1A-73

Special Tool Illustration


5-8840-2621-0 J-43263 Valve spring remover Rank B

8-9439-6862-0 EN-46721 Pivot ASM Rank B Name 1. Bridge Cap 2. Bridge 7. Install the camshaft ASM. Refer to “Camshaft ASM”. 8. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 9. Install the cylinder head cover. Refer to “Cylinder Head Cover”.

8-9439-6815-0 EN-47685 Valve stem seal installer (4HK1) Rank B

5-8840-2625-0 J-43267 Valve guide oil seal installer (6HK1) Rank B


Cylinder Head Components

* 4HK1 is shown for illustration. Name 1. Bridge Cap 2. Bridge 3. Bridge Guide 4. Split Collar 5. Spring Upper Seat 6. Valve Spring 7. Valve Stem Oil Seal 8. Valve Guide Caution: To avoid electric shock; Set the switch to the ‘OFF’ position and disconnect battery negative cable before checking or repairing the fuel injector, wiring or/and connectors.

9. 10. 11. 12. 13. 14. 15. 16.

Idle Gear C Cover Idle Gear C Glow Plug Intake And Exhaust Valves Cylinder Head Valve Spring Seat Thermostat Water Outlet Pipe

Removal 1. Drain the coolant. 2. Remove the engine harness. 3. Disconnect the exhaust pipe.

ENGINE MECHANICAL (4HK1, 6HK1) 4. Remove the turbocharger. Refer to the “Turbocharger and Exhaust Manifold”. 5. Remove the left-hand EGR adapter and right-hand EGR pipe. 6. Remove the EGR water feed pipe. 7. Remove the EGR water return pipe. 8. Remove the EGR cooler. 9. Remove the water feed pipe for coolant water for the EGR cooler and the water return pipe.

* 4HK1 is shown for illustration. Name 1. Harness Bracket 2. Harness Connector 3. Fuel Injector Terminal Nut 4. Nozzle Leak-Off Pipe 17. Remove the fuel leak-off hose. 18. Remove the fuel leak-off pipe (2). * 4HK1 is shown for illustration.

4HK1

Name 1. EGR Adapter 2. Water Return Pipe 3. EGR Cooler 4. EGR Pipe 5. Water Feed Pipe 10. Remove the fan guide bracket. 11. Remove the left-hand intake pipe between the inter-cooler and the inlet duct. 12. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 13. Remove radiator upper hose. 14. Loosen the fuel injector terminal nuts alternately to the same level, and remove the terminal. 15. Loosen the fuel injector harness bracket bolt, remove the inside connector, and remove the harness bracket. 16. Remove the nozzle leak-off pipe (4).

Name 1. High Pressure Pipe 2. Leak-Off Pipe

1A-75


6HK1 1 1

2

WSHK0020

WSHK0019

Name 1. High Pressure Pipe 2. Leak-Off Pipe 19. Remove the water bypass hose from the cylinder head side. • Remove the engine coolant temperature sensor connector. 4HK1

Name 1. Water Bypass 20. Remove the EGR valve and EGR valve connector. 21. Remove the cam angle sensor connector. 22. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 23. Remove the camshaft ASM. Refer to “Camshaft ASM”. 24. Remove the bridge cap carefully so that it does not fall into inside the engine. 25. Remove the bridge. Caution: Store the removed bridge and bridge cap so that they can be placed in their original locations. 26. Remove the glow plug connector. 27. Remove the glow plug.

Name 1. Water Bypass

ENGINE MECHANICAL (4HK1, 6HK1) 28. Remove the injection pipe clip, and remove the injection pipe. Important: Do not reuse the high-pressure pipe in fuel system if it has been removed. 4HK1

1A-77

31. If you have difficulty in removing the fuel injector, set the fuel injector remover in the fuel injector, tighten the attachment part on the joint of the leakoff pipe and pull out the fuel injector upward. Special tool Fuel injector remover: 5-8840-2826-0 (EN-46720) Sliding hammer: 5-8840-0019-0 (J-23907) Caution: When pulling out the fuel injector using a special tool, check that the fuel injector sleeve does not come off.

Name 1. Fuel Injection Pipe 2. Fuel Injection Pipe Clip 6HK1 2 1

Name 1. Sliding Hammer 2. Fuel Injector Remover 3. Fuel Injector ASM

WSHK0021

Name 1. Fuel Injection Pipe 2. Fuel Injection Pipe Clip 29. Remove the common rail. • Remove the common rail connector.

pressure

30. Remove the fuel injector bracket.

sensor

Caution: Attach a cylinder number to the removed fuel injector when storing it. Be sure not to make the nozzle touch something.


32. Remove the lower head cover. 33. Remove the cylinder head ASM. • Loosen the cylinder head bolts in the order described in the drawing. Caution: Be sure not to overlook (1) and (2) because they are attached with the flywheel housing with M10 bolts. • Remove the cylinder head gasket.

WSHK0022

Disassembly 1. Remove the case ASM. • Be sure not to lose the gasket. 2. Remove the boost pressure sensor and bracket. 1

Caution: Replace the head gasket with a new one once it was removed. 2

4HK1

WSHK0236

Name 1. Boost Pressure Sensor 2. Bracket 3. Remove the inlet cover. • Remove liquid gasket adherent to the removed inlet cover.



1A-79

10. Remove the idle gear C.

4. Remove the A/C compressor bracket. 5. Remove the exhaust manifold. • Remove the heat protector and remove the exhaust manifold. 6. Remove the exhaust gasket. 7. Disconnect the water outlet pipe. 8. Remove the thermostat.

Name 1. Idle Gear C 2. Shaft

* 4HK1 is shown for illustration. 9. Remove the idle gear C cover. • Put the edge of a driver on the outer circle of the sealing cup as shown in the drawing, tap it lightly, reverse it, then pull it out with pliers or other equipment.

11. 12. 13. •

Remove the split collar. Remove the spring upper seat. Remove the valve spring. Use a replacer to compress the valve spring to remove the split collar.

Special tool Valve spring replacer: 5-8840-2621-0 (J-43263) Pivot: 8-9439-6862-0 (EN-46721) • Remove the special tool, then remove the upper sheet and springs. Sort the removed valve springs by cylinder number.


14. Remove the intake and exhaust valves. • Sort the removed valves according to cylinders by using tags and others.

16. Remove the valve guide. • Use the valve guide replacer to press out the valve guides from the bottom side of the cylinder head. Special tool Valve guide replacer: 5-8840-2628-0 (J-43272)

15. Remove the valve stem oil seal. • Use pliers to remove the oil seals. * 4HK1 is shown for illustration. 17. Put the nozzle sleeve remover on the nozzle sleeve from the bottom side of the cylinder head, then pull out the nozzle sleeve. Special tool Nozzle sleeve remover: 5-8840-2623-0 (J-43265) Caution: • Be sure not to scratch the bottom side of the cylinder head. • Do not reuse the removed nozzle sleeve. • Carefully remove sawdust in the screw groove.


Name 1. Nozzle Sleeve 18. Remove the bridge guide. • Electrically weld the nut on the head of the bridge guide, attach the sliding hammer and pull it out.

1A-81

Inspection 1. Check the cylinder head ASM. • Remove varnish, soot and others adhered on the metal surface completely. Use metal brush and others so that the seal surface of the surface where the gasket is installed is not hurt. • Check the following causes in the case of leak of the seal surface of the cylinder head, corrosion, air leak and defective gasket. – – – a.

Improper installation Defective tightening of the cylinder head. Winding seal surface of the cylinder block. Damage on the screw surface or extracted cylinder head bolt due to extra tightening torque

Caution: Replace suspicious bolt. b. Inside the combustion chamber, glow plug hole.

Name 1. Nut 19. Remove the oil seal. • Press the tool against the oil seal. Strike the tool to remove the seal from the inside of the cylinder head.

1A-82 ENGINE MECHANICAL (4HK1, 6HK1) • Check whether there is a crack between the valve seats and in the cylinder head of the exhaust port part, and replace the cylinder head if there is serious damage or crack. Check the collar if necessary.

• Use a straight edge ruler and thickness gauge to measure the four sides and diagonal lines as shown in the drawing, and replace if they exceed the limit. Distortion of the surface where the manifold and cover are installed Standard Limit

c. Flatness of the under surface of the cylinder head • Use a straight edge ruler and thickness gauge to measure the four sides and diagonal lines as shown in the drawing, and replace if they exceed the limit. Distortion of the under surface of the cylinder head Standard Limit

mm (in)

0.05 (0.002) or less 0.20 (0.0079)

0.05 (0.002) or less 0.2 (0.0079)

* 4HK1 is shown for illustration. e. Flatness of the exhaust manifold • Use a straight edge ruler and thickness gauge to measure the flatness. If it exceeds the limit, replace the exhaust manifold. Distortion of the exhaust manifold Standard Limit

* 4HK1 is shown for illustration. d. Flatness of the surface where the exhaust manifold and inlet cover are installed

mm (in)

mm (in)

0.3 (0.0118) or less 0.5 (0.0197)

ENGINE MECHANICAL (4HK1, 6HK1) Gap

1A-83 mm (in)

Assembly standard

0.020 (0.00079) – 0.057 (0.00224)

Usage limit

0.1 (0.0039)

* 4HK1 is shown for illustration. 2. Bridge cap • Inspect abrasion and deformation of the surface where the cap and the rocker arm adjust bolt contact. • If the amount of abrasion is 0.1 mm (0.0039 in) or larger, or if it abrades away in a zonal shape, replace it. Abrasion of the bridge cap Limit

mm (in) 0.1 (0.0039)

Name 1. Bridge 2. Bridge Guide 4. Check the valve guide. Caution: If there is a scratch or abnormal abrasion in the valve stem and the inner diameter part of the valve guide, replace it with new one along with valve guide. a. Measure the valve guide clearance. • Measure the diameter of the valve stem with a micro meter. If the diameter of the valve stem is smaller than the limit, replace the valve and valve guide altogether. 4HK1 The external diameter of the valve stem

3. Bridge • Make sure the bridge moves smoothly along the bridge guide. • Measure the gap between the bridge and bridge guide.

mm (in)

Standard

Limit

Intake valve

8.946 (0.3522) – 8.962 (0.3528)

8.88 (0.3496)

Exhaust valve

8.921 (0.3512) – 8.936 (0.3518)

8.80 (0.3465)

1A-84 ENGINE MECHANICAL (4HK1, 6HK1) 6HK1 The external diameter of the valve stem Intake valve Exhaust valve

mm (in)

Standard

Limit

8 (0.315)

7.88 (0.3102)

5. Inspect abrasion of the bridge gap. • Measure the contact surface of bridge cap and the rocker arm, using a dial gauge. • If the abrasion exceeds the limit, or there is an abnormal abrasion (zonal abrasion), replace the bridge cap. • Measure the gap between the valve guide and valve stem within 10 mm (0.39 in) from the valve guide, using a dial gauge. • If the measured value exceeds the limit, replace the valve guide and valve altogether.

Abrasion of the bridge cap Limit

mm (in) 0.1 (0.00394)

4HK1 Gap between the valve guide and valve stem

mm (in)

Standard

Limit

Intake valve

0.038 (0.00150) – 0.071 (0.00280)

0.20 (0.00787)

Exhaust valve

0.064 (0.00252) – 0.096 (0.00378)

0.25 (0.00984)

6HK1 Gap between the valve guide and valve stem

mm (in)

Standard

Limit

Intake valve

0.039 (0.00153) – 0.062 (0.00244)

0.20 (0.00787)

Exhaust valve

0.064 (0.00252) – 0.096 (0.00378)

0.25 (0.00984)

6. Check the valve. Thickness of valve • Measure the thickness of the valve. • If the measured value exceeds the limit, replace the valve and valve guide altogether.


1A-85

4HK1 Thickness of valve

mm (in) Standard

Limit

Intake valve

1.8 (0.0709)

1.3 (0.0512)

Exhaust valve

1.75 (0.0689)

1.3 (0.0512)

6HK1 Thickness of valve

mm (in) Standard

Limit

Intake valve

1.88 (0.074)

1.3 (0.0512)

Exhaust valve

1.75 (0.0689)

1.3 (0.0512)

• Measure the contact width of the valve seat. If the seat contact surface has a scratch or is rough, or if the abrasion of the contact surface exceeds the limit, modify or replace it. Contact width of the valve seat

mm (in)

Standard

Limit

Intake valve

2.5 (0.0984)

3.0 (0.1181)

Exhaust valve

2.0 (0.0787)

2.5 (0.0984)

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

mm (in) 0.7 (0.0276) – 1.2 (0.0472) 2.5 (0.0984)

• If the contact surface of the valve seat is defective, modify it or replace the valve, valve guide and valve seat altogether.

6HK1 Depth of the valve Intake valve Exhaust valve

Contact surface of the valve seat

mm (in) Standard

Limit

1 (0.039)

2.5 (0.098)

1.3 (0.051)

2.8 (0.11)

Angle of the contact Exhaust side of 4HK1 and surface: 6HK1: 45° Intake side of 6HK1: 30°


Repair of the seat surface • Remove carbon from the surface of the valve seat. • Use a seat cutter to minimize the scratch and other roughness (15/45/75°-blade), thereby returning the contact width to the standard value.

Caution: Remove only scratches and roughness, and do not cut the surface too much. Use the free adjustment valve cutter pilot. Do not let the valve cutter pilot waver inside the valve guide.

• Attach compound in the valve insert seat. • Insert the valve into the valve guide. • Attach compound on the valve seat surface, rotate the valve and hit it lightly to grind them, and confirm that it has even contact all round. Caution: Remove compound completely after grinding.


1A-87

Replace the valve seat insert Remove the valve seat insert • Arc-weld the entire inner diameter of the valve seat insert. • Cool the valve seat insert for two to three minutes. Contraction fur to cooling makes it easier to remove the valve seat insert. • Remove the valve seat insert, using a screw driver. Be sure not to hurt the cylinder head.

Name 1. Washer 2. Valve Seat 3. Press

Reassembly 1. Install the oil seal. • Install on the surface of injection pipe insert. Name 1. Arc-Weld 2. Valve Seat Insert 3. Screw Driver Install the valve seat insert • Carefully place a washer (the outer diameter is smaller than the valve seat insert) on the valve seat insert. • Use the press to apply pressure gradually on the washer, thereby pushing the valve seat insert. • After replacement of the valve seat, Attach compound on the valve seat surface, rotate the valve and hit it lightly to grind them, and confirm that it has even contact all round. Caution: Do not apply too much pressure with the press. Remove compound completely after grinding.

• Hammer it in so that the seal does not incline. Caution: Be sure not to hurt the rip. Special tool Oil seal installer: 5-8840-2627-0 (J-43269)


Name 1. Cylinder Head 2. Oil Seal Installer 2. Install the bridge guide. • Apply engine oil on the outer diameter of the guide, then use the installer to hammer it into the depth of the finishing part of the hole of the cylinder head. (Note: the height of the bridge guide is about 37.5 mm {1.48 in} from the upper surface of the head) Special tool Bridge guide installer: 5-8840-2626-0 (J-43268) Engine oil

Name 1. O-Ring 2. O-Ring 3. Apply Seal Material 4. Engine Oil • Install the nozzle sleeve on the cylinder head, insert the guide sleeve. • Use the guide sleeve to push in so that the nozzle sleeve fully contacts with the under surface of the cylinder head. • Insert the sleeve and fix it with the tighten and bolt. • Insert the ball (bearing steel ball 9.525 mm {0.375 in}) into the guide sleeve, attach the punch bar and hammer out the ball. Caution: • Leave the cylinder head floating so that the ball comes off from the under surface.

3. Nozzle sleeve • Install the O-ring on the nozzle sleeve, apply engine oil. • Apply seal material on the taper section. Loctite No. TL620

ENGINE MECHANICAL (4HK1, 6HK1) Special tool Nozzle sleeve installer: 5-8840-2624-0 (J-43266)

1A-89

Special tool Valve guide replacer: 5-8840-2628-0 (J-43272)

Height from the upper surface of the cylinder head to the edge surface of the valve guide: 13.9 mm (0.5472 in) – 14.3 mm (0.5630 in) Caution: When replacing the valve guide, it must be replaced together with the valve.

Name 1. Punch Bar 2. Ball 3. Guide Sleeve 4. Nozzle Sleeve 5. Bracket 6. Bolt 4. Install the valve guide. • Hammer in the valve guide from the upper surface of the cylinder head, using the valve guide replacer.

5. Install the valve stem oil seal. • Apply engine oil on the outer diameter of the valve guide, use the valve stem seal installer to install the oil seal. Caution: After installation of the valve stem seal, confirm that the oil seal is not inclining and the garter spring is in place.

1A-90 ENGINE MECHANICAL (4HK1, 6HK1) Special tool 4HK1 Valve stem seal installer: 8-9439-6815-0 (EN-47685) 6HK1 Valve guide oil seal installer: 5-8840-2625-0 (J43267)

Name 1. Spring Pitch 2. Paint Mark

6. Install the intake and exhaust valves. • Apply engine oil on the valve stem part and install the valve.

8. Install the spring upper seat. 9. Install the split collar. • Use a replacer to compress the valve spring and install the split collar. Special tool Valve spring replacer: 5-8840-2621-0 (J-43263) Pivot: 8-9439-6862-0 (EN-46721)

7. Install the valve spring. • Install the valve spring with the paint mark or the narrower side of the spring pitch on the under side (the cylinder head side). Paint mark Intake side

Light blue

Exhaust side

Yellow

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


1A-91

4HK1


Name 1. Thermostat

Name 1. Idle Gear C 2. Shaft

6HK1

11. Install the idle gear C cover. • Apply liquid gasket (Loctite 262 or 962T) on the outer diameter of the idle gear C cover, use the sealing cup setting tool to hammer it in so that the measurements follow the drawing. Special tool Sealing cup installer: 5-8840-2222-0 (EN-47690)

1

WSHK0024

Name 1. Thermostat 13. Connect the water outlet pipe. • Tighten the water outlet pipe to the specified torque. WSHK0023

12. Install the thermostat. • Install the thermostat on the position shown in the drawing.

• Tighten it up together with the fan shroud bracket. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)


Name 1. Distance Tube 2. Conical Spring 3. Nut

6HK1

• Tighten the exhaust manifold in the order described in the drawing. Tightening torque: 34 N⋅m (3.5 kg⋅m/25 lb ft) Caution: Do not tighten it too much so that it hinders extraction and contraction of the manifold due to heat. 4HK1

WSHK0025

14. Install the exhaust gasket. 15. Install the exhaust manifold. • Install the distance tube conical spring and the nut on the stud of the cylinder head in this order.


1A-93

4HK1

WSHK0014

• Install the heat protector.

6HK1

Tightening torque: 10 N⋅m (1.0 kg⋅m/89 lb in) 16. Install the inlet cover. • Apply liquid gasket (ThreeBond 1207C or equivalent) in accordance with the groove of the inlet cover, with the bead diameter of φ2.5 mm (0.0984 in) – 5.5 mm (0.2165 in).

13

14

9

10

5

6

4

1

3

2

8

7

12

11

WSHK0026

17. Install the boost pressure sensor and bracket. Apply Loctite to the bolt shown on the illustration and install it. Tightening torque: 21.6 N⋅m (2.2 kg⋅m/16 lb ft)

* 4HK1 is shown for illustration. • Tighten in the order described in the drawing. • Tighten the stud bolts (6) and (9) jointly with the common rail. Tightening torque: 22 N⋅m (2.2 kg⋅m/16 lb ft)

1A-94 ENGINE MECHANICAL (4HK1, 6HK1) 1

2

WSHK0236

Name 1. Boost Pressure Sensor 2. Bracket 18. Install the inlet pipe. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)

Measurement points: Standard point:

Head of the piston

(2) and (3)

Upper surface of the cylinder block

(1)

Caution: Note that there are three options for the head gasket according to the amount of extrusion of piston shown in the following table. (4HK1 only) • Calculate the piston extrusion amount of each cylinder. (4HK1 only) Extrusion amount =

(measurement of (2) + measurement of (3)) /2


70

• Select a gasket of an appropriate grade based on the maximum extrusion amount among all the cylinders. (4HK1 only)

Installation 1. Install the cylinder head gasket. • Select the cylinder head gasket. (4HK1 only) • Clean the head of the piston and the upper surface of the cylinder block. • Use a dial gauge to measure the extrusion of the piston. Measure at two points of each cylinder. • The following drawing shows the measurement points and the standard point of the cylinder block.

WSHK0231

ENGINE MECHANICAL (4HK1, 6HK1) Gasket Grade

1A-95

Recognized Piston Protrusion amount mm (in)

A

(no hole)

0.520 (0.02047) – 0.600 (0.02362)

B

(1 hole)

0.601 (0.02366) – 0.680 (0.02677)

C

(2 holes)

0.681 (0.02681) – 0.760 (0.02992)

(4HK1 only) 4HK1 only

• Install the cylinder head gasket. • Install the cylinder head gasket with the parts number upside, along with the cylinder head rear gear case and knock pin.

Name 1. Grade Recognition Hole • Apply liquid gasket • Apply liquid gasket (ThreeBond 1207B or equivalent) on the joint (1) of the cylinder block and the flywheel housing with the bead diameter of 3 mm (0.118 in). • Install the cylinder head within seven minutes after applying liquid gasket.

* 4HK1 is shown for illustration. 2. Install the cylinder head ASM. • Install the cylinder head, adjusting the knock pin of the cylinder block. Caution: Be sure not to hurt the head gasket when installing it.

1A-96 ENGINE MECHANICAL (4HK1, 6HK1) Special tool Angle gauge: 5-8840-0266-0 (J-45059, KM470-B) 4HK1

* 4HK1 is shown for illustration. • Apply molybdenum disulfide on the screw part and setting face of the head bolt of M14, and apply engine oil on the screw part and setting face of the head bolt of M10.

6HK1

• Use a torque wrench and angle gauge to tighten the head bolts in the order described in the drawing. Tightening torque: M14 bolt (4HK1: 1 – 18, 6HK1: 1 – 26) 1st step = 98 N⋅m (10.0 kg⋅m/72 lb ft) 2nd step = 147 N⋅m (15.0 kg⋅m/108 lb ft) 3rd step = 30° – 60° M10 bolt (4HK1: 19, 20; 6HK1: 27, 28) 4th step = 38 N⋅m (3.9 kg⋅m/28 lb ft) Use a stud bolt for (4HK1: 16).

WSHK0027

3. Install the fuel injector on the cylinder head. 4. Apply molybdenum disulfide on the screw part and setting face of the fuel injector tighten bolt and tighten it tentatively. Important: Reinstall each fuel injector to the original cylinder from which it was removed during the disassembly procedure.


1A-97

Name 1. Fuel Injector ASM 2. Fuel Injector Tighten Bolt 5. Install the common rail. Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb ft) • Install the common rail pressure sensor. 6. Install the injection pipe. Important: Replace the high-pressure pipe in fuel system with new one if it has been removed. • Apply a thin coat of engine oil on the outer diameter of the sleeve nut on the side of the fuel injector and install the injection pipe. • Use a spanner to tighten the sleeve nut until it completely contacts both on the fuel injector and common rail. • Tighten the injection pipe clip with the designated torque. Tightening torque: 6 N⋅m (0.6 kg⋅m/53 lb in)

* 4HK1 is shown for illustration. Name 1. Fuel Injection Pipe 2. Fuel Injection Pipe Clip 7. Final tighten the injection clamp bolts to the specified torque. Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft) 8. Tighten the injection pipes to the specified torque. Tightening torque: 44 N⋅m (4.5 kg⋅m/32 lb ft)


* 4HK1 is shown for illustration. Name 1. Injection Clamp Bolt 2. Injection Pipe Sleeve Nut 9. Install the glow plug. Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft) 10. Install and tighten the glow connector with the designated torque. Tightening torque: 1.2 N⋅m (0.1 kg⋅m/10.6 lb in)

Name 1. Bridge Cap 2. Bridge 13. Install the camshaft ASM. Refer to “Camshaft ASM”. 14. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 15. Install and tighten the camshaft speed sensor with the designated torque. Tightening torque: 8 N⋅m (0.8 kg⋅m/71 lb in)

11. Apply engine oil over the bridge and install it. Caution: Move it up and down to check if it moves smoothly. 12. Apply a thin coat of engine oil inside the bridge cap, install it.

16. Connect the water bypass hose. • Install the engine coolant temperature sensor on the thermostat housing. 17. Install the leak off pipe. Leak off pipe tightening torque: Tightening torque: 12 N⋅m (1.2 kg⋅m/106 lb in) 18. Install the fuel leak-off hose.

ENGINE MECHANICAL (4HK1, 6HK1) • Install the fuel leak-off hose on the fuel leak-off pipe and fix it with a clip.

1A-99

4HK1

19. Clip a new gasket to the fuel nozzle leak-off pipe and install the fuel leak-off pipe. Tightening torque: 12 N⋅m (1.2 kg⋅m/106 lb in)

6HK1


WSHK0028 21. Install the terminal nuts on the fuel injector. Tightening torque: 2 N⋅m (0.2 kg⋅m/18 lb in)

20. Install the fuel injector harness connector from inside, tighten the harness bracket with the designated torque. Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb ft)

Caution: • Tighten the terminal nuts alternately in order to prevent imbalance in tightening because they are unified. • Do not tighten the nuts too tightly because it leads to damage to the terminal stud.

1A-100 ENGINE MECHANICAL (4HK1, 6HK1) 26. Connect the exhaust pipe. 27. Install the engine harness. 28. Replenish the coolant.

Name 1. Fuel Injector 2. Fuel Injector Harness 3. Fuel Injector Terminal Nut 22. Install the cylinder head cover. Refer to “Cylinder Head Cover”. 23. Connect the radiator upper hose. 24. Install the EGR valve & EGR cooler. For details of installation, refer to “EGR Valve and EGR Cooler” of the section of exhaust system.

* 4HK1 is shown for illustration. Name 1. EGR Adapter 2. Water Return Pipe 3. EGR Cooler 4. EGR Pipe 5. Water Feed Pipe 25. Install the oil level gauge and guide tube.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-101 Torque Specifications




Illustration


5-8840-0019-0 J-23907 Sliding hammer Rank B

8-9439-6815-0 EN-47685 Valve stem seal installer (4HK1) Rank B

5-8840-2628-0 J-43272 Valve guide remover Rank B

5-8840-2625-0 J-43267 Valve guide oil seal installer (6HK1) Rank B

1A-102 ENGINE MECHANICAL (4HK1, 6HK1) Illustration


Illustration


5-8840-0266-0 J-45059 KM470-B Angle gauge Rank B

5-8840-2621-0 J-43263 Valve spring remover Rank B

5-8840-2624-0 J-43266 Nozzle sleeve installer Rank A

8-9439-6862-0 EN-46721 Pivot ASM Rank B

5-8840-2626-0 J-43268 Bridge guide installer Rank A

5-8840-2222-0 EN-47690 Seal ring installer Rank A

5-8840-2627-0 J-43269 Oil seal installer Rank A

5-8840-2623-0 J-43265 Nozzle sleeve remover Rank A

5-8840-2826-0 EN-46720 Injector remover Rank A

ENGINE MECHANICAL (4HK1, 6HK1) 1A-103

Piston, Connecting Rod Components

7 1

2

6

1

5 3

4

WSHK0184

Name 1. Snap Ring 2. Piston 3. Bearing 4. Connecting Rod Cap

5. Connecting Rod 6. Piston Pin 7. Piston Ring

Removal 1. Remove the oil pan. Refer to “Oil Pan”. 2. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 3. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 4. Remove the camshaft ASM. Refer to “Camshaft ASM”. 5. Remove the cylinder head. Refer to the “Cylinder Head”. 6. Remove the connecting rod cap. Caution: Sort the removed bearings according to cylinders by using tags. 7. Remove the piston and connecting rod.

1A-104 ENGINE MECHANICAL (4HK1, 6HK1) • Remove carbon on the upper side of the cylinder liner with a scraper. • Pull out the piston and connecting rod towards the cylinder head. Caution: Be sure not to damage the oil jet and cylinder liner when pushing out the connecting rod.

2. Remove the snap ring. 3. Remove the piston pin. Caution: Sort the disassembled piston pins, pistons and connecting rods together in the order of cylinders.

8. Remove the connecting rod bearing. Caution: Sort the bearings in the order of cylinders when reusing them so that they will not be confused with the bearing of other cylinders.

Disassembly 1. Remove the piston ring. • Use ring pliers to remove the piston ring. Caution: Sort the piston rings in the order of cylinders when reusing them so that they will not be confused with the pistons and piston rings of other cylinders. 4. Remove the connecting rod from the piston. 5. Piston • Clean carbon carefully that is adhered to the head of the piston and the groove of the piston ring. Caution: Do not use wire brush to clean the piston because it scratches the piston. Inspect the piston with eyes for cracks, burns and other excessive wear, and replace it if there is any abnormality. 6. Measure the gap between the piston and the inner diameter of the cylinder liner.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-105 Cylinder liner inner diameter • Use a cylinder bore dial indicator to measure the liner inner diameter both in the thrust and radial directions in the designated position. • Measurement position (from the upper surface of the cylinder block) 1. 20 mm (0.79 in) 2. 110 mm (4.33 in) 3. 190 mm (7.48 in) • Measure the liner inner diameter based on the average value of the actual measurement values on 6 positions. Cylinder liner inner diameter

mm (in)

115.021 – 115.050 (4.52838 – 4.52952)

Gap between the piston and the inner diameter of the cylinder liner Standard

mm (in)

0.082 – 0.130 (0.0032 – 0.0051)

6HK1 Piston diameter Standard

mm (in) 114.974 – 114.989 (4.52652 – 4.52711)

Gap between the piston and the inner diameter of the cylinder liner Standard

mm (in)

0.042 – 0.066 (0.00165 – 0.00259)

Caution: If it is found that the gap between the cylinder liner inner diameter and the piston exceeds the standard value, replace the piston or cylinder liner.

Name 1. 20 mm (0.79 in) 2. 110 mm (4.33 in) 3. 190 mm (7.48 in) Piston outside diameter • Use a micrometer to measure the outside diameter of the piston in the right angle to the piston pin in the designated position. • Measurement position (from the upper surface of the piston) 82 mm (3.2 in). 4HK1 Piston diameter Standard

mm (in) 114.920 – 114.949 (4.52440 – 4.52554)

7. Piston replacement • You do not need to select grades because there is only one grade for each of the piston and the cylinder liner inner diameter. If you replace the cylinder liner, you must select the cylinder block (1, 2, 3) because there are two types of the liner outer diameter. • Refer to “Cylinder Block” if you replace the cylinder liner. Caution: The head of piston has a marking of grade B or C when it is shipped from the factory.


Name 1. Front Mark Cut 8. Inspect the piston ring. Measure the joint of the piston ring (remove carbon on the ring joint) • Insert the piston ring into the cylinder liner. • Use the piston to push the ring to reach the under edge of the cylinder liner.

• If the measurement exceeds the limit, replace the piston ring. Piston ring gap

mm (in) Standard

Limit

Top ring

0.18 – 0.28 (0.0071 – 0.0110)

1.2 (0.047)

Second ring Third ring

0.35 – 0.50 (0.0138 – 0.0197)

1.2 (0.047)

Oil ring

0.15 – 0.35 (0.0059 – 0.0138)

1.2 (0.047)

Measure the clearance between the piston ring groove and the piston. • Remove carbon on the piston ring groove completely. • Put the piston ring in the piston ring groove, use a thickness gauge to measure the gap between them. • If the clearance between the piston ring groove and the piston exceeds the limit, replace the piston and the piston ring.

• Use a thickness gauge to measure the gap of the ring joint.

Piston ring and piston ring groove clearance Piston ring

mm (in)

Standard

Limit

Top ring

0.057 – 0.097 (0.0022 – 0.0038)

0.20 (0.0079)

Second ring Third ring

0.085 – 0.120 (0.0033 – 0.0047)

0.20 (0.0079)

Oil ring

0.020 – 0.060 (0.0008 – 0.0024)

0.20 (0.0079)

ENGINE MECHANICAL (4HK1, 6HK1) 1A-107 Expansion force

N (kgf/lbf) Standard

Limit

Top ring

22.7 – 30.7 (2.31 – 3.13/5.10 – 6.90)

11.8 (1.2/2.7)

Second ring

16.7 – 22.6 (1.70 – 2.30/3.75 – 5.08)

5.9 (0.6/1.3)

Third ring

20.8 – 28.2 (2.12 – 2.88/4.68 – 6.34)

4.9 (0.5/1.1)

Oil ring

43.0 – 58.1 (4.38 – 5.92/9.67 – 13.06)

41.2 (4.2/9.3)

• Inspect to make sure that there is a resistance to the extent which the piston can push the piston pin lightly in normal temperatures. • If it feels a large looseness or instability in normal temperatures, replace the piston or piston pin.

9. Inspect the piston pin. • Inspect the piston pin with eyes for cracks, scratches and other damages, replace it if necessary. • Use a micrometer to measure the outer diameter of the piston pin. If the measured value exceeds the limit, replace the piston pin. 4HK1 Piston pin outer diameter Standard

mm (in)

35.995 – 36.000 (1.4171 – 1.4173)

Limit

35.970 (1.4161)

6HK1 Piston pin outer diameter

mm (in)

Standard

40.0 (1.5748)

Limit

39.95 (1.5728)

• Measure the bush of the small edge of the connecting rod. If the clearance between the bushing inner diameter and the pin diameter exceeds the limit, replace the bushing or connecting rod ASM, and the pin. Piston pin and connecting rod small end bushing clearance Standard Limit

mm (in)

0.012 – 0.027 (0.0005 – 0.0011) 0.05(0.0020)


10. Measure the clearance between the piston and the piston pin. • Apply engine oil on the piston pin. Use your finger to push it in the piston hole and rotate it. If the pin smoothly rotates without instability, the clearance is normal. If there is instability, measure the clearance. If the clearance exceeds the limit, replace the piston and the piston pin. Piston pin and piston pin hole clearance Standard

mm (in)

0.004 – 0.017 (0.00016 – 0.00067)

Limit

0.04 (0.0016)

11. Remove the bushing. • Set the collar, connecting rod and collar on the setting bar as shown in the drawing.

Name 1. Setting Bar 2. Connecting Rod 3. Nut 4. Collar 5. Bushing 6. Collar • Place the connecting rod bushing replacer base on the bench press, tighten the fixation bolt. • Use the bench press to replace the bush. Special tool Connecting rod bushing replacer: 5-8840-2340-0 (EN-47682)

• Tighten the nut.

Name 1. Bolt 2. Connecting Rod Bushing Replacer 12. Measure the connecting rod alignment.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-109 • Use a connecting rod aligner to measure the torsion and parallel level of the big end hole and the small end hole. If the measured value exceeds the limit, replace it. Connecting rod alignment (per length of 100 mm {3.94 in}) Distortion and Parallelism

mm (in)

Standard

Limit

0.05 (0.002)

0.20 (0.008)

– Remove the cap. – Measure the largest width of the plastigauge to calculate the oil clearance. If the clearance exceeds the limit, replace the bearing ASM. Crank pin and bearing clearance Standard Limit

mm (in)

0.036 – 0.077 (0.0014 – 0.0030) 0.10 (0.0039)

– Remove the plastigauge from the bearing and crank pin. 13. Measure the bearing oil clearance. • Measure the oil clearance between the connecting rod bearing and the crank pin with the following method. – Remove the connecting rod cap. Sort the removed caps according to the cylinder number. – Clean the bearing and the shaft pin. – Check the bearing. If it is damaged or worn seriously, replace the bearing ASM. • Place the plastigauge on the crankshaft pin. • Install the bearing cap and tighten the bolt with the designated torque. Apply molybdenum disulfide on the screw part and the bearing surface. Connecting rod bearing cap bolt torque:

N⋅m (kg⋅m/lb ft)

1st step

39 (4.0/29)

2nd step

60°

3rd step

30°

Caution: Do not rotate the crankshaft.

14. Select the connecting rod bearing. • Refer to the bearing selection table when installing a new connecting rod or replacing bearings in use. • Select and install the bearing, paying attention to the large edge hole diameter of the connecting rod.

1A-110 ENGINE MECHANICAL (4HK1, 6HK1) Reassembly 1. Install the bush • Place the connecting rod bushing replacer base on the bench press, set the connecting rod and tighten the fixation bolt. Special tool Connecting rod bushing replacer: 5-8840-2340-0 (EN-47682)

Name 1. Recognition Boss: When putting, 4HK1:Front, 6HK1:Back 2. Big End Diameter Grade Mark 3. Cylinder Number Bearing selection table Big end hole diameter Grade

Bearing recognition color

Oil clearance

A

Green

0.036 – 0.077 (0.0014 – 0.0030)

B

Yellow

0.036 – 0.077 (0.0014 – 0.0030)

mm (in)

Name 1. Bolt 2. Connecting Rod Bushing Replacer • Set the collar, new bushing and collar on the setting bar as shown in the drawing. • Tighten the nut. • Adjust the oil hole of the connecting rod and the oil hole of the bush, and use the bench press to install the bush.

Name 1. Grade Identification Color

ENGINE MECHANICAL (4HK1, 6HK1) 1A-111 • 6HK1: Install it so that the front mark of the head of the piston and the connecting rod forging mark (projecting) on the connecting rod face the opposite direction. • Use snap ring pliers to install the snap ring of one side.

Name 1. Setting Bar 2. Connecting Rod 3. Nut 4. Collar 5. Bushing 6. Collar • After installing the new bush, use a grinder to machine the pin hole so that the pin clearance equals the standard value.

Name 1. Snap Ring 2. Front Mark 3. Forging Mark (Projecting): 4HK1: Front, 6HK1: Back 4. Apply enough engine oil on the piston pin, push it in the piston and the connecting rod small edge. 5. Use snap ring pliers to install the snap ring. Caution: Make sure that the snap ring is installed in the ring groove properly. Make sure that the connecting rod moves smoothly.

2. Install the piston. 3. Install the connecting rod. • 4HK1: Install it so that the front mark of the head of the piston and the connecting rod forging mark (projecting) on the connecting rod face the same direction.

6. Use piston ring setting tool to install the piston ring.

1A-112 ENGINE MECHANICAL (4HK1, 6HK1) • Install the oil ring so that the joint angle of the ring and coil expander is in the opposite 180° direction. • Install the piston ring so that the marks “N” face upward. Special tool Piston ring setting tool: 1-8522-1029-0

Installation 1. Install the connecting rod bearing. • Install the bearing on the connecting rod, apply engine oil on the bearing. 2. Install pistons and connecting rod ASM. • Apply enough engine oil on the piston ring, ring groove and piston side surface. • Dislocate the piston ring joint so that (1) is top ring, (3) is 2nd ring, (2) is 3rd ring and (4) is oil ring, as shown in the drawing. • Face the piston front mark cut to forward, use the piston ring compressor to insert the piston in the cylinder liner. Caution: • Be sure not to make the connecting rod touch the oil jet when pushing in the piston. • Be sure not to hurt the inside of the liner when pushing in the piston. Special tool Piston ring compressor: 5-8840-9018-0 (J-8037)

Name 1. Top Ring 2. Second Ring 3. Third Ring 4. Oil ring Caution: Note that the shapes are different for each piston ring. Make sure that there is not gap in the position indicated in the drawing when the oil ring coil expander was installed.

3. Install the connecting rod cap. • Install the bearing on the connecting rod cap and apply engine oil. • Install the cap, matching the numbers (1, 2, 3, 4) of the caps and connecting rods.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-113 5. Install the camshaft ASM. Refer to “Camshaft ASM”. 6. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 7. Install the cylinder head cover. Refer to “Cylinder Head Cover”. 8. Install the oil pan. Refer to “Oil Pan”.

Name 1. Recognition Boss: When putting, 4HK1:Front, 6HK1:Back 2. Big End Diameter Grade Mark 3. Cylinder Number • Apply molybdenum disulfide on the screw part and the setting face of the tightening bolt and tighten it with the designated torque. Tightening torque: 1st step = 39 N⋅m (4.0 kg⋅m/29 lb ft) 2nd step = 60° 3rd step = 30° Special tool Angle gauge: 5-8840-0266-0 (J-45059, KM470-B) Caution: Make sure that the crankshaft rotates smoothly.

4. Install the cylinder head. Refer to the “Cylinder Head”.




Illustration


5-8840-2340-0 EN-47682 Connecting rod bushing remover Rank B

x-xxxx-xxxx-x Piston ring setting tool Rank B

x-xxxx-xxxx-x x-xxxx Piston ring compressor Rank B



Flywheel Components

Name 1. Flywheel Housing 2. Flywheel ASM

Removal 1. Remove the starter motor. • Remove the ground cable of the starter motor. • Remove the two nuts on the upper side and lower side that fix the starter, remove the starter from the fly wheel housing.

3. Washer 4. Crankshaft Position Sensor

4HK1


Special tool Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx)

WSHK0030 2. Remove the crankshaft position sensor. • Remove to prevent contact damage when the flywheel is removed.

• Gradually loosen the flywheel installation bolts in the order shown in the drawing so that the flywheel does not rotate.

• Do not throw or drop because it is vulnerable to shock. * 4HK1 is shown for illustration.

• After loosening all the bolts, remove the stopper to remove the flywheel.

3. Remove the washer and flywheel. • Install the crankshaft stopper to the starter installing portion of the flywheel housing.

4. Take out the ring gear. • Put a bar on the ring gear and hit it with a hammer to remove it.

Caution: Make sure that the stopper is properly fitted and engaged with the ring gear.


Inspection

Installation

1. Visual check • Inspect the flywheel friction surface for cracks and damages, and replace it if it has abnormality.

1. Install the ring gear. • After heating the ring gear with a gas burner equally, install it in the flywheel.

• Inspect the tooth part of the ring gear, replace the ring gear if it has damage or serious wear.

• In the case of shrinkage cooling of the ring gear, maintain the flatness by applying weight of 68.6 kN (15,400 lbf).

2. Measurement of the friction surface • Measure the depth of the flywheel friction surface. • Adjust it if the measured value is within the standard value and the limit. • If the measured value exceeds the limit, replace the flywheel. Depth of the friction surface of the flywheel Standard

19 (0.75)

Limit

20 (0.79)

Caution: • Install the ring gear so that the side with a pattern faces forward. • Shrink fit the ring gear to the flywheel. Make sure that flywheel and ring gear adhesion is complete.

mm (in)

Depth = From the pressure installation surface to the friction surface.

2. Install the flywheel. 3. Install the washer. • Install the flywheel to match with the knock pins of the crankshaft, tighten them in the order shown in the illustration.

1A-118 ENGINE MECHANICAL (4HK1, 6HK1) • Apply molybdenum disulfide on the screw part and setting face of the bolt.

4HK1

• Install the crankshaft stopper to the starter installing portion of the flywheel housing. Tightening torque: 1st step = 78 N⋅m (8.0 kg⋅m/58 lb ft) 2nd step = 120° – 150° Special tool Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx) Angle gauge: 5-8840-0266-0 (J-45059)

6HK1

WSHK0030 • Install the ground cable of the starter motor.

4. Install and tighten the crankshaft position sensor with the designated torque. Tightening torque: 8 N⋅m (0.8 kg⋅m/71 lb in) 5. Install the starter motor on the flywheel housing with nuts and tighten them with the designated torque. Tightening torque: 76 N⋅m (7.7 kg⋅m/56 lb ft)


N m{kg m/lb ft}

78 {8 / 58}

60

60

8 {0.8 / 5.9}

WSHK0067






Front Cover Components 4HK1

1

6 2

7 8 9

3

4 5 10

WSHK0239

ENGINE MECHANICAL (4HK1, 6HK1) 1A-121 6HK1

12

11

1

2

8

6

7

3 9

10

4

5

WSHK0240

Name 1. Front Cover 2. Oil Pan Gasket 3. Oil Pan 4. Front Oil Seal 5. Crankshaft Pulley 6. Water Pump ASM

Removal 1. Remove the front oil seal. Refer to “Crankshaft Front Oil Seal”. 2. Remove the oil pan. Refer to “Oil Pan”. 3. Remove the water pump. Refer to the “Water Pump” in the cooling system section. 4. Remove the front cover. • Remove the generator adjust plate. (6HK1 only)

7. 8. 9. 10. 11. 12.

Fan Belt Water Pump Pulley Spacer Fan ASM Adjusting Plate Generator

• Remove the oil relief valve (arrow), loosen the front cover installation bolts and remove the front cover.


1 1

WSHK0243

Installation 1. Install the front cover. • Clean the cylinder block front surface. In particular, remove liquid gasket leaked during installation of the crankcase.

Name 1. O-Ring 6HK1

• Install two O-rings and apply liquid gasket (ThreeBond 1207B or equivalent), or each equivalent along with the groove of the front cover installation surface. Beat width Beat height

1.5 – 5mm (0.059 – 0.20 in) 0.3 mm – 1.5 mm (0.012 – 0.059 in) from the surface

1

joint

• Install within seven minutes after applying liquid gasket. Caution: Apply liquid gasket so that it does not adhere to the Oring.

020EY00062

Name 1. O-Ring • Align with the knock pin of the cylinder block and install the front cover. Caution: Along with the front cover, install the water pump ASM (before liquid gasket hardens). 4HK1 Tightening torque Front cover bolt (1): 23.5 N⋅m (2.4 kg⋅m/17 lb ft) Front cover bolt (2): 52 N⋅m (5.3 kg⋅m/38 lb ft) Front cover bolt (3): 23.5 N⋅m (2.4 kg⋅m/17 lb ft)

ENGINE MECHANICAL (4HK1, 6HK1) 1A-123 • Tighten the oil relief valve (4) to the specified torque. Tightening torque Oil relief valve: 39 N⋅m (4.0 kg⋅m/29 lb ft)

1

WSHK0032

WSHK0233

Name 1. Bolt: L = 35 2. Bolt: L = 30 3. Bolt: L = 65 4. Oil Relief Valve 6HK1 Tightening torque Front cover bolts (13 bolts): 18 N⋅m (1.8 kg⋅m/13 lb ft) • Tighten bolt with (*) mark together with the adjust plate of the generator. • When you remove the stud bolt (1), install in original position. Tightening torque Stud bolt for water pump: 12.7 N⋅m (1.3 kg⋅m/9.4 lb ft)

2. Install the water pump. Refer to the “Water Pump” of the section of the “Cooling System” 3. Install the oil pan. Refer to “Oil Pan”. 4. Install the front oil seal. Refer to “Crankshaft Front Oil Seal”.

1A-124 ENGINE MECHANICAL (4HK1, 6HK1) Torque Specifications 4HK1 N m{kg m/lb ft}

23.5 {2.4 / 17}

52 {5.3 / 38}

39 {4 / 29}

WSHK0241

ENGINE MECHANICAL (4HK1, 6HK1) 1A-125 6HK1 N m(kg m/lb ft)

39 (4 / 29)

20 (2 / 14)

39 (4 / 29)

18 (1.8 / 13)

WSHK0164


Crankshaft Front Oil Seal Components

* 4HK1 is shown for illustration. Name 1. Crankshaft Pulley

Removal 1. Drain coolant. 2. Remove the starter. • Disconnect the starter ground cable. • Unscrew two mounting nuts, upper and lower, from the starter to dismount the starter from the flywheel housing.

2. Crankshaft Front Oil Seal

4HK1


Special tool Crankshaft stopper: x-xxxx-xxxx-x (xx-xxxxx)

WSHK0030 3. Disconnect the upper radiator hose on the engine side. 4. Disconnect the coolant reserve tank hose on the radiator side. 5. Disconnect the lower radiator hose on the engine side. 6. Remove the radiator (with the fan guide) detaching right and left brackets. 7. Remove the fan ASM. • Remove the fan ASM unscrewing four mounting bolts.

10. Remove the crankshaft front oil seal. • Remove the oil seal off with a screwdriver or the like avoiding damage to the oil seal contact surface on the front cover and the shaft.

8. Remove the fan belt. 9. Remove the crankshaft pulley. • Loosen the pulley nut blocking the crankshaft from turning by placing a crankshaft stopper on the starter mounting position on the flywheel housing. Caution: Make sure that the stopper is properly fitted and engaged with the ring gear.

Name 1. Felt 2. Slinger 3. Oil Seal Caution: Be sure to replace the slinger and oil seal as a set. 11. Remove the front slinger. • Use the slinger remover to remove the front slinger.

1A-128 ENGINE MECHANICAL (4HK1, 6HK1) Special tool Slinger remover: 1-8521-0027-0 (For 4HK1 and 6HK1) x-xxxx-xxxx-x (For 4HK1) 8-9439-6858-0 (For 6HK1)

WSHK0197

• After pressing in the slinger, make sure that the distance between crankshaft end surface and the slinger is A as specified. WSHK0205

4HK1

Installation 1. Install the front slinger using installer, setting tool. Special tool 4HK1 Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx) 6HK1 Oil seal setting tool: 8-94396-856-0 • Install the slinger (1) to the end of adapter (2). Install the adapter to the crankshaft (3). • Install the slinger sleeve (4) to the adapter. Tighten the center bolt (5) until the sleeve comes in contact with the adapter stopper.

WSHK0206

Distance (A): 40.5±0.3 mm Distance (B): 34±0.1 mm

(1.6±0.01 in) (1.3±0.004 in)


Special tool 4HK1 Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx) 6HK1 Oil seal setting tool: 8-94396-856-0 (Use the parts listed below for the front oil seal.) No.

WSHK0199


Part Name

Oil seal

1

Sleeve (front)

{

2

Adapter (front)

{

3

Adapter ring (front)

{

4

Washer (front)

{

5

Center bolt

{

6

Fixing bolt

{

• Mount the adapter onto the crankshaft with fixing bolts.

(0.7±0.01 in)

Caution: Be sure to replace the slinger and oil seal as a set. 2. Install the crankshaft front oil seal. • Press fit the oil seal using an oil seal installer, setting tool.

Name 1. Adapter • Apply engine oil to the lip of the oil seal and place it on the front side adapter.

Name 1. Oil Seal 2. Adapter (Front) 3. Adapter Ring (Front) 4. Fixing Bolt 5. Sleeve (Front) 6. Washer (Front) 7. Center Bolt

• Put the front side adapter ring in the sleeve and fix the sleeve on the adapter with the center bolt and a washer. • Tighten the bolt until the sleeve touches the adapter to press fit the front oil seal.


Name 1. Oil Seal 2. Adapter Ring 3. Sleeve 4. Bolt and Washer

Name 1. Adapter Ring 2. Sleeve 3. Adapter 4. Oil Seal 6HK1

• After you have press-fitted the front oil seal, confirm the measurement shown (depth from the end surface of the crankshaft to the oil seal) and check for deflection of the oil seal.

WSHK0203

Distance (B): 8.5±0.15 mm

(0.33±0.006 in)

3. Install the damper to the crankshaft pulley. (6HK1) • Tighten in the sequence shown. Tightening torque: 48 N⋅m (4.9 kg⋅m/35 lb ft)


WSHK0033

4. Install the crankshaft pulley. • Apply engine oil to the threads of the fastening bolts. • Install the crankshaft pulley aligning with the knock pins on the crankshaft. • Tighten in the sequence shown. Tightening torque: 200 N⋅m (20.4 kg⋅m/148 lb ft)

Name 1. Crankshaft Pulley 2. Generator 3. Fan Pulley b. Fan belt adjustment • Loosen the adjustment bolt (1) of the AC generator and adjust the fan belt moving the generator. Tightening torque:

5. Install the fan belt. a. Inspection of fan belt deflection • Check with a scale if the belt deflection is within the specified limits when pressure of 98 N (22 lb) is applied mid-way along the belt’s longest run. Also check the belt for damage. Amount of fan belt deflection

mm (in)

for new belt

5.0 – 5.8 (0.19 – 0.23)

for reused belt

6.1 – 6.9 (0.24 – 0.27)

(2) = 24 N⋅m (2.4 kg⋅m/18 lb ft) (3) = 40 N⋅m (4.1 kg⋅m/30 lb ft)

Name 1. Adjusting Bolt 2. Fixing Bolt 3. Fixing Bolt 6. Tighten the fan ASM to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 7. Install the radiator.

1A-132 ENGINE MECHANICAL (4HK1, 6HK1) 8. 9. 10. 11.

Connect the lower radiator hose. Connect the coolant reserve tank hose. Connect the upper radiator hose. Install the starter in the flywheel housing with nuts and tighten to the specified tightening torque.

Tightening torque: 76 N⋅m (7.7 kg⋅m/56 lb ft) • Connect the starter ground cable.

* 4HK1 is shown for illustration. 12. Fill the radiator with coolant.





Illustration







Crankshaft Rear Oil Seal Components

Name 1. Flywheel

2. Crankshaft Rear Oil Seal

Removal 1. Remove the flywheel. Refer to the “Flywheel”. 2. Remove the crankshaft rear oil seal. • Remove the oil seal off with a screwdriver or the like avoiding damage to the oil seal contact surface on the flywheel housing and the shaft.

Name 1. Felt 2. Slinger 3. Oil Seal

ENGINE MECHANICAL (4HK1, 6HK1) 1A-135 3. Use the slinger remover to remove the slinger. Caution: If the oil seal has been removed, both the oil seal and slinger must be replaced as a set. Special tool Slinger remover: 1-8521-0027-0 (For 4HK1 and 6HK1) x-xxxx-xxxx-x (For 4HK1) 8-9439-6858-0 (For 6HK1)

Installation 1. Install the front slinger using installer, setting tool. Special tool 4HK1 Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx) 6HK1 Oil seal setting tool: 8-94396-856-0 • Install the slinger (1) to the end of adapter (2). Install the adapter to the crankshaft (3). • Install the slinger sleeve (4) to the adapter. Tighten the center bolt (5) until the sleeve comes in contact with the adapter stopper.

WSHK0197

• After pressing in the slinger, make sure that the distance between crankshaft end surface and the slinger is A as specified.


WSHK0198

Distance (A): 17.3±0.3 mm Distance (B): 10.8±0.1 mm

(0.7±0.01 in) (0.4±0.004 in)

6HK1

Name 1. Adapter (Rear) 2. Fixing Bolt 3. Center Bolt 4. Sleeve (Rear) 5. Collar (Rear) 6. Adapter Ring (Rear) 7. Oil Seal Special tool 4HK1 Oil seal installer kit: x-xxxx-xxxx-x (x-xxxxx) 6HK1 Oil seal setting tool: 8-94396-856-0 No.

WSHK0199


(0.7±0.01 in)

Caution: Be sure to replace the slinger and oil seal as a set. 2. Install the crankshaft rear oil seal. • Press-fit the rear oil seal using an oil seal installer, setting tool.

Part Name

Oil seal

1

Sleeve (rear)

{

2

Adapter (rear)

{

3

Collar (rear)

{

4

Adapter ring (rear)

{

5

Center bolt

{

6

Fixing bolt

{

• Put a collar on the fixing bolt and mount the adaptor onto the crankshaft.


* 4HK1 is shown for illustration. Name 1. Collar 2. Fixing Bolt 3. Adapter

* 4HK1 is shown for illustration. • After you have pressed in the rear oil seal, confirm the measurement shown (depth from the end surface of the crankshaft to the oil seal).

• Apply engine oil to the lip of the oil seal and place it in the rear side adapter. • Put the rear side adapter ring in the sleeve and put the sleeve on the adapter and fix with the center bolt.

* 4HK1 is shown for illustration. Name 1. Sleeve 2. Adapter Ring • Tightening the center bolt until the sleeve touches the adapter to press fit the oil seal.

Name 1. Rear Part of The Crankshaft 2. Oil Seal 3. 4HK1: 7.8 ± 0.3 mm (0.31 ± 0.012 in), 6HK1: 7.5 ± 0.15 mm (0.3 ± 0.006 in) 4. Collar 5. Adapter Ring 6. Sleeve 7. Adapter 3. Install the flywheel. Refer to the “Flywheel”.

1A-138 ENGINE MECHANICAL (4HK1, 6HK1) Special Tool Illustration






Crankshaft Components

* 4HK1 is shown for illustration. Name 1. Upper Bearing 2. Upper Thrust Bearing 3. Gear 4. Crankshaft

Removal 1. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 2. Remove the rocker arm shaft. Refer to “Rocker Arm Shaft ASM”. 3. Remove the camshaft. Refer to “Camshaft ASM”.

5. Lower Bearing 6. Lower Thrust Bearing 7. Crankcase

4. Remove the cylinder head. Refer to the “Cylinder Head”. 5. Remove the fuel supply pump. Refer to “Fuel Supply Pump” in the fuel system section. 6. Remove the crankshaft front oil seal. Refer to “Crankshaft Front Oil Seal”.

1A-140 ENGINE MECHANICAL (4HK1, 6HK1) 7. Remove the crankshaft rear oil seal. Refer to the “Crankshaft Rear Oil Seal”. 8. Remove the oil pan. Refer to “Oil Pan”. 9. Remove the water pump. Refer to the “Water Pump” in the Cooling System Section. 10. Remove the front cover. Refer to the “Front Cover”. 11. Remove the timing gear train. Refer to the “Timing Gear Train”. 12. Remove the oil pump. Refer to the “Oil Pump”. 13. Remove the piston and connecting rod. Refer to the “Pistons and Connecting Rod”. 14. Remove the crankcase. • Gradually loosen crankcase mounting bolts in the sequence shown and remove the crankcase using the replacer holes (arrowed holes in the figure). 4HK1

6HK1

3

7 11

15 19

26

30

34

38

37

33

29

27

31

35

39

36

32

28

2

6 10

22 25

21 17

14 18

23 24

20 16 12 8

13

9

4 1

5

WSHK0034

15. Remove the lower thrust bearing. 16. Remove the lower crankshaft bearings.

* 4HK1 is shown for illustration. 17. Remove the crankshaft ASM. 18. Remove the upper thrust bearing. 19. Remove the upper crankshaft bearings.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-141 Special tool Crankshaft gear puller: 8-9439-6819-0 (EN-41222)


Disassembly 1. Remove the gear. • Remove the gear using a gear puller. Special tool Crankshaft gear puller: 8-9439-6818-0 (EN-47684)

Name 1. Alignment Mark

Inspection 1. Thrust clearance • Set a dial gauge as shown and measure the crankshaft thrust clearance. • If the thrust clearance exceeds the limit, replace the thrust bearings in a pair. Axial play of the crankshaft Standard Limit

mm (in)

0.104 – 0.205 (0.0041 – 0.0081) 0.35 (0.0138)

Caution: Measure the thrust clearance before dismounting.

Reassembly 1. Install the gear. • Heat the gear to 170 – 250°C (338 – 482°F) and install it aligning the groove on the gear with the pin on the crankshaft. • Insert the gear at one push into the flange with its end side with the alignment mark “S” facing outward. If you are fitting the gear while it is cold, beat the gear in until it impinges on the end using the installer.


* 4HK1 is shown for illustration. 2. Main bearing clearance • Remove the crankcase. Set out disassembled main bearings in the order of the numbers. • Remove the crankshaft. Remove the main bearing.

* 4HK1 is shown for illustration. • Place Plastigauge on the crankshaft journal as shown. • Place the lower bearings at original positions on the crankcase.

• Clean the crankshaft journal and the upper and lower bearings. • Check the bearings for damage or excessive wear. If you find damage or excessive wear in the check, replace the bearings in pairs. • Place the upper bearings and the crankshaft on the cylinder block. Install the crankshaft so that it becomes horizontal. Caution: Turn the crankshaft about 30° to allow the bearings to settle in.

• Install the crankcase and tighten bolts to the specified tightening torque. • Tighten the crankcase in the sequence shown using a torque wrench and an angle gauge.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-143 Tightening torque: M14 bolt 4HK1: (1 – 10), 6HK1: (1 – 14) 1st step = 98 N⋅m (10.0 kg⋅m/72 lb ft) 2nd step = 132 N⋅m (13.5 kg⋅m/97 lb ft) 3rd step = 30° – 60° M10 bolt 4HK1: (11 – 27), 6HK1: 15 – 39) 4th step = 37 N⋅m (3.8 kg⋅m/27 lb ft) • Tighten bolts from 1 to 10 (M14) and confirm that they are tightened to a torque of 142 N⋅m (14.5 kg⋅m/105 lb ft) or more. Special tool Angle gauge: 5-8840-0266-0 (J-45059, KM470-B) Caution: Do not rotate the crankshaft after tightening the crankcase. • Loosen the bolts and gently remove the crankcase.

* 4HK1 is shown for illustration. 4HK1

• Measure the widest part of the Plastigauge flattened by tightening the crankcase to determine the clearance. 4HK1 Journal oil clearance

mm (in) Standard

Limit

No.1, 2, 4, 5

0.037 – 0.072 (0.0015 – 0.0028)

0.11 (0.0043)

No.3

0.051 – 0.086 (0.0020 – 0.0034)

0.11 (0.0043)

6HK1 Journal oil clearance 6HK1

37

33 29

14

10

6

2

3

7

11

13

9

5

1

4

8

12

18 15

19 23

27 31

38

34 30

25 21

26 22

17 16

20 24 28 32

3639

35

WSHK0035

mm (in) Standard

Limit

No. 1, 2, 3, 5, 6, 7

0.063 – 0.094 (0.0025 – 0.0037)

0.14 (0.0055)

No. 4

0.093 – 0.124 (0.0037 – 0.0049)

0.14 (0.0055)


• If the journal oil clearance exceeds the limit, replace the main bearings altogether or the crankshaft. • Remove the plastigauge from the bearing and crank pin.

4. Measure the journal and the crank pin diameters and uneven wear. • Measure outer diameters of the journal and the pin and calculate differences between the maximum and the minimum values. Take measurements at four positions for both the journal and the pin.

Inspection of crankshaft • Check the crankshaft journal and crank pin surfaces for wear and damage. Check the oil seal contact surface for excessive wear and damage. • Check the oil port for clogging. 3. Crankshaft run-out Carefully set the crankshaft on the V block. Slowly turn the crankshaft to measure the run-out. If the crankshaft run-out exceeds the limit, replace the crankshaft. 4HK1 Crankshaft run-out Standard Limit

mm (in) 0.05 or less (0.0020 or less) 0.30 (0.012)

4HK1

6HK1

Crankshaft outside diameter

Crankshaft run-out Standard Limit

Standard

Limit

Journal #1, 2, 4, 5

81.905 – 81.925 (3.22460 – 3.22538)

81.85 (3.222)

Journal #3

81.891 – 81.911 (3.22408 – 3.22483)

81.85 (3.222)

Pin

65.902 – 65.922 (2.59456 – 2.59535)

65.850 (2.5925)

mm (in) 0.06 or less (0.0024 or less) 0.45 (0.018)

mm (in)

ENGINE MECHANICAL (4HK1, 6HK1) 1A-145 6HK1 Crankshaft outside diameter

mm (in)

Standard

Limit

Journal No. 1, 2, 3, 5, 6, 7

81.905 – 81.925 (3.22460 – 3.22538)

81.85 (3.222)

Journal No. 4

81.875 – 81.895 (3.22341 – 3.22421)

81.85 (3.222)

Pin

72.902 – 72.922 (2.87015 – 2.87093)

72.850 (2.8681)

Caution: Tufftriding (soft nitriding treatment) is applied to enhance strength of the crankshaft. Therefore, you shall not polish the surface of the crankshaft. Selection of crankshaft bearing • When installing new crankshaft bearings or replacing bearings in use, make reference to the Bearing Selection Table. • Select and install new bearings paying close attention to the cylinder block journal internal diameter grade and the crankshaft journal diameter grade. • Journals are numbered from 1 to 5 (4HK1) or 1 to 7 (6HK1) from left to right when viewed so that the numbers are in normal reading orientation.

Caution: Be careful about difference in the shape of the bearings when installing them.

Name 1. Upper Bearing 2. Oil Gallery 3. Grade Identification Color 4. Oil Groove 5. Lower Bearing 6. Grade Identification Color

1A-146 ENGINE MECHANICAL (4HK1, 6HK1) Bearing selection table 4HK1 Combination of grades

Oil clearance

mm (in)

Cylinder block Grade

Crank journal Grade

Bearing identification color

#1, 2, 4, 5

#3

1

1

Black

0.039 – 0.070 (0.00154 – 0.00276)

0.053 – 0.084 (0.00209 – 0.00331)

1

2

Brown

0.037 – 0.068 (0.00146 – 0.00267)

0.051 – 0.082 (0.00201 – 0.00323)

2

1

Blue

0.041 – 0.072 (0.00161 – 0.00283)

0.055 – 0.086 (0.00217 – 0.00339)

2

2

Black

0.039 – 0.070 (0.00154 – 0.00276)

0.053 – 0.084 (0.00209 – 0.00331)

6HK1 Combination of grades

Oil clearance

mm (in)

Cylinder block Grade

Crank journal Grade

Bearing identification color

#1, 2, 3, 5, 6

#4

1

1

Black

0.065 – 0.092 (0.00256 – 0.00362)

0.095 – 0.122 (0.00374 – 0.00480)

1

2

Brown

0.063 – 0.089 (0.00248 – 0.00350)

0.093 – 0.119 (0.00366 – 0.00469)

2

1

Blue

0.067 – 0.094 (0.00264 – 0.00370)

0.097 – 0.124 (0.00382 – 0.00488)

2

2

Black

0.065 – 0.091 (0.00256 – 0.00358)

0.095 – 0.121 (0.00374 – 0.00476)

Installation 1. Install the crankshaft upper bearing. • Install the upper bearing in the cylinder block and apply oil. Caution: When replacing the crankshaft bearings, select grades referring to the Crankshaft Bearing Grade Selection. Do not apply oil to the bearing installation surface on the cylinder block and external surface of the bearing.

* 4HK1 is shown for illustration. 2. Install the upper thrust bearing.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-147 • Install the upper thrust bearing in the front side of the cylinder block journal No.5 (4HK1) or No.7 (6HK1). In doing this, you may attach the upper thrust bearing to the cylinder block with grease. Then, be sure to wipe up excess grease. Caution: Install the thrust bearing so that the oil groove contacts the crankshaft.

5. Install the lower thrust bearing. • Install the lower thrust bearing in the rear side of the crankcase journal No.5 (4HK1) or No.7 (6HK1). • Install the thrust bearing so that the oil groove contacts the crankshaft.

* 4HK1 is shown for illustration. 3. Install the crankshaft ASM. • Apply engine oil to the crankshaft journal and gently place the crankshaft on the cylinder block.

6. Install the crankcase. • Apply liquid gasket (ThreeBond 1207B or equivalent) to the crankcase forming beads with diameters of 3 – 4 mm (0.12 – 0.16 in).

• Press the crankshaft to the rear and insert the upper thrust bearing in the rear side of the cylinder block journal No.5 (4HK1) or No.7 (6HK1).

• Install the crankcase within 7 minutes after you have applied the liquid gasket.

Caution: Install the thrust bearing so that the oil groove contacts the crankshaft.

* 4HK1 is shown for illustration. 4. Install the lower crankshaft bearing.

• Gently place the crankcase on the cylinder block.


6HK1 mm(in) 2(0.08)

)

.4

(0

10

12(0.47)

2.5(0.1) 5(0.2)

8(0.31)

0.4

)

8(0.31)

8(0.31)

)

59

. (0

15

10(

2.5(0.1)

2.5(0.1) WSHK0036

ENGINE MECHANICAL (4HK1, 6HK1) 1A-149 • Apply Molybdenum Disulfide to M14 bolts’ threads and setting faces and tighten them to the specified tightening torque in the sequence shown.

6HK1

• You need not apply engine oil to M10 bolts. Tightening torque: M14 bolt 4HK1: (1 – 10), 6HK1: (1 – 14) 1st step = 98 N⋅m (10.0 kg⋅m/72 lb ft) 2nd step = 132 N⋅m (13.5 kg⋅m/97 lb ft) 3rd step = 30° – 60° M10 bolt 4HK1: (11 – 27), 6HK1: (15 – 39) 4th step = 37 N⋅m (3.8 kg⋅m/27 lb ft) • Tighten the bolts (M14) from 1 to 10 (4HK1) or 1 to 14 (6HK1) and confirm that they are tightened to a torque of 142 N⋅m (14.5 kg⋅m/105 lb ft) or more. Special tool Angle gauge: 5-8840-0266-0 (J-45059, KM470-B) Caution: Confirm that the crankshaft turns smoothly. 4HK1

37

33 29

14

10

6

2

3

7

11

13

9

5

1

4

8

12

18 15

19 23

27 31

38

34 30

25 21

26 22

17 16

20 24 28 32

3639

35

WSHK0035

7. Install pistons and connecting rods. Refer to the “Pistons and Connecting Rod”. 8. Install the oil pump. Refer to the “Oil Pump”. 9. Install the timing gear train. Refer to the “Timing Gear Train”. 10. Install the front cover. Refer to the “Front Cover”. 11. Install the water pump. Refer to the “Water Pump” in the Cooling System Section. 12. Install the oil pan. Refer to “Oil Pan”. 13. Install the crankshaft rear oil seal. Refer to the “Crankshaft Rear Oil Seal”. 14. Install the crankshaft front oil seal. Refer to “Crankshaft Front Oil Seal”. 15. Install the fuel supply pump. Refer to the “Fuel Supply Pump”. 16. Install the cylinder head. Refer to the “Cylinder Head”. 17. Install the camshaft ASM. Refer to “Camshaft ASM”. 18. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 19. Install the cylinder head cover. Refer to “Cylinder Head Cover”.





8-9439-6818-0 EN-47684 Crankshaft gear remover Rank B

Illustration


8-9439-6819-0 J-41222 Crankshaft gear installer Rank B

ENGINE MECHANICAL (4HK1, 6HK1) 1A-151 Illustration




Cylinder Block Components

* 4HK1 is shown for illustration. Name 1. Cylinder Liner

Removal 1. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 2. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 3. Remove the camshaft ASM. Refer to “Camshaft ASM”. 4. Remove the cylinder head. Refer to the “Cylinder Head”.

2. Cylinder Block

5. Remove the fuel supply pump. Refer to “Fuel Supply Pump” in the fuel system section. 6. Remove the crankshaft front oil seal. Refer to “Crankshaft Front Oil Seal”. 7. Remove the crankshaft rear oil seal. Refer to the “Crankshaft Rear Oil Seal”. 8. Remove the oil pan. Refer to “Oil Pan”.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-153 9. Remove the water pump. Refer to the “Water Pump” in the Cooling System Section. 10. Remove the front cover. Refer to the “Front Cover”. 11. Remove the timing gear train. Refer to the “Timing Gear Train”. 12. Remove the oil pump. Refer to the “Oil Pump”. 13. Remove the piston and connecting rod. Refer to the “Pistons and Connecting Rod”. 14. Remove the crankshaft. Refer to the “Crankshaft”. 15. Remove the piston oil jet

If the cylinder liner cannot be pulled free by hand, tap around the lower side of the liner with a hammer grip or similar object loosen it.

Inspection 1. Carefully remove water stains or other foreign matters on the surface of the cylinder block. • Be careful not to damage the cylinder block. 2. Carefully remove the liquid gasket on the crankcase mounting surface. 3. Clean up the cylinder block. 4. Visually inspect the cylinder block. • Conduct color check and hydraulic (or pneumatic) test and if you find crack or other damage, replace the cylinder block.

5. Cylinder liner wear measurement • Check the internal surface of the liner for flaw or damage. • Measure the liner bore diameter at the most worn part (it wears more in the rotation direction) at 15 – 20 mm (0.59 – 0.79 in) from the top end of the liner with the liner installed in the cylinder block. If the wear is over the application limit, replace it.

16. Remove the cylinder liner.


Cylinder liner bore diameter Standard Limit

mm (in)


115.021 – 115.050 (4.52837 – 4.52952) 115.20 (4.5354)

Caution: You need not select cylinder liner bore grade since the liners are only available in one size. 6. Cylinder block upper face warpage • Pull out the cylinder liners and remove water stains on the cylinder block. • Measure four sides and two diagonals of the top surface of the cylinder block using a straight edge (1) and a thickness gauge (2). • Replace the cylinder block if the measurements exceed limit values. Cylinder block upper face warpage Standard Limit

mm (in)

0.05 or less (0.002 or less) 0.20 (0.079)

Installation 1. Cylinder liner grade selection • Select liner outer diameter grades according to the cylinder block bore grades stamped on the cylinder block at arrowed positions in the figure. • The cylinder liner grade is stamped on the outside of the cylinder liner (1). • Matching the grades of the cylinder block and the liner outer diameter Cylinder block (stamp)

1, 2

3

Liner outside diameter

1X

3X

ENGINE MECHANICAL (4HK1, 6HK1) 1A-155 Cylinder block bore and liner grade (Reference) Grade

(1, 2) / (1X)

mm (in) (3) / (3X)

Cylinder 118.001 – 118.020 118.021 – 118.030 block (4.64699 – 4.64654) (4.64649 – 4.64684) Bore diameter Liner 117.991 – 118.000 118.001 – 118.010 outside (4.64531 – 4.64566) (4.64570 – 4.64605) diameter 1

WSHK0636

4HK1

(Reference) When replacing liners, a “liner set” let you obtain a piston of proper grade for a given liner bore diameter only by specifying a liner outside diameter grade. 2. Install the cylinder liners. • Install the cylinder liners perpendicular to the cylinder block. • Do not hammer the liner or apply excessive forth to insert it. Caution: Clean up and blow with compressed air the cylinder block and the cylinder liners before installing them.

6HK1

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

mm (in)

0.05 – 0.10 (0.0020 – 0.0039)

1A-156 ENGINE MECHANICAL (4HK1, 6HK1) Caution: Be sure to measure the cylinder liner extrusion whenever you have replaced cylinder liners.

4. Install the piston oil jet. • Align the knock pin of the oil jet with the pin hole of the cylinder block and tighten with the check valve. Tightening torque: 21 N⋅m (2.1 kg⋅m/15 lb ft) Caution: Be careful not to deform or damage the oil jet nozzle.

5. Install the crankshaft. Refer to the “Crankshaft”. 6. Install pistons and connecting rods. Refer to the “Pistons and Connecting Rod”. 7. Install the oil pump. Refer to “Oil Pump”. 8. Install the timing gear train. Refer to the “Timing Gear Train”. 9. Install the front cover. Refer to the “Front Cover”. 10. Install the water pump. Refer to the “Water Pump” in the Cooling System Section. 11. Install the oil pan. Refer to “Oil Pan”. 12. Install the crankshaft rear oil seal. Refer to the “Crankshaft Rear Oil Seal”. 13. Install the crankshaft front oil seal. Refer to “Crankshaft Front Oil Seal”. 14. Install the fuel supply pump. Refer to “Fuel Supply Pump” in the Fuel System section. 15. Install the cylinder head. Refer to the “Cylinder Head”. 16. Install the camshaft ASM. Refer to “Camshaft ASM”. 17. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 18. Install the cylinder head cover. Refer to “Cylinder Head Cover”.


Lubrication System Precautions on Service Work • During each disassembly, remove the old gasket adhering to each part and mating part completely using a scraper at the location, where the fluid gasket is to be used, clean the traces of oil, moisture, and dirt completely using waste cotton and apply the specified new fluid gasket at each location.

• Avoid excessive or insufficient coating volume. Note that seizure may occur in case of excessive coating due to clogging of the oil gallery and oil jet, and oil and water leakage may occur if the coating is insufficient. • Always, the start and end of the application should be overlapped. Explanations on functions and operation The lubrication system uses the filter element combined with a full flow bypass, water-cooled oil cooler, and oil jet for piston cooling.

Lubricating system diagram

1A-158 ENGINE MECHANICAL (4HK1, 6HK1) Function Check

Oil Temperature 85 (185 F) 1000 (145.0)

Oil pressure check

Special tool Oil pressure gauge: J43620-20 Hose: J43630 Connector (4HK1 only): J43630-14 Oil pressure testing adapter (4HK1 only): EN-46333

4

900 (130.5) 800 (116.0)

Oil Pressure kPa(psi)

1. Check whether the engine oil is contaminated with dirt, light oil, or water. If contaminated with dirt, light oil, or water (after examining the cause and taking the appropriate measures for light oil or water contamination), replace the oil. 2. Check the engine oil level. The oil level should be between the two holes of the level gauge. If the oil level is insufficient, replenish it. 3. Remove the oil pressure switch on the oil filter body. 4. Install the oil pressure gauge on the oil filter body.

700 (101.5) 600 (87.0) 500 (72.5)

1 2

400 (58.0) 300 (43.5)

3 4

200 (29.0) 100 (14.5) 0 (0)

600

800

1000

1200

1400

1600

Engine speed (rpm)

1800

2000

2200

WSHK0238

Name 1. 4HK1 Oil Pressure (Oil Port) 2. 4HK1 Oil Pressure (Oil Gallery) 3. 6HK1 Oil Pressure (Oil Port) 4. 6HK1 Oil Pressure (Oil Gallery) 5. Warm the engine. 6. Measure the oil pressure, to check whether it is more than 550 kPa (80 psi) at 2000 rpm. 7. Stop the engine. 8. Remove the oil pressure gauge. 9. Install the oil pressure switch. 10. Start the engine and check for oil leakage. Engine oil

1

3

2 WSHK0237

* 6HK1 is shown for illustration. Name 1. Oil Port 2. Oil Gallery 3. Hose 4. Oil Pressure Gauge

• Ensure the engine is at a level ground. Before starting the engine or when 5 minutes or more have elapsed after stopping the engine, check the engine oil volume using the level gauge. The volume is appropriate if the engine oil is between the upper and lower limits of the level gauge. Replenish the engine oil, if level is below the lower limit. Also, check for contamination of the engine oil.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-159 Special Tool Illustration


J-43620-20 Oil pressure gauge Rank B


J-43630 Hose Rank B

J-43630-14 Connector (4HK1) Rank A

J-46333 Oil pressure gauge testing adapter (4HK1) Rank A Name 1. Upper Limit 2. Lower Limit Engine oil leakage • In the lift up condition, confirm that there are no leaks from the cylinder head cover and oil pan.


Oil Port Cover ASM Components

Name 1. Oil Pressure Switch 2. Oil Port Cover

3. O-Ring

Removal 1. Remove the oil pressure switch. 2. Remove the oil port cover. 3. Remove the O-ring.

Installation 1. Install the O-ring on the oil port cover.

Name 1. O-Ring 2. O-Ring

ENGINE MECHANICAL (4HK1, 6HK1) 1A-161 2. Install the oil port cover on the cylinder block and tighten it to the specified torque. Tightening torque: 4HK1 48 N⋅m (4.9 kg⋅m/35 lb ft) 6HK1 39.2 N⋅m (4.0 kg⋅m/29 lb ft)

Name 1. Bolt M10X L = 80 2. Bolt M10X L = 25 3. Install the oil pressure switch to the oil port cover. • Apply the liquid gasket (Loctite 262) on 2 to 3 peaks from the tip of the threaded part of the oil pressure switch and install it at the position shown in the figure. Tightening torque: 41.2 N⋅m (4.2 kg⋅m/30 lb in)


Oil Cooler Components 4HK1

Name 1. Bypass Hose 2. EGR Cooler Water Return Pipe 3. Oil Cooler 4. Common Rail

5. Fuel Supply Pump 6. EGR Cooler Water Feed Pipe 7. Suction Pipe


5

1

2

3

4

WSHK0038 Name 1. EGR Cooler Water Return Pipe 2. Oil Cooler 3. Common Rail

4. Fuel Supply Pump 5. Suction Pipe

Removal 1. Remove the common rail. Refer to the “Common Rail” in the fuel system section. 2. Remove the fuel supply pump.

* 4HK1 is shown for illustration. 3. Remove the EGR cooler water return pipe. • Remove the brackets to the water pipe at two locations to make the pipe unsupported.

1A-164 ENGINE MECHANICAL (4HK1, 6HK1) 4. Remove the EGR cooler water feed pipe. (4HK1) 5. Remove the clip on the head side of the water bypass hose (4HK1) and remove the hose from the suction pipe ASM.

• Screw the removed fixing bolt of the oil cooler into the replacer hole at the location 1 of the figure and remove the oil cooler.

4HK1

* 4HK1 is shown for illustration. 7. Remove the O-ring. Name 1. Bypass Hose 2. EGR Cooler Water Return Pipe 3. EGR Cooler Water Feed Pipe 4. Suction Pipe

Disassembly 1. Remove the element mounting bolts. 2. Remove the element. 3. Remove the O-ring.

6HK1

1

2

WSHK0039

Name 1. Suction Pipe 2. EGR Cooler Water Return Pipe 6. Remove the oil cooler ASM with glow plug controller bracket (4HK1 only).

* 4HK1 is shown for illustration. Name 1. Element 2. O-Ring

Reassembly 1. Install the O-ring on the oil cooler case. 2. Install the element.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-165 3. Tighten the element fixing bolts using the specified torque.

2 (0.08 0.16)

1(0.04)

(0.04

2 0.08)


WSHK0242


* 4HK1 is shown for illustration. Name 1. Element 2. O-Ring

Installation 1. Install the oil cooler ASM. • Apply liquid gasket (ThreeBond 1207B or equivalent) to the flange surface groove (cylinder block). Bead diameter must be between 2 and 4 mm (0.08 and 0.16 in). Refer to the illustration for the offset position (no more than 1 mm {0.04 in}). • Install the O-rings (1) and (2) to the oil passage inlet and outlet. Do not allow the liquid gasket to contact the O-ring.

Name 1. O-Ring 2. O-Ring 3. Liquid Gasket – Align the oil cooler holes with the cylinder block studs. – Install the oil cooler and glow plug controller bracket to the cylinder block. – Tighten the bolts to the specified torque in the order shown in the illustration. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) • Liquid gasket quickly hardens. Make it complete within 7 minutes after applying the liquid gasket. 4HK1


6HK1

1

2

WSHK0040 2. Connect the water suction pipe. • Apply liquid gasket (ThreeBond 1207B) to the flange of the water suction pipe. Bead diameter must be between 2 and 5 mm (0.08 and 0.20 in). Refer to the illustration for the offset position (no more than 1 mm {0.04 in}). (4HK1) • Install the water suction pipe to the oil cooler. Refer to the illustration. • Tighten the bolts to the specified torque.

WSHK0041 Name 1. Gasket 2. Suction Pipe Caution: The water suction pipe must be installed immediately after the oil cooler (the pipe and cooler use the same liquid gasket). 4HK1

Tightening torque: 4HK1: 24 N⋅m (2.4 kg⋅m/18 lb ft) 6HK1: 20 N⋅m (2.0 kg⋅m/15 lb ft) 4HK1

3. Install the EGR cooler water feed pipe. (4HK1) • Install the O-ring on the EGR cooler water feed pipe.

Name 1. Liquid Gasket

• Install at the position shown in the figure and tighten using the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)


4. Install the EGR cooler water pipe. (4HK1) 5. Install the body cover ASM LH on the surface of the oil cooler and cylinder block and tighten it using the specified torque. (4HK1) Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb ft) 6. Remove the oil drain adapter. (4HK1) 7. Install the fuel supply pump. • Refer to “Fuel Supply Pump” in the fuel system section. 8. Install the common rail. • Refer to the “Common Rail” in the fuel system section.


Oil Pan Components

* 4HK1 is shown for illustration. Name 1. Oil Pan Gasket

Removal 1. Drain engine oil. 2. Remove the oil pan.

2. Oil Pan

ENGINE MECHANICAL (4HK1, 6HK1) 1A-169 3. Remove the Oil strainer.

4HK1

WSHK0180

4. Remove the O-ring.

6HK1

Installation 1. Install the oil strainer with new O-ring to the crank case. Tightening torque: M8 Bolt (4HK1): 32 N⋅m (3.3 kg⋅m/24 lb ft) M8 Bolt (6HK1): 24 N⋅m (2.4 kg⋅m/18 lb ft) M10 Bolt: 48 N⋅m (4.9 kg⋅m/35 lb ft)

• Install the gasket using the studs of the crankcase, flywheel housing, and front cover as guide and mount the oil pan. Install the rubber ASM on the oil pan and secure it using nuts and bolts.

WSHK0181

2. Install the oil pan. • At the seam between the cylinder block and the front cover with the flywheel housing, apply the liquid gasket (4H: ThreeBond 1207B or 6H: 1207C) to a bead diameter of 3 mm (0.12 in). • Apply the liquid gasket and install the oil pan within 7 minutes.


6HK1 • Fastening the oil pan from the part of A or B in clock wise order. • It tightens again by specified torque.

6HK1

Tightening torque: 24.5 N⋅m (2.5 kg⋅m/18 lb ft)

WSHK0195

Name 1. Oil Pan 2. Gasket 4HK1 • Tighten the locations (1), (2), (3), and (4) as shown in the figure and then tighten others. (In any sequence) Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft)

WSHK0196


Oil Pump Components

* 4HK1 is shown for illustration. Name 1. Oil Pump ASM 2. Spring 3. Ball 4. Split Pin

Removal 1. Drain engine oil. 2. Drain out the cooling water. 3. Remove the cylinder head cover. Refer to “Cylinder Head Cover”. 4. Remove the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 5. Remove the camshaft ASM. Refer to “Camshaft ASM”. 6. Remove the cylinder head ASM. Refer to “Cylinder Head Cover”. 7. Remove the fuel supply pump ASM. Refer to “Fuel Supply Pump” in the Fuel System section. 8. Remove the flywheel. Refer to the “Flywheel”.

5. Driven Gear And Shaft 6. Oil Pump Body 7. Gasket

9. Remove the rear oil seal of the crankshaft. Refer to “Rear oil seal of Crankshaft”. 10. Remove the oil pan.

1A-172 ENGINE MECHANICAL (4HK1, 6HK1) 11. Remove the flywheel housing. • Make sure you remove the bolts shown in the figure.

Disassembly * 4HK1 is shown for illustration. 12. Remove the idle gear A.

1. 2. 3. 4.

Remove the driven gear and shaft. Remove the split pin. Remove the spring. Remove the ball.

Reassembly 1. Install the ball. 2. Install the spring. 3. Install the split pin and fold it according to (1).

13. Remove the oil pump ASM and gasket.

4. Apply engine oil on the driven gear and shaft and mount them on the oil pump body.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-173 • Measure the clearance between the gear surface and the upper surface of the oil pump body using the thickness gauge and square. • If the gap between the gear and the body inner wall exceeds the limit, replace the gear ASM or the driven gear ASM. Clearance between the gear side surface and the upper surface of the oil pump body Standard Limit

mm (in)

0.064 – 0.109 (0.0025 – 0.0043) 0.20 (0.0079)

Inspection 1. Measure the clearance between the gear and the inner wall of the oil pump body. • Measure the clearance between the gear and oil pump body using a thickness gauge. • If the gap between the gear and the body inner wall exceeds the limit, replace the gear ASM or the driven gear ASM. Clearance between the gear and inner wall of the body Standard Limit

mm (in)

0.125 – 0.220 (0.0049 – 0.0087) 0.30 (0.0118)

3. Measure the clearance between the driven gear shaft and the bush. • Measure the outside diameter of the driven gear shaft using a micrometer. Outside diameter of the driven gear shaft Standard Limit

2. Measure the clearance between the gear side surface and the upper surface of the oil pump body.

mm (in)

15.989 – 16.000 (0.62949 – 0.62992) 15.900 (0.62598)

1A-174 ENGINE MECHANICAL (4HK1, 6HK1) 3. Install the idling gear A. • Install the idling gear shaft at the position shown in the figure and apply engine oil on the shaft. • Rotate the crankshaft clockwise and bring the piston of the No.1 cylinder to the top dead center.

• Measure the inside diameter of the bushes of the oil pump body and cylinder block using the dial gauge. • If the clearance between the driven gear shaft and bushing exceeds the limit, replace the driven gear ASM. Clearance between the driven gear shaft and bush Standard Limit

mm (in)

* 4HK1 is shown for illustration. • Match the alignment marks of the crankshaft gear and the idle gear A, and install them on the cylinder block.

0.04 – 0.07 (0.0016 – 0.0028) 0.20 (0.0079)

* 4HK1 is shown for illustration. • Tighten the mounting bolts using the specified torque. Tightening torque: 133 N⋅m (13.6 kg⋅m/98 lb ft)

Installation 1. Install the gasket. 2. Install the oil pump ASM. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)

4. Install the flywheel housing. • Clean the rear side of the cylinder block. Remove the protruding fluid gasket thoroughly, especially, when mounting the crankcase.

ENGINE MECHANICAL (4HK1, 6HK1) 1A-175 • Apply the liquid gasket (ThreeBond 1207B) uniformly on the inside surface of the bolt holes (excluding the bolt holes indicated by arrows) as shown in the figure. • After applying the liquid gasket, quickly install it. 4HK1

Tightening torque: (6HK1) Bolt holes marked with “1” = 96 N⋅m (9.8 kg⋅m/71 lb ft) Bolt holes marked with “2” = 86 N⋅m (8.8 kg⋅m/63 lb ft) Bolt holes marked with “3” = 119 N⋅m (12.1 kg⋅m/88 lb ft) Bolt holes marked with “4” = 53 N⋅m (5.4 kg⋅m/39 lb ft) Bolt holes marked with “5” = 73 N⋅m (7.4 kg⋅m/54 lb ft) Bolt holes marked with “6” = 26 N⋅m (2.7 kg⋅m/19 lb ft) • The seal is tightened from the cylinder block side.

WSHK0235

6HK1

WSHK0043 • Align with the knock pin of the cylinder block and install the flywheel housing. Tightening torque: (4HK1) Bolt holes marked with “1” = 96 N⋅m (9.8 kg⋅m/71 lb ft) Bolt holes marked with “2” = 77 N⋅m (7.9 kg⋅m/57 lb ft) Bolt holes marked with “3” = 38 N⋅m (3.9 kg⋅m/28 lb ft)


6HK1

1 1

2

5

1 6

3

1 3

4

1 1

WSHK0044

ENGINE MECHANICAL (4HK1, 6HK1) 1A-177 5. Install the oil pan. Refer to “Oil Pan”. 6. Install the rear seal of the crankshaft. Refer to “Rear Oil Seal of Crankshaft”. 7. Install the flywheel. Refer to the “Flywheel”. 8. Install the fuel supply pump ASM. Refer to “Fuel Supply Pump” in the Fuel System section. 9. Install the cylinder head ASM. Refer to “Cylinder Head Cover”. 10. Install the camshaft ASM. Refer to “Camshaft ASM”. 11. Install the rocker arm shaft ASM. Refer to “Rocker Arm Shaft ASM”. 12. Tighten the cylinder head cover. Refer to “Cylinder Head Cover”.


Oil Pressure Switch Inspection Check the continuity between the switch terminal and the body grounding in the no-load condition. If there is no connectivity, replace with normal parts.

Circuit check 1. Turn the key switch to ON. 2. Disconnect the oil pressure switch connector, and confirm that the oil pressure-warning lamp lights when the connector on the harness side is grounded. If the warning lamp does not light up, check the circuit between the meter and the oil pressure switch, and repair the disconnected locations.

Cooling System

ENGINE Cooling System TABLE OF CONTENTS Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Precautions on Service Work. . . . . . . . . . . . . . . 1B-2 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 A List of Defective Phenomena . . . . . . . . . . . . . 1B-8 Main Data and Specifications. . . . . . . . . . . . . . . 1B-8 Water Pump (4HK1) . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-12 Water Pump (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1B-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-17 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18 Inspection and Repair . . . . . . . . . . . . . . . . . . . 1B-19 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-20 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24 Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Torque Specifications . . . . . . . . . . . . . . . . . . . . 1B-27

Cooling System

Cooling System

1B-1

1B-2 Cooling System

Cooling System Precautions on Service Work

Explanations on functions and operation

WARNING: Do not remove the radiator cap when the cooling water is at high temperature. Steam or boiling water will gush out and you may be burnt. To open the radiator cap, cover the cap with a thick cloth when the cooling water is cool, release the pressure by slowly turning the cap, and then remove the cap. 4HK1

Cooling water system

Name 1. Water Jacket 2. Drain Plug 3. Oil Cooler 4. Water Pump 5. Drain Cock 6. Radiator 7. Cooling Fan 8. Radiator Cap 9. Heater Core

The cooling water system, which is the forced circulation system, consists of a water pump, thermostat, and radiator as its main components.

10. 11. 12. 13. 14. 15. 16. 17.

Reservoir Tank Air Bleeding Plug Water Outlet Pipe Thermostat (2 units) Thermometer Unit Bypass Route Turbocharger EGR Cooler

Cooling System

1B-3

6HK1

10 9

8

11

14

12 13 7 6

1 4 3

5

2

WSHK0045 Name 1. Water Jacket 2. Drain Plug 3. Oil Cooler 4. Water Pump 5. Drain Cock 6. Radiator 7. Cooling Fan

8. 9. 10. 11. 12. 13. 14.

Radiator Cap Reservoir Tank Water Outlet Pipe Thermostat (2 units) Thermometer Unit Bypass Route EGR Cooler

1B-4 Cooling System Water pump The water pump, which uses the centrifugal impeller system, is driven by the engine fan belt.

* 4HK1 is shown for illustration. Name 1. Fan Center 2. Bearing

3. Impeller 4. Seal Unit

Cooling System

1B-5

Thermostat The thermostat is a wax pellet type and consists of two units, in which one unit (bottom bypass type) has an valve initial opening temperature of 82 °C (180 °F) and the second (inline type) has an valve initial opening temperature of 85 °C (185 °F). It is designed such that the water temperature can be adjusted finely and it is mounted within the thermostat-housing unit.

Name 1. Jiggle Valve 2. Stamp Mark (Valve Initial Opening Temperature) 3. Valve

Function Check Cooling water level check • Check the cooling water level within the reserve tank and the level is appropriate when the cooling water level is within the MAX (upper limit) and MIN (lower limit) range. In case the volume of the cooling water is deficient, remove the reserve tank cap and replenish with a mixture of tap water and engine coolant in the ratio of 1:1 until the level comes close to the MAX line. 4HK1 Standard value Cooling level

water 14 L (14.8 qts) (between MIN and MAX levels)

4. Gasket 5. Piston

6HK1 Standard value Cooling level

water 14.5 L (15.3 qts) (Engine only)

Inspection Cooling water leak check • Use the radiator cap tester and apply a pressure of 200 kPa (29.0 psi) and check for leaks in the locations given below. Check that the radiator hose and heater hose are not damaged or degraded and the hose clamp is not loose.

1B-6 Cooling System Inspection location • Radiator ASM, water pump ASM, radiator hose, heater hose Coolant 1. About the engine coolant concentration • Take the concentration corresponding to the minimum temperature because the freezing temperature varies according to the concentration of the engine coolant. • Use only genuine engine coolant. • Use engine coolant with a mix ratio in the range of 30 to 60% because over heating is likely to occur if the ratio is greater than 60% and corrosion prevention is inadequate if the ratio is less than 30%.

Name 1. Antifreeze Hydrometer 2. Radiator • Fix the temperature of the cooling water being measured in the range of 0 to 50 °C (32 to 122 °F). • Measure the temperature and specific gravity and determine the concentration from the table given below.

Freezing temperature guideline

Mix ratio Liter (qts) Engine coolant

Tap water

Concentration of engine coolant

-18°C (-0.4°F) 4.2 (4.4)

7.8 (8.2)

35%

-25°C (-13°F)

5.0 (5.3)

7.0 (7.4)

42%

-35°C (-31°F)

6.0 (6.3)

6.0 (6.3)

50%

-40°C (-40°F)

6.4 (6.8)

5.6 (5.9)

53%

2. Engine coolant density measurement Methods for measuring specific gravity • Measure the specific gravity and the temperature of the cooling water using an anti-freeze specific gravity meter and thermometer. Take precautionary measures as the boiled cooling water may gush out at high temperatures if the cap is removed. • Use a deep container to suit the height of the specific gravity meter.

Coolant scooping method • Measure the concentration using the coolant scoop.

Cooling System EGR cooler air bleeding procedure When replacing the coolant, bleed air from the EGR cooler with the following procedure. Caution: Be sure to replace the coolant when it is cooled. Loosen the air bleeder plug (1) on the EGR cooler.

1

WSHK0246

3. Pour coolant into the radiator via its opening. 4. Tighten the plug when the coolant spills over from the air bleeder plug. • Replace the copper packing if it is faulty. Caution: • Take care to prevent the spilt coolant from getting the exhaust system parts wet. • Be sure to wipe off the spilt coolant. Tightening torque: 24.5—30.5 N⋅m (2.5—3.1 kg⋅m/ 18—23 lb ft) • Pour coolant into the radiator via its opening again until it is filled. • Bleed air from the engine body coolant with idling the engine.

1B-7

1B-8 Cooling System A List of Defective Phenomena • Engine overheats • Engine overcools Engine overheats Condition Engine overheats

Possible Cause

Correction

Cooling water volume is deficit.

Replenish.

Thermometer unit is defective.

Replace.

Thermostat is defective.

Replace.

Radiator pump is defective.

Replace.

Radiator is clogging.

Clean or replace.

Radiator cap is defective.

Replace.

Engine oil volume is deficient or incorrect engine oil is used.

Replenish or change the engine oil.

Cylinder head gasket is defective.

Replace.

The fan belt is loose.

Adjust.

Exhaust system is clogging.

Clean or replace.

The fuel injection quantity is in surplus.

Diagnose the engine control system.

Fuel injection timing is incorrect.


Starting pressure of fuel injection is low.


Engine overcools Condition Engine overcools

Possible Cause Thermostat is defective.

Correction Replace.

Main Data and Specifications Water pump

Centrifugal impeller system

Pulley ratio

0.950

Thermostat

Wax pellet system

Valve opening temperature

°C (°F)

With jiggle valve 85 (185) Without jiggle valve 82 (180)

Temperature when fully open

°C (°F)

With jiggle valve 100 (212) Without jiggle valve 95 (203)

Cooling System

Water Pump (4HK1) Components

Name 1. Fan 2. Spacer 3. Water Pump Pulley

Removal 1. Drain the coolant. 2. Remove the four mounting bolts and then the fan ASM and spacer, water pump pulley.

4. Fan Belt 5. Water Pump ASM 6. Gasket

1B-9

1B-10 Cooling System

Name 1. Fan 2. Spacer 3. Water Pump Pulley 4. Bolt 3. (2) and (3) that tighten the setting plate and water pump together. Loosen the adjusting bolts (1) in the generator and remove the fan belt.

Name 1. Adjusting Bolt 2. Lock Nut 3. Bolt 4. Remove the water pump ASM while inserting and scraping with the driver at the position shown in the figure.

Name 1. Water Pump 5. Remove the gasket.

Inspection 1. Appearance check • Check for cracks or damage in the pump body. • Check for cracks and corrosion in the impeller. • Check for water leakage from the seal unit. • If you find abnormalities, replace with the water pump ASM. 2. Bearing nut check • Rotate the fan center while pushing it along the radial direction. Confirm that there is no abnormal noise and no excessive play. • If you find abnormalities, replace with the water pump ASM.

Cooling System 1B-11 Installation 1. Install the gasket. 2. Install the water pump ASM. • Mount the water pump to match with the studs of the front cover. 3. Temporarily fit the bolts until the water pump pulley and the spacer and fan are properly seated in the water pump ASM. 4. Mount the fan belt, tighten the adjusting bolts of the generator, and adjust the tension. • Refer to the “Drive Belt”. 5. After fan belt adjustments, tighten the generator using the specified torque.

Name 1. Fan ASM 2. Spacer 3. Water Pump Pulley 4. Bolt 7. Pour coolant.

Name 1. Adjusting Bolt 2. Lock Nut 3. Bolt 6. After the fan belt adjustments, tighten the temporarily fitted fan pulley and spacer and fan using the specified torque. Tightening torque: M8: 24 N⋅m (2.4 kg⋅m/18 lb ft) M10: 45 N⋅m (4.6 kg⋅m/33 lb ft)

1B-12 Cooling System Torque Specifications

52(5.3 / 38)

24(2.4 / 18) 76(7.7 / 56)

127(13 / 94)

24(2.4 / 18)

M8:24(2.4 / 18) M10:45(4.6 / 33) WSHK0247

Cooling System

1B-13

Water Pump (6HK1) Removal 1. Loosen the fan fixing nuts to remove the cooling fan.

• Loosen the mounting bolt (2) and the sliding piece nut (1). • Pivot the alternator at the mounting bolt toward the center of the engine.

WSHK0207 WSHK0209

2. Remove the fan guide.

WSHK0208

Name 1. Bolt 2. Washer 3. Rubber mount 4. Rubber mount 5. Guide tube 6. Fan guide 3. Loosen the fan pulley fixing bolts. 4. Remove the fan belt.

1B-14 Cooling System 5. Remove the adapter and fan pulley.

WSHK0210

Name 1. Adapter 2. Fan pulley 3. Water pump 6. Disconnect the bypass hose. 7. Loosen the fixing nuts and bolts from the water pump. 8. Remove the water pump from the front plate. 9. Discard the gaskets.

4. Bypass hose 5. Water duct 6. Water duct

Cooling System Installation 1. Install the water pump with new gaskets to the front plate. Use the locating pin. 2. Tighten the fixing nuts and bolts to the specified torque.

1B-15

6. Clamp the bypass hose. 7. Install the fan pulley and adaptor to the water pump. Tighten the fixing bolts to the specified torque. Tightening torque: 52 N⋅m (5.3 kg⋅m/38 lb ft)

Tightening torque: Nut A: 39 N⋅m (4.0 kg⋅m/29 lb ft) Bolt: 20 N⋅m (2.0 kg⋅m/15 lb ft)

WSHK0213

WSHK0211

3. Install the water duct with new gasket to the cylinder head. Tighten the bolts to the specified torque.

8. Install the fan belt. 9. Adjust the fan belt tension. • Depress the drive belt midway between the alternator and fan pulley. Drive Belt Deflection: 8 - 11 mm (0.31 - 0.43 in)

Tightening torque: Bolt (1) : 221.6 N⋅m (22.6 kg⋅m/163 lb ft) Bolt (2) : 24.5 N⋅m (2.5 kg⋅m/18 lb ft) Water pump Alternator

Crankshaft

WSHK0214

WSHK0212

4. Install the water duct with new gasket to the oil cooler and water pump. Tighten the bolts to the specified torque. Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft) 5. Connect the bypass hose.

1B-16 Cooling System 10. Install the cooling fan. Tighten the fixing nuts to the specified torque. Tightening torque: 52 N⋅m (5.3 kg⋅m/38 lb ft)

WSHK0207

11. Install the fan guide. Tighten the fixing bolts to the specified torque. Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft)

WSHK0208

Name 1. Bolt 2. Washer 3. Rubber mount 4. Rubber mount 5. Guide tube 6. Fan guide

Cooling System

1B-17

Torque Specifications N m(kg m/lb ft)

39(4 /29)

20(2 / 14) 221.6(22.6 / 163)

20(2 / 14)

20(2 / 14)

24.5(2.5 / 18)

52(5.3 / 38)

F06E100076

1B-18 Cooling System Disassembly

WSHK0215

Name 1. Center 2. Dust cover 3. Snap ring 4. Bearing 5. Bearing 6. Spacer 7. Bearing 8. Washer

9. 10. 11. 12. 13. 14. 15. 16.

Shaft Water pump body Dowel pin Seal unit Impeller Gasket Cover Bolt

Cooling System 1. Remove the rear cover from the water pump body. 2. Use a remover 1-8521-0062-0 to remove the impeller from the water pump. 3. Use a puller to remove the water pump center. 4. Remove the dust cover and snap ring. 5. Remove the water pump shaft with ball bearings. • Use a plastic hammer to lightly tap on the water pump shaft from the impeller side.

1B-19

Inspection and Repair Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection. Water pump impeller 1. Check the impeller for corrosion.

WSHK0218 WSHK0216

6. Use a bench press to remove the bearing from the shaft.

Water pump shaft 1. Measure the water pump shaft and center or impeller interference. If the measured interference is less than the specified limit, the pump shaft and / or the center and impeller must be replaced. Pump shaft and center interference: Limit: 0.048 – 0.078 mm (0.0019 – 0.0031 in) Pump shaft and impeller interference: Limit: 0.022 – 0.062 mm (0.0009 – 0.0024 in)

WSHK0217

7. Remove the seal unit.

WSHK0219

1B-20 Cooling System 2. Carefully wipe away any bearing grease. 3. Listen for excessive bearing operating noise.

• Use a bench press to gradually press the water pump shaft down until the bearings are seated correctly.

WSHK0220

Excessive bearing operating severe bearing wear.

noise

indicates

Reassembly

WSHK0222

2. Install the water pump shaft with bearings to the water pump body. • Repack the bearings with multipurpose grease.

1. Install the ball bearing to the water pump shaft. • Apply engine oil to the water pump shaft. • Place the water pump shaft and the bearings on the base plates. • Install the washer (4), ball bearing (3), spacer (2), and bearings (1).

WSHK0223

• Place the water pump body on bench press base plate. NOTE : To prevent damage to the water pump shaft, place soft brass or copper sheets between the base plates and the water pump shaft. WSHK0221

Cooling System • Position the pump shaft with bearings to the water pump body. • Use a bench press to gradually press the water pump shaft into the water pump body. NOTE : Do not drive the bearing into position with a hammer or similar object. Bearing damage will result.

1B-21

4. Install the seal unit to the water pump body. • Press in the seal unit to the specified position using a bench press and installer 1-85220-0470. Seal unit installation position A: 11.0 – 11.6 mm (0.433 – 0.457 in)

WSHK0226 WSHK0224

3. Install the snap ring and dust cover. • Use pliers to install the snap ring into water pump body groove. • Install the dust cover with the flange facing out.

5. Install the water pump impeller to the water pump shaft. • Use a bench press to press in the impeller. • The impeller must be flush with the water pump shaft end. 6. Use a bench press to gradually press the water pump center onto the water pump shaft to the specified dimension.

WSHK0225

WSHK0227

Dimension A:

202.9 mm (7.988 in)

7. Install the rear cover with new gasket to the water pump body.

1B-22 Cooling System Special tool Illustration

Tool Number/Description

1-8521-0062-0 Impeller remover

1-8522-0047-0 Seal unit installer

Cooling System

Thermostat Components

* 4HK1 is shown for illustration. Name 1. Water Outlet Pipe 2. Thermostat

Removal 1. Drain the coolant. Prepare the container for discharging and use it for replenishment when mounting the thermostat. Set the discharge of cooling water such that the water does not flow out of the thermostat housing. 2. Disconnect the water outlet pipe. 3. Remove the thermostat. 4. Remove the gasket from the thermostat.

Inspection • Place the thermostat in water and increase the temperature while stirring it sufficiently. • Measure the temperature when the valve is just opened and when it is fully open.

3. Gasket

1B-23

1B-24 Cooling System Installation

6HK1

1. Mount the gasket on the thermostat and mount it at the position shown in the figure. • The thermostat with the jiggle valve (A) is installed to the left side of the engine. The jiggle valve faces the rear of engine. • Fit the thermostat gasket ensuring that it does not come out of and on top of the external housing on the cylinder head side.

1

WSHK0024

Name 1. Thermostat 2. Connect the water outlet pipe.

A


031EY00026

4HK1

* 4HK1 is shown for illustration. 3. Replenish the cooling water stored during the discharge, and check the volume of the cooling water. Name 1. Thermostat 2. Cylinder Head

Cooling System

1B-25

Drive Belt Components

Name 1. Crankshaft Pulley 2. Generator Drive Belt 3. Bolt 4. Generator

5. 6. 7. 8.

Adjusting Bolt Lock Nut Adjusting Plate Water Pump Pulley

Inspection

Drive Belts Adjustment

Check for the presence of wear or damage in the drive belt and renew the parts if necessary. Check the tension of the belt and adjust if necessary.

Adjustment procedure

Inspection procedure Apply a pressure of 98 N (22 lb) at the center of the long span of each belt and check the deflection of the belt. Deflection of generator drive belt When the belt is new 5.0 to 5.8 mm (0.19 to 0.23 in) When the belt is reused 6.1 to 6.9 mm (0.24 to 0.27 in)

Adjust simultaneously the generator drive belt for adjustment of belt. 1. Loosen the adjusting plate lock nuts and the mounting bolts of generator on the underside of the generator. 2. Rotate the adjusting bolts of generator and adjust the belt (remove and fit). • When replacing the belt, you must always replace both the belts. 3. After adjustments, tighten the adjusting plate lock nuts and the mounting bolts of generator on the underside of the generator using the specified torque. Tightening torque: Lock nut: 76 N⋅m (7.7 kg⋅m/56 lb⋅ft) Bolt: 127 N⋅m (13.0 kg⋅m/94 lb⋅ft)


Name 1. Crankshaft Pulley 2. Bolt 3. Generator 4. Adjusting Bolt 5. Lock Nut 6. Water Pump Pulley 7. Generator Drive Belt

Cooling System Torque Specifications


1B-27


Fuel System

ENGINE Fuel System TABLE OF CONTENTS Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-2 Precautions on Service Work. . . . . . . . . . . . . . .1C-2 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-12 Fuel Filter ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13 Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . .1C-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-14 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-15 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-19 Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-22 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-23 Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . .1C-24 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-26 Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-29 Gauze filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-30 Electromagnetic Pump Filter . . . . . . . . . . . . . . . .1C-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-31 Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32 Components. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-33 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .1C-35 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1C-36 Torque Specifications . . . . . . . . . . . . . . . . . . . .1C-39

Fuel System

Fuel System

1C-1

1C-2 Fuel System

Fuel System Precautions on Service Work Parts of the fuel system such as the internal part of the fuel injector, holes and clearances that form passages for fuel are finished to a very high degree of accuracy. They are therefore highly sensitive to foreign matter and the entry of foreign matter could cause damage to the fuel passage. Therefore, effective measures should be taken to prevent the entry of foreign matter. If water removal agent is used in the fuel then it will absorb moisture in the light oil and may cause rust. Therefore, do not use water removal agent in the fuel tank. When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system. • Before beginning the service procedure, wash the fuel line and the surrounding area. • Perform the service procedures with clean hands. Do not wear work gloves. • Immediately after removing the fuel hose and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe. • Always replace the high-pressure pipe in fuel system with new one if it has been removed. Reuse of it causes damage the seal surface, resulting in fuel leakage. • If parts are to be replaced (fuel hose, fuel pipe, etc.) do not open the new part packaging until installation. Discard gaskets and O-rings and replace them with new ones. Work procedure • The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and common rail. • The eyebolts and gasket must be stored in a clean parts box with a lid to prevent adhesion of foreign matter. • Fuel leakage could cause fires. Therefore, after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.

Fuel System

1C-3

Explanations on functions and operation Fuel system diagram 2

4HK1

3 1

8

9

6 7

5

6HK1

4

8

6

7 9

WSHK0248

Name 1. Common Rail 2. Fuel Filter 3. Electromagnetic Pump 4. Pre-fuel Filter 5. Fuel Tank

6. 7. 8. 9.

Supply Pump Fuel Injector Leak-Off Pipe Fuel Return Pipe

1C-4 Fuel System Removal of Foreign Material between Main Filter and Supply Pump

ZX200-3 class

IMPORTANT: When the bolt at fuel outlet side in main filter is loosened or the hose is removed, remove foreign material between main filter and supply pump. When the main filter or the hose between main filter and supply pump is replaced, remove foreign material between main filter and supply pump. 1. Install the base to the fuel outlet in main filter. : 19 mm : 44±5 N⋅m (4.5±0.5 kgf⋅m, 32±3.69 lbf⋅ft)

Main Filter Fuel Outlet

M1U1-07-014

Bolt Base Clamp

2. Install the hose to the base and secure with the clamp. 3. Remove the hose at the fuel inlet side in supply pump.

Hose

To Supply Pump

W1GR-01-01-001

4HK1 Supply Pump Fuel Inlet


W1GR-01-01-002

W1GR-01-01-003

Fuel System 1C-5 4. Turn the key switch ON and operate the fuel solenoid pump. Put fuel from the hose into the container.

Hose Incorrect

CAUTION: Use the container which can measure beyond 10 liters. Make the hose extend straight in order not to accumulate foreign material inside. Keep away the hose end from the container or fuel in the container in order not to enter foreign material.

Correct

W1GR-01-01-004

Hose

5. When fuel in the container is beyond 4 liters, turn the key switch OFF and stop the fuel solenoid pump.

Container

W1GR-01-01-005

6. Install the hose to the fuel inlet in supply pump and secure with the clamp. 7. Release any pressure in the fuel system. (Refer to Bleeding Air in Fuel System on the Operator’s Manual.) 8. Start the engine. Check for any leaks in fuel system.



W1GR-01-01-002

W1GR-01-01-003

1C-6 Fuel System Caution: • Be careful foreign material does not into the fuel system, because the precise fuel system is used. Common rail 4HK1

Name 1. Flow Damper 2. Pressure Limiter

3. Pressure Sensor

Fuel System 1C-7 6HK1

MFW41DMF000201

Name 1. Flow Damper 2. Pressure Limiter

3. Fuel Inlet 4. Pressure Sensor

1C-8 Fuel System Fuel supply pump 4HK1

Name 1. Fuel Temperature Sensor 2. Suction Control Valve 3. High Pressure Pipe

4. Camshaft Key 5. Camshaft Nut

Fuel System

1C-9

6HK1

2

4

1

3

WSHK0046 Name 1. Fuel Temperature Sensor 2. Suction Control Valve

3. High Pressure Pipe 4. Camshaft Key

1C-10 Fuel System Fuel injector

Fuel filter

Name 1. Terminal Stud 2. Part for Mounting Leak Off Pipe 3. O-ring 4. Part for Mounting Injection Pipe 5. Parts Number 6. ID Plate

Name 1. Priming Pump 2. Air Bleed 3. Case 4. Drain Plug Function check Air bleeding 1. Before starting the engine a. Fit a tray below the fuel filter (below the air bleed plug). b. Turn the key switch to ON, and activate the electromagnetic pump. (on the machine with electromagnetic pump) c. Loosen the plug adequately and operate the priming pump more than 20 times until the fuel near the plug overflows. d. Tighten the plug, and operate the priming pump more than 10 times until it is filled with fuel. After waiting for approximately a minute, loosen the plug and bleed out the air in the fuel filter. (This work must be repeated a minimum of three times until no more air comes out from the plug.)

Fuel System

1C-11

e. Tighten the plug firmly and wipe the fuel in the surrounding area. Operate the priming pump (10 to 15 times) till it is filled with fuel and then send fuel to the engine. 2. After starting the engine a. Start the engine, but do not control the engine speed on machine side. b. After starting, maintain the idling rotation for 5 seconds. c. Increase the engine speed slowly and keep this for three minutes. d. Operate the engine speed to maximum on the machine side. (Repeat this operation several times) e. Return to idling speed. Caution: If the air bleeding work is insufficient then it could lead to faults in the engine. Therefore, the procedures after starting the engine should always be implemented. Water drain It is designed that the float inside of the water sedimenter floats when water accumulates. When the float level goes up to the aluminum body section, be sure to drain the water. Water draining procedure Loosen the air bleed plug at the top of the water sedimenter. Then loosen the drain plug to drain the water inside of it. After draining, tighten each plug securely. Then bleed air from the fuel. Fuel system vacuum check Use this procedure to measure the vacuum (negative pressure) discharge side the fuel system. Important: The fuel pressure/vacuum gauge ASM (gauge (1)) and the fuel pressure/vacuum gauge adapter (adapter (5)) must be cleaned before connecting to the fuel line. Otherwise, foreign material adherent to the tools may damage the fuel supply pump. 1. Disconnect the fuel hose from the fuel filter housing. (fuel supply pump side). 2. Install the adapter. Special tool Fuel pressure/vacuum gauge adapter (4HK1 only): EN-47667 3. Connect the gauge (1) with hose to the adapter (3). Special tool Fuel pressure/vacuum gauge ASM: J-44638

Name 1. Fuel Pressure/Vacuum Gauge ASM 2. Fuel Pipe (Discharge Side) 3. Fuel Pressure/Vacuum Gauge Adapter (4HK1 only) 4. Loosen the air bleeding plug on the supply pump. 5. Use your hand to operate the fuel filter priming pump. Operate the pump until all the air has been bled from the system. 6. Start the engine and allow it to idle. 7. Note the gauge (1) reading. If the reading is normal, go to Step 8. If the fuel vacuum is greater than the specified value, there is a problem in the fuel system. Perform the procedures outlined below. Standard fuel vacuum Less than 17 kPa (170 mbar) • Replace the cartridge fuel filter element. • Check the fuel delivery pipe. If it is clogged, it must be replaced. • Remove the fuel pipe at the fuel filter inlet. Use high-pressure air forced through the fuel pipe to clean the fuel system. Caution: • Remove the fuel filler cap before applying highpressure air.

1C-12 Fuel System • Do not perform this procedure if the fuel tank is nearly full (fuel approaching or flowing into the fuel filler neck). The forced air will spray fuel from the fuel filler neck. 8. Remove the gauge (1) and hose from the adapter (3). 9. Remove the adapter (3). 10. Connect the fuel hose. 11. Use your hand to operate the fuel filter priming pump. Operate the pump until all the air has been bled from the system. 12. Start the engine and allow it to idle. 13. Inspect the fuel system for fuel leakage.



EN-47667 Fuel pressure/vacuum gauge adapter (4HK1) Rank B

J-44638 Fuel pressure/vacuum gauge ASM Rank B

Fuel System 1C-13

Fuel Filter ASM Components

Name 1. Priming Pump 2. Air Bleed 3. Case 4. Drain Plug

Removal 1. Remove the feed hose and the return hose from the fuel filter and plug it so that the fuel does not flow out. 2. Remove the bolts for mounting the fuel filter. 3. Remove the fuel filter ASM.

Installation 1. 2. 3. 4. •

Install the fuel filter ASM. Install the bolts for mounting the fuel filter. Install the feed hose and the return hose. Bleed out the air. Refer to “Fuel System”.

1C-14 Fuel System

Fuel Filter Element Removal 1. Remove the case using the filter wrench. Special tool Main filter wrench: 8-9801-3170-0 2. Remove the Fuel Filter element.

Special tool Main filter wrench: 8-9801-3170-0



8-9801-3170-0 Main filter wrench Rank A

Name 1. Priming Pump 2. Air Bleed 3. Case 4. Drain Plug

Installation 1. Assemble the Fuel Filter element. 2. To simplify air bleed, fill light oil in the case. 3. Tighten the case by hand. During this process take adequate care that the light oil that is inside does not flow out. 4. Use the filter wrench and tighten rotating by 1/3 to 2/3.

Fuel System

Fuel Injector Components 4HK1

1C-15

1C-16 Fuel System 6HK1

9

11 8

7 10 12

6

5

3 4

1 2

WSHK0162

Name 1. Fuel Injection Pipe Clip 2. Fuel Injection Pipe 3. Fuel Injector Leak-Off Pipe 4. Fuel Injector 5. Fuel Injector Clamp 6. Fuel Injector Clamp Bolt

7. 8. 9. 10. 11. 12.

EGR Adapter EGR Cooler EGR Valve Cylinder Head Cover Fuel Injector Harness Bracket Fuel Injector Terminal

The fuel system consists of many tiny holes and spaces that allow the movement of fuel from one place to another. These holes and spaces are milled to extremely high precision. This is especially true of the fuel injectors.

Caution: To avoid electric shock; Set the switch to the ‘OFF’ position and disconnect battery negative cable before checking or repairing the fuel injector, wiring or/and connectors.

The fuel injector is very sensitive to foreign material. Foreign material will result in fuel system breakdown. Exercise great care not to allow the entry of foreign material into the fuel system or fuel injectors during the removal and installation procedure.

Removal 1. Remove the engine harness, the EGR valve, the pressure sensor, and all of the fuel injector connectors. 2. Remove the EGR valve and the EGR adapter.

Fuel System

1C-17

3. Tape the EGR case holes shut to prevent the entry of foreign material. 4HK1

* 4HK1 is shown for illustration. Name 1. Cylinder Head Cover

6HK1 2

1

5. Alternately loosen the fuel injector terminal nuts a little at a time in sequence. Several loosening cycles should be required before the nuts are loose. 6. Loosen the fuel injector harness bracket bolts. Remove the inside connector and the harness bracket. 7. Remove the fuel injector leak-off pipe. 8. Remove the lower cover.

WSHK0163

Name 1. EGR Adapter 2. EGR Valve 4. Remove the cylinder head cover.

* 4HK1 is shown for illustration. Name 1. Harness Bracket 2. Harness Connector 3. Fuel Injector Terminal 4. Fuel Leak Off Pipe

1C-18 Fuel System 9. Remove the fuel injection pipe clips and the injection pipes. Important: Do not reuse the high-pressure pipe in fuel system if it has been removed.

Caution: Do not remove the fuel injector sleeve. Special tool Fuel injector remover: 5-8840-2826-0 (EN-46720) Sliding hammer: 5-8840-0019 (J-23907)

4HK1

6HK1 2 1

Name 1. Sliding Hammer 2. Remover 3. Fuel Injector ASM 11.

WSHK0021

Name 1. Fuel Injection Pipe 2. Pipe Clip 10. Loosen the fuel injector clamp fixing bolts and remove the fuel injectors. If the fuel injectors are difficult to remove, use the fuel injector remover. Install the fuel injector remover to the leak-off pipe attachment part on the fuel injector. Use a sliding hammer to force the fuel injector clamp off the fuel injector.

Mark each fuel injector with the number of the cylinder from which it was removed. Store the fuel injectors in a safe place. Position the fuel injector so that the nozzle is protected.

Caution: • Do not tamper with the electromagnetic portion of the fuel injector. Reduced electromagnetic function will result in injector failure. Recording Injector ID Code Information from the Injector ID plate on the replaced fuel injector housing; Record all numbers of replaced fuel injector's from ID plate.

Fuel System

1C-19

3. Install the fuel injector clamps to the cylinder head. 4. Temporarily tighten the clamp bolts. 5. Apply a thin coat of engine oil to the outer surface of the fuel injector side sleeve nuts. 6. Install the fuel injector pipes to the position shown in the illustration. Important: Replace the high-pressure pipe in fuel system with new one if it has been removed. 7. Use a spanner to carefully the sleeve nuts until the fuel injector pipes contact the fuel injector and common rail. 8. Tighten the fuel injection pipe clips to the specified torque. Tightening torque: 6 N⋅m (0.6 kg⋅m/53 lb in) Name 1. Injector ID Plate 2. Injector ID Code 3. Fuel Injector

Installation Important: Install each of the fuel injectors on its original position. (the cylinder from which it was removed) 1. Install a new gasket and O-ring to each of the fuel injector clamps. Refer to the illustration.

* 4HK1 is shown for illustration. Name 1. Fuel Injection Pipe 2. Pipe Clip 9. Final tighten the injection clamp bolts to the specified torque. Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft) 10. Tighten the injection pipes to the specified torque. Tightening torque: 44 N⋅m (4.5 kg⋅m/32 lb ft) Name 1. Gasket 2. Fuel Injector 3. Bolt 4. Fuel Injector Clamp 2. Apply molybdenum to the threads and seating surfaces of the clamp bolts.


* 4HK1 is shown for illustration. Name 1. Clamp Bolt 2. Sleeve Nut

6HK1

11. Install the nozzle leak off pipes together with the new gaskets. Tighten the pipes to the specified torque. Tightening torque: 12 N⋅m (1.2 kg⋅m/106 lb in)

WSHK0028 14. Install the fuel injector terminal nuts to the injector. 15. Alternately tighten each nut 2 or 3 turns at a time until the specified torque is reached. Tightening torque: 2 N⋅m (0.2 kg⋅m/18 lb in) Caution: Do not overtighten the nuts. Damage to the terminal studs will result. * 4HK1 is shown for illustration. 12. Install the fuel injector harness connectors. Work from the inside out. 13. Install the harness bracket and tighten the bolts to the specified torque. Tightening torque: 4HK1: 48 N⋅m (4.9 kg⋅m/35 lb ft) 6HK1: 22 N⋅m (2.2 kg⋅m/16 lb ft)

Fuel System

1C-21


Name 1. Fuel Injector 2. Harness 3. Terminal Nut 16. Install the gasket to the cylinder head cover. 17. Install the cylinder head cover and tighten the bolts to the specified torque. Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft) 6HK1: 13 N⋅m (1.3 kg⋅m/9.6 lb ft)

* 4HK1 is shown for illustration. Name 1. Cylinder Head Cover 18. Install the gasket to the EGR valve and tighten the bolts to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 19. Install the gasket to the EGR adapter and tighten the bolts to the specified torque.

* 4HK1 is shown for illustration. Name 1. EGR Adapter 2. EGR Valve 20. Attach the engine harness connectors. Each composite connector should make a loud click when it is securely attached. Before Programming the Injector ID Code Important: DO NOT program the fuel injector ID code data unless you are directed by a service procedure or you are directed by a service bulletin. Programming the fuel injector at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming the ECM. • System voltage for machine – There is no charging system concern. All charging system concerns must be repaired before programming the ECM. – Battery voltage is 12 volts or 24 volts (varies depending on the machine). The battery must be charged before programming the ECM if the battery voltage is low. – A battery charger is NOT connected to the machine’s battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or ECM damage. – Turn OFF or disable and system that may put a load on the machine’s battery. • The key switch is in the proper position. DO NOT change the position of the key switch during the programming procedure, unless instructed to do so. • All tool connections are secure. – RS-232

1C-22 Fuel System – The connection at the data link connector (DLC) is secure. – Voltage supply circuit • DO NOT disturb the tool harness while programming. If an interruption occurs during the programming procedure, programming failure or ECM damage may occur. • Surrounding environment – Surrounding temperature must be between 0 and 50°C (32 and 122°F) during the programming procedure. Excessively low or high temperature may cause the programming failure or ECM damage.

– Electromagnetic interference (EMI) on the tool harness and ECM may cause the programming failure or ECM damage. Injector ID Code Programming Procedure Programming of the injector ID code is refered to “Injector Replacement” in the EMPS or EMPS III operating instructions manual.

Torque Specifications 4HK1 : 48 (4.9 / 35) 6HK1 : 22 (2.2 / 16)

N m(kg m/lb ft)

2 (0.2 / 1.5)

4HK1 : 18 (1.8 / 13) 6HK1 : 13 (1.3 / 9.6)

12 (1.2 / 8.9) 30 (3.0 / 22)

24 (2.4 / 17) 6 (0.6 / 4.4) 44 (4.5 / 32) WSHK0047


Fuel System Special Tool Illustration


5-8840-0019-0 J-23907 Sliding hammer Rank B

5-8840-2826-0 EN-46720 Injector remover Rank A

1C-23

1C-24 Fuel System

Fuel Supply Pump Components

* 4HK1 is shown for illustration. Name 1. Fuel Leak Off Pipe 2. Fuel Pipe 3. Fuel Supply Pump 4. O-ring The fuel system consists of many tiny holes and spaces that allow the movement of fuel from one place to another. These holes and spaces are milled to extremely high precision. This is especially true of the fuel injectors. The fuel injector is very sensitive to foreign material. Foreign material will result in fuel system breakdown. Exercise great care not to allow the entry of foreign material into the fuel system or fuel injectors during the removal and installation procedure.

5. 6. 7. 8.

Bracket Bracket O-ring Drive Gear Oil Drain Adapter

Fuel System

1C-25

Removal 1. Remove the intake pipe and case ASM. 2. Remove the fuel pipe and fuel leak-off pipe. Important: Do not reuse the high-pressure pipe in fuel system if it has been removed. 4HK1

* 4HK1 is shown for illustration. 6. Use a gear puller to remove the fuel supply pump gear and the bracket O-ring.

6HK1

* 4HK1 is shown for illustration. 7. Loosen the 3 bolts holding the fuel supply pump bracket. Remove the bracket and the O-ring.

WSHK0048 3. Disconnect the fuel feed hose. 4. Disconnect the connector of fuel temperature sensor and the common rail pressure regulator from the fuel supply pump. 5. Remove the fuel supply pump. Note: A single bolt (1) secures the pump and the flywheel housing.

Caution: • Do not hold the high pressure pipe, during the supply pump removal procedure. • Do not grasp the high pressure pipe, when moving the supply pump form one location to another.

1C-26 Fuel System



Name 1. Fuel Supply Pump 2. O-ring 3. Fuel Supply Pump Bracket

Name 1. Fuel Supply Pump 2. O-ring 3. Fuel Supply Pump Bracket

Installation 1. Install the O-ring to the fuel supply pump. 2. Install the pump to the bracket and tighten the 3 bolts to the specified torque.

3. Align the fuel supply pump shaft key and gear. Install the gear and tighten the nut to the specified torque. There is a round alignment mark on the gear (white paint). Tightening torque: 64 N⋅m (6.5 kg⋅m/47 lb ft)

Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb ft) Caution: Take care not to twist the O-ring.

* 4HK1 is shown for illustration. Name 1. Fuel Supply Pump 2. Fuel Supply Pump Gear 3. Nut

Fuel System 4. Apply white paint to the top of the fuel supply pump gear tooth directly above the stamped ‘O’ mark. Refer to the illustration.

1C-27

6HK1

WSHK0049 * 4HK1 is shown for illustration. 5. Turn the crankshaft in the normal direction of engine rotation until the No. 1 or No. 4 cylinder is at TDC on the compression stroke. Refer to the illustration. 4HK1

6. 7. 8. 9.

Remove the oil drain adapter. Install the O-ring to the fuel supply pump. Align the slits as shown in the illustration. Insert the stud bolts into the guides and temporarily tighten them.

Caution: • If the stud bolts (cylinder block side) have been loosened or replaced, apply Loctite 262 to the recessed portion of the bolts.

* 4HK1 is shown for illustration. • Check that the round alignment mark (white paint) is positioned as shown in the illustration when viewed from the plug hole. If necessary, reposition the gear. • Tighten the stud bolts and the nuts to the specified torque. Tightening torque Nut: 50 N⋅m (5.1 kg⋅m/37 lb ft) Bolt: 76 N⋅m (7.7 kg⋅m/56 lb ft)

1C-28 Fuel System 14. Install the case ASM. • Apply the liquid gasket and mount within 7 minutes. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 4HK1

* 4HK1 is shown for illustration. Name 1. Plug Hole 2. Alignment Mark 10. Apply a light coat of engine oil to the O-ring. 11. Install the oil drain adapter to the plug hole. Tighten the bolts to the specified torque.

6HK1

Tightening torque: 8 N⋅m (0.8 kg⋅m/71 lb in)

WSHK0050 15. Install the fuel pipe and fuel leak-off pipe.

* 4HK1 is shown for illustration. Name 1. Oil Drain Adapter 2. O-ring 12. Connect the fuel temperature sensor and the suction control valve connectors to the fuel supply pump. 13. Connect the fuel feed hose.

Important: Do not reuse the high-pressure pipe in fuel system if it has been removed. 16. Start and idle the engine. Important: In order to make the fuel supply pump characteristic learn into the ECM, let the engine idle until warm-up. If the fuel system DTC' stored in the meantime, once clear DTD and warm-up the engine again.

Fuel System Torque Specifications


1C-29

1C-30

Fuel System

Gauze filter 4HK1

1

2

3 WSHK0249

6HK1

3

2

1

WSHK0250

Name 1. Fuel Supply Pump 2. Eyebolt

Removal 1. Remove the eyebolt. 2. Disconnect the C-ring from the eyebolt and detach the gauze filter. 3. Clean the gauze filter with solvents, then blow dust particles off with compressed air.

3. Gauze Filter

Installation 1. Attach the gauze filter to the eyebolt, then secure it using a C-ring. 2. Install the eyebolt to the supply pump. Tightening torque: 14.6 — 24.6 N⋅m (1.5 — 2.5 kg⋅m/11 — 18 lb ft) 3. Bleed out the air. • Refer to "Fuel System".

Fuel System

1C-31

Electromagnetic Pump Filter

1

2

4 3

WSHK0251

Name 1. Electromagnetic Pump 2. Filter Element

Removal 1. Remove the ground cable that is installed on the electromagnetic pump cover. 2. Turn the pump cover with your hand to remove it and take out the filter element. 3. Clean the filter element with solvents, then blow dust particles off with compressed air.

3. Pump Cover 4. Ground Cable

Installation 1. Insert the filter element to the pump, then attach the cover. 2. Install the ground cable to the cover. 3. Bleed out the air. • Refer to "Fuel System".

1C-32 Fuel System

Common Rail Components 4HK1

Name 1. Fuel Leak Off Pipe 2. Fuel Pipe 3. EGR Valve 4. EGR Cooler 5. EGR Adapter

6. 7. 8. 9.

Injection Pipe Clip Injection Pipe (#1 to #4) Common Rail Common Rail Bracket

Fuel System

1C-33

6HK1

3 6 7 4

5

8

1

2

WSHK0165

Name 1. Fuel Leak Off Pipe 2. Fuel Pipe 3. EGR Valve 4. EGR Cooler Parts of the fuel system such as the internal part of the fuel injector, holes and clearances that form passages for fuel are finished to a very high degree of accuracy. They are therefore highly sensitive to foreign matter and the entry of foreign matter could cause damage to the fuel passage. Therefore, effective measures should be taken to prevent the entry of foreign matter.

Removal 1. Remove the air intake pipe. • Disconnect the connector for the intake air temperature sensor. 2. Remove the fuel leak off hose from the leak off pipe.

5. 6. 7. 8.

EGR Adapter Injection Pipe Clip Injection Pipe (#1 to #6) Common Rail • Cover the removed fuel hose with a lid, keep it facing upward and secure it using wire, etc.

Note: Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel system. 3. Disconnect the connected of common rail pressure sensor, and all the connectors. 4. Remove the EGR valve and the EGR adapter. 5. Tape the EGR case holes shut to prevent the entry of foreign material.


4HK1

6HK1

6HK1 2

1 2

1

WSHK0166

Name 1. EGR Adapter 2. EGR Valve 6. Remove the injection pipe clip and remove the injection pipes. Important: Do not reuse the high-pressure pipe in fuel system if it has been removed. Note: Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel system.

WSHK0167

Name 1. Fuel Injection Pipe 2. Pipe Clip 7. Remove the fuel pipe. Note: Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel system. 8. Remove the clip and the fuel leak off pipe. Note: Cover the areas exposed during part removal to prevent the entry of foreign material into the fuel system.

Fuel System 4HK1

* 4HK1 is shown for illustration. Name 1. Fuel Leak Off Pipe

Name 1. Common Rail Bracket (4HK1) 2. Common Rail

6HK1

Disassembly 1. Remove the fuel pressure limiter. 4HK1

1

WSHK0051 Name 1. Fuel Leak Off Pipe 9. Remove the common rail and the common rail bracket. Caution: • Do not grasp the pressure sensor, during the common rail removal procedure. • Take care not to damage the connector unit of the pressure sensor.

1C-35


6HK1

3

3

1

1

2

2 WSHK0168

WSHK0168

Name 1. Common Rail 2. Pressure Sensor 3. Pressure Limiter

Name 1. Common Rail 2. Pressure Sensor 3. Pressure Limiter

Reassembly

Installation

1. Install the fuel pressure limiter. Tightening torque: 172 N⋅m (17.5 kg⋅m/127 lb ft) 4HK1

1. Tighten the common rail bracket to the specified torque. (4HK1) Tightening torque: 19 N⋅m (1.9 kg⋅m/14 lb ft) 2. Tighten the common rail to the specified torque. Tightening torque: 4HK1: 19 N⋅m (1.9 kg⋅m/14 lb ft) 6HK1: 25 N⋅m (2.5 kg⋅m/18 lb ft) Caution: • Do not grasp the pressure sensor, during the common rail reassembly procedure. • Take care not to damage the connector unit of the pressure sensor.

Fuel System

1C-37

4HK1

* 4HK1 is shown for illustration. Name 1. Common Rail Bracket (4HK1) 2. Common Rail

6HK1

3. Tighten the fuel leak off pipe (1) using the mounting eyebolt and the clip using the specified torque. Tightening torque 4HK1 6HK1 4HK1 6HK1 4HK1 4HK1 6HK1

3 7

(2): (2): (3): (3): (4): (7): (7):

18 N⋅m (1.8 kg⋅m/13 lb ft) 10 N⋅m (1.0 kg⋅m/7.4 lb ft) 12 N⋅m (1.2 kg⋅m/106 lb in) 14.2 N⋅m (1.4 kg⋅m/126 lb in) 8 N⋅m (0.8 kg⋅m/71 lb in) 6 N⋅m (0.6 kg⋅m/53 lb in) 8.8 N⋅m (0.9 kg⋅m/78 lb in)

4. Tighten the fuel pipe (5) using the mounting sleeve nut and the specified torque. Tightening torque (6): 44 N⋅m (4.5 kg⋅m/32 lb ft) (8): 44 N⋅m (4.5 kg⋅m/32 lb ft)

1 6

8

5 2

WSHK0169

5. Tighten the injection pipe and the clip using the specified mounting torque. Important: Replace the high-pressure pipe in fuel system with new one if it has been removed. Injection pipe sleeve nut Tightening torque: 44 N⋅m (4.5 kg⋅m/32 lb ft) Injection pipe clip Tightening torque: 6 N⋅m (0.6 kg⋅m/53 lb in) • Apply a thin coat of engine oil on the periphery of the sleeve nut on the fuel injector side and assemble.


4HK1

6HK1

6HK1 2

1 2

1

WSHK0167

Name 1. Fuel Injection Pipe 2. Pipe Clip 6. Install the gasket to the EGR valve and tighten the bolts to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 7. Install the gasket to the EGR adapter and tighten the bolts to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)

WSHK0166

Name 1. EGR Adapter 2. EGR Valve

Fuel System Torque Specifications 4HK1

1C-39

1C-40 Fuel System 6HK1 N.m (lb ft) N m(kg m/lb

39 (4.0 / 29) 24 (2.4 / 17)

6 (0.6 / 4) 44 (4.5 / 33)

24 {17} (2.4 / 17) 25 (2.5 / 18.4)

8.8 (0.9 / 6.5) 19.6 (2.0 / 14.5)

44 (4.5 {33} / 33)

10 (1.0 / 7.4)

WSHK0172

Engine Electrical

ENGINE Engine Electrical TABLE OF CONTENTS Service Precautions . . . . . . . . . . . . . . . . . . . . . . .1D-2 General Procedure. . . . . . . . . . . . . . . . . . . . . . .1D-2 Charging System. . . . . . . . . . . . . . . . . . . . . . . . . .1D-3 General Description . . . . . . . . . . . . . . . . . . . . . .1D-3 Generator (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . .1D-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-6 Torque Specifications . . . . . . . . . . . . . . . . . . . . .1D-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-7 Generator (6HK1) . . . . . . . . . . . . . . . . . . . . . . . .1D-14 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-14 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . .1D-14 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-15 Disassembly and Inspection of Generator . . . .1D-16 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-20 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-22 Bench Testing. . . . . . . . . . . . . . . . . . . . . . . . . .1D-23 Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . .1D-24 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-24 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .1D-25 General Description . . . . . . . . . . . . . . . . . . . . .1D-25 On-machine Service: Starting System . . . . . . .1D-26 Starter (4HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-28 Torque Specifications . . . . . . . . . . . . . . . . . . . .1D-28 Main Data and Specifications. . . . . . . . . . . . . .1D-29 Starter (6HK1) . . . . . . . . . . . . . . . . . . . . . . . . . . .1D-37 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-37 Sectional view (reference) . . . . . . . . . . . . . . . .1D-38 Output Characteristic (reference). . . . . . . . . . .1D-39 Disassembly and Inspection of Starter. . . . . . .1D-40 Assembly of Starter . . . . . . . . . . . . . . . . . . . . .1D-46 No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . .1D-50 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1D-50 Preheating System . . . . . . . . . . . . . . . . . . . . . . .1D-51 Glow Plug Replacement. . . . . . . . . . . . . . . . . .1D-51 Precautions on Service Work. . . . . . . . . . . . . .1D-52 A List of Defective Phenomena . . . . . . . . . . . .1D-52 Main Data and Specifications. . . . . . . . . . . . . .1D-53

Engine Electrical

1D-1 Engine Electrical


Service Precautions General Procedure When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

Engine Electrical 1D-3

Charging System General Description The main charging system components are the batteries, the generator and the battery discharge indicator light circuit. The generator is a selfrectifying type with a built-in regulator.

ACG

11

10

12

13

3

5

4 2

WSHK0053 Name 1. Generator 2. Lower Mount Bolt 3. Nut 4. Spring Washer 5. Washer 6. Bracket 7. Bracket Mount Bolt

8. 9. 10. 11. 12. 13.

Plate Bolt ACG Adjust Bolt Sliding Piece Washer Adjust Nut

1D-4 Engine Electrical Maintenance The most common indication of charging system troubles is an undercharged or overcharged battery. Since the battery itself may be defective, the first step should be to check its condition. In the case of an undercharged battery, check for battery drain caused by grounds or by accessories left turned on. Keep the generator and all other electrical system terminals clean and tight. A loose or badly corroded terminal connection will create excessive resistance in the system and result in hard starting, dim lights etc. Inspect the generator system at regular intervals and correct any potential causes of trouble before machine performance is affected. Diagnosis of Charging System Trouble in the charging system will be evidenced as one or more of the following three conditions: 1. The battery discharge warning light will stay on. 2. An undercharged battery as evidenced by slow cranking. 3. An overcharge, or overvoltage, condition. Undercharged Battery Inspection 1. Accessories to be sure none were left on for extended periods. 2. Drive belt for proper tension. 3. The ECM main relay has been ON stuck at the key switch OFF position. (Battery voltage is consumed.) 4. Wiring and connections for corrosion or looseness. Overcharge (or Overvoltage) condition A charging rate in excess of 29.5-volts for a prolonged period may cause early electrical system failure. Blown fuses. light bulbs burned out, and even battery failure may result. If this condition exists, test the generator as described under “Generator Output Test” later in this section. Noisy Generator Inspection 1. 2. 3. •

Drive pulley for looseness. Mounting bolts for looseness. Bearings for dirt, damage, or wear. Generator noise may also be caused by worn or damaged diodes and/or starter.

Electrical Tests Before performing the following generator electrical tests on the vehicle, be certain that the system wiring is not defective and generator belts are not slipping. Also, the battery must be fully charged for a valid test of the charging system.

Notice: To avoid damage to the vehicle electrical system, always observe the following precautions: • Do not polarize the generator. • Do not short across or ground any of the terminals in the charging circuit except as specifically instructed herein. • NEVER operate the generator with the output terminal open-circuited. • Be sure the generator and battery have the same ground polarity. • When connecting a charger or booster battery to the battery, connect negative to negative and positive to positive. 1. With the engine control switch “ON” and engine not running, connect a voltmeter from terminal “E” to ground. The voltmeter should show 0 volts. 2. With the engine control switch “ON,” and engine not running, connect a voltmeter from terminal “B” to ground. The voltmeter should read at least 24 volts. 3. With the engine control switch “ON” and the engine not running, connect a voltmeter from white wire side of the connector to ground. The voltmeter should show 24 volts. 4. With the engine control switch “ON” and the engine not running, the “charge” light should be on. This shows that the other circuit in the connection is working. 5. With the engine running and the headlight high beams (if equipped) turned on, read the voltage at the “B” post on the generator. The voltmeter should read at least 24 volts. 6. If steps 1 through 4 are not OK, check connectors in the harness for looseness or corrosion and retest. 7. If step 5 voltage is low, substitute a known good regulator and test again. If the voltage is still low, bench test the generator.

Engine Electrical 1D-5

Generator (4HK1)

Removal • 1. 2. 3. 4. 5.

Battery negative cable. Electrical wiring at the generator. Loosen the adjust nut. Loosen the ACG adjust bolt. Loosen the lower mount bolt. Drive belt

1D-6 Engine Electrical 6. Generator.

2. ACG Adjust bolt. 3. Adjust nut. Tightening torque: Adjust Nut 68 N⋅m (6.9 kg⋅m/50 lb ft)

Installation 1. Generator. Tightening torque: Lower Mount Bolt 127 N⋅m (13.0 kg⋅m/94 lb ft)

4. Electrical wiring at the generator. • Battery negative cable.

Torque Specifications N m(kg m/lb ft)

52(5.3 / 38)

ACG

68(6.9 / 50)

127(13 / 94)

52(5.3 / 38)

WSHK0054

Engine Electrical 1D-7 Specifications

Connector terminal

Isuzu Part No.

8973750170

Nominal output

(V-A)

24-50

Rated speed

(rpm)

5000

Regulator-type Regulated voltage Weight

IC type (V)

28.5±1

(kg)

9.5

Terminal symbol

Lead wire color

Wire specifications

R

R

AEX 0.75f

L

L

AEX 0.75f

1

2

WSHK0101 Name 1. R Terminal 2. L Terminal

Internal connections

B

R

SG

L

IC REGULATOR

E

WSHK0102

1D-8 Engine Electrical Disassembly of generator

5 6

12

7

8 3 11

10 9 13 18 15 14

19

23

21 20 2

1

17 16 22

WSHK0103 Disassembly Procedure 1. Screw 2. Cover 3. Through Bolt 4. Rotor, Front Bracket Assembly 5. Nut, Washer 6. Pulley 7. Fan 8. Collar 9. Screw 10. Retainer 11. Ball Bearing 12. Front Bracket

13. Collar 14. Ball Bearing 15. Rotor Assembly 16. Screw 17. Field Coil Assembly 18. Stator Assembly 19. Holder 20. Regulator Assembly 21. Bolt (B terminal) 22. Condenser 23. Rectifier Assembly Assembly is the reverse order of disassembly.

Engine Electrical 1D-9 Inspection and repair of generator 1. Diode Check the continuity of forward and inverse directions with a tester. Normal diodes show low resistance in forward direction and high resistance in inverse one. Judge that they are faulty other than those above.

WSHK0104 2. Condenser Charge the condenser with a tester (at Ω × 1000 range), and connect a tester lead inversely. Judge it as normal if the needle on a meter deflects a little and returns to the original position. Judge that they are faulty other than those above.

3. Diode for initiating excitation, Resistor Check the continuity between connector terminals R and L with a tester (at Ω × 100 range). Normal diodes and resistors show low resistance in forward direction and high resistance in inverse one. Judge that they are faulty other than those above.

WSHK0106 4. Field coil • To judge the insulating condition of field coil, measure between the protrusion portions and core of the coil with a tester (at Ω × 1000 range). Judge as faulty if it has continuity.

WSHK0107 WSHK0105

1D-10 Engine Electrical • Measure between the protrusion portions of field coil with a tester, and judge as normal if the resistance is about 6.7Ω (20°C {68°F}).

WSHK0108 5. Stator coil • To judge the insulating condition of stator coil, measure between the stator coil and core with a tester (at Ω × 1000 range). Judge as faulty if it has continuity.

WSHK0109

• Judge as normal if there is continuity between N lead of stator coil and three leads.

WSHK0110 6. Bearing • Check if the bearing rotates smoothly or has no noise. If the result of the inspection is unsatisfactory, replace the bearing.

WSHK0111

Engine Electrical 1D-11 Performance test In the performance test of generator, connect as follows and measure the regulated voltage and output current. Actual wiring diagram for performance test of IC regulator built-in generator

5

2

3

SW 1

SW 2

4

1

V

6

E

7

E

WSHK0112 Disassembly Procedure 1. Voltmeter 2. R Terminal 3. L Terminal 4. Charging Lamp 24 V-3 W

5. Clamp Tester Ammeter 6. Battery 24 V 7. Variable Resistor

Regulated voltage measurement of regulator

Measurement of the output current

Close SW1 switch, and warm-up five to ten minutes at approx. 1500 rpm in generator until an ammeter shows 6 A or less. After confirming that an ammeter shows between 2 and 6 A, set the generator between approx. 3000 to 4000 rpm. If an voltmeter shows between 27.5 and 29.5 V, the regulated voltage of regulator is normal. If the ammeter shows 6 A or more, charge the battery for a while or replace it with full-charged battery. Replace the regulator if the voltmeter shows out of range between 27.5 and 29.5 V.

Close SW1 and SW2 switches, and raise the generator speed to 5000 rpm. While keeping the voltmeter showing 27 V, measure the maximum value of output current with a variable resistor. In this time, judge as normal if the output current is 50 A or more.

Specified value of regulated voltage 27.5 V — 29.5 V (+25°C {77°F})

Caution: • Do not cut off battery circuit during generator rotating. • Do not connect to L terminal if the charging lamp (24 V-3 W) is not used. Never connect L terminal and B circuit directly. Diode for excitation may be broken.

1D-12 Engine Electrical Handling of generator Be careful with the following when handling a generator. • Connecting the polarities of battery inversely causes generator diode to be broken. • While the engine runs, NEVER disconnect the wiring of battery terminal and charging circuit. • Wiring connection to terminal must be performed properly according to terminal symbol. • Do not perform megger test on semiconductor device. • Be sure to disconnect the battery terminal (−) before inspection on equipment. • Do not open/close the battery relay switch while the engine runs. • Disconnect the battery terminal when charging from external source such as quick charge. • Do not pour steam cleaner or water directly on it. • After connecting to B terminal and E terminal, tighten them to the following torque. B terminal 4.9 N⋅m {50 kgf⋅cm/43 lb in} E terminal 4.9 N⋅m {50 kgf⋅cm/43 lb in} • Refer to “Belt Adjustment” for tension adjustment of V-belt.

Engine Electrical

1D-13

Trouble and Action Trouble symptom Charging is impossible.

Trouble location

Action to be taken

Wiring and ammeter

Open or short circuit, disconnection

Generator.

Open circuit, short to ground, short circuit in each coil

Replace

Broken diode

Replace

Defective regulator.

Replace

Regulator Insufficient charging

Trouble cause

Repair

Poor contact in terminal of regulator

Repair

Wiring

Open or short circuit, looseness in connection

Repair

Generator.

Looseness of generator driven belt

Repair

Layer or short circuit in field coil

Replace

Layer or short circuit in stator coil

Replace

Defective diode

Replace

Poor contact in each terminal Regulator

Defective regulator. Poor contact in terminal of regulator

Repair Replace Repair

Excessive charging

Regulator


Unstable charging current

Wiring

Intermittent contact or nearly disconnected connection in wiring

Repair

Generator.

Looseness of generator driven belt

Repair

Short circuit or nearly disconnected connection in field coil

Repair

Short circuit or nearly disconnected connection in stator coil

Repair

Poor contact in each terminal

Repair

Regulator Noisy generator

Generator.


Replace

Replace

Poor contact in terminal of regulator

Repair

Improper installation of generator

Repair

Defective bearing Contact of rotor core and stator core

Replace Repair

Defective diode

Replace

Short circuit in stator coil

Replace


Generator (6HK1) Specifications Manufacturer

Mitsubishi Electric Co.

Isuzu Part No.

1-81200-633-0

1-81200-603-2

Model by manufacturer

A009TU3782

A004TU6285

Nominal voltage

(V)

Output current

(A)

Rated speed

24 90

50

(rpm)

Output current/Voltage

5000

(A/V/rpm)

No load voltage

114/27/5000

50/27/5000

(V/rpm)

24/900

Revolution direction

Clockwise

Polarity

(−)

Pulley diameter (P. C. D)

(mm/in)

90/3.543

80/3.150

Charging Circuit

N B 3

4

5

L

2

L R

R

F

6

E

1

7 E 8

WSHK0091 Name 1. Field Coil 2. Stator Coil 3. Diode Trio 4. Charging Lamp

5. 6. 7. 8.

Key Switch Battery 24 V IC Regulator Generator

Charging circuit and internal circuit are shown in the illustration above. Charging system consists of IC regulator built-in generator, battery, charging lamp and wires to connect them.

Engine Electrical

1D-15

Structure

5

6

4 7

8

3

2

1

9 10

Name 1. Rear Bracket 2. IC Regulator 3. Bearing 4. Rectifier 5. Stator This generator has no brush. Main parts are a rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator, bearing, pulley and so on. Moving parts are a rotor and pulley. A field coil is secured to rear bracket. Six main diodes and two additional diodes are used to convert three-phase alternating current, generated in stator coil, into direct current. Among six main diodes, there are three positive diodes and three negative diodes. In addition, three tiny diodes, called trio diode, are used to supply field current. This generator has three terminals, which are B

WSHK0092 6. 7. 8. 9. 10.

Rotor Bearing Pulley Front Bracket Coil Assembly (Field Coil)

terminal (for direct current output), L terminal and R terminal. The L terminal is connected to field coil. Therefore, as well as R terminal, it becomes input terminal for initiating excitation current until the generator starts to generate electric power. It also provides function as output terminal. (Current capacity is 1 A.) The charging lamp will be off if the voltage on L terminal reaches battery voltage. Both bearings are sealed, therefore periodic lubricant is not necessary. IC regulator cannot be disassembled. Handle it as assembly.


Disassembly and Inspection of Generator 9 8 10 7

5 6 4 2 1

3

11 12 13

14 15

Name 1. Nut Washer 2. Pulley, Fan 3. Collar 4. Through Bolt 5. Front Bracket 6. Ball Bearing 7. Retainer 8. Rotor Assembly

WSHK0160 9. 10. 11. 12. 13. 14. 15.

Ball Bearing Screw Cover Rectifier Assembly Regulator Assembly Stator Assembly Field Coil Assembly

Engine Electrical

1D-17

11 10 9 8

6 7 5 3 2 1

4

12 13

14

15 16 17

18

Name 1. Nut Washer 2. Pulley, Fan 3. Key 4. Collar 5. Through Bolt 6. Front Bracket 7. Ball Bearing 8. Retainer 9. Rotor Assembly

Disassembly Caution: To facilitate re-assembly, put alignment marks on front bracket and rear bracket before disassembly. 1. Remove out the four through-bolts. Pry between stator and front bracket with a tip of flathead screwdriver and separate the front bracket pulley rotor assembly from stator rear bracket assembly carefully. Caution: Take care not to damage the stator coil.

WSHK0161 10. 11. 12. 13. 14. 15. 16. 17. 18.

Ball Bearing Field Coil Assembly Connector Set Screw Terminal Set Cover Rectifier Assembly Regulator Assembly Stator Assembly

2. Hold the rotor with a vise without deforming the rotor ball. Remove the nut which fixes pulley, and remove the pulley, fan, spacer and front bracket. Caution: Do not lose a half-moon key when removing the pulley. Caution: To hold the rotor with a vise, grip the portion A. Portion B is not strong enough to be gripped.


B

A

5. To remove the coil assembly from rear bracket, firstly remove the screw A (which fixes coil terminal portion to IC regulator). Removing a screw B (which fixes the coil assembly to rear bracket) prior to screw A may cause damage to terminal portion. Hold the coil assembly by hand not to damage to terminal portion. Then, remove the screw B and remove the coil assembly.

A 1 1

A

WSHK0093 Name 1. Ball 3. If the front bearing needs to be removed, remove the screw which fixes retainer, and push out the bearing using appropriate socket. Caution: Do not remove it if not necessary. Do not reuse the removed bearing. 4. If the rotor bearing needs to be removed, it can be done by a general bearing puller. Caution: Do not remove it if not necessary. Do not reuse the removed bearing.

B

WSHK0094 Name 1. Connector 6. Disconnect the connector. 7. Remove the cap and nut from terminal bolt of rectifier. Pry between rear bracket and B terminal assembly to remove the B terminal. A tube remains on rear bracket. Caution: Do not lose the tube.

Engine Electrical

1D-19

3 2

4

5 6 12 7 8

13 11

9

1

10

WSHK0095 Name 1. IC Regulator 2. Rectifier 3. B terminal 4. Terminal Bolt 5. B terminal 6. Cap 7. Nut

8. 9. 10. 11. 12. 13.

Cap Nut Terminal Bolt Terminal Bolt Terminal Bolt Rectifier


3

2 4

5 1 N

6

WSHK0159 Name 1. IC Regulator 2. Terminal Bolt 3. Nut

4. B terminal 5. Tube 6. Rectifier

8. Remove two screws which fix rectifier and two screws which fix regulator. Remove the stator and rectifier assembly from rear bracket as a unit. Then, remove the IC regulator. 9. Disconnect four lead wires of stator coil and remove the stator from rectifier. 1

Caution: Lead wires of stator coil are soldered (melting point: 230°C {446°F}) on rectifier terminal. Disconnect them quickly (within five seconds) not to heat the rectifier causing damage to diode.

Inspection 1. Stator Check visually for damage, loose connection and discoloration of coil. • Check the continuity between two lead wires of stator coil with a circuit tester. Replace the stator if no continuity is present. • Check the continuity between lead wire of stator coil and core with a circuit tester. Replace the stator if continuity is present.

WSHK0096 Name 1. Stator Coil Lead

Engine Electrical 2. Rotor • Check the bearings for noise, rattle or grease leakage (wipe off if tiny amount of grease). Replace it if faulty. It is easier to check for noise and rattle when it is press-fitted into shaft than when it is a single unit.

1

2

WSHK0097 Name 1. Stator Coil Lead 2. Core

1D-21

4. Rectifier assembly • Check the continuity between positive diode, additional diode positive heat sink on positive side and four diode terminals with a circuit tester. The positive diode has short circuit if continuity is present in both directions. Replace the rectifier assembly. The positive diode has open circuit if no continuity is present in both directions. Replace the rectifier assembly. • Negative diode and additional diode on negative side Check the continuity between negative heat sink and four diode terminals with a circuit tester. The negative diode has short circuit if continuity is present in both directions. Replace the rectifier assembly. The negative diode has open circuit if no continuity is present in both directions. Replace the rectifier assembly. • Diode trio (three tiny diodes) Check the continuity in both directions with a circuit tester. The diode is faulty if continuity is present in both directions or no continuity is in both directions. Replace the rectifier assembly.

3. Coil assembly Measure the resistance between terminal portions with a circuit tester. Replace the coil assembly if the value is out of specified value.

2

1

3

1

WSHK0099 Name 1. Diode Terminal Portion 2. Positive Diode 3. A Part of Negative Diode

2

WSHK0098 Name 1. Terminal 2. Terminal Portion

5. Front bearing Check the bearings for noise, rattle or grease leakage (wipe off if tiny amount of grease). Replace them if faulty. It is easier to check for noise and rattle when the bearing is press-fitted into bracket than when it is a single unit.

1D-22 Engine Electrical 6. Regulator The regulator cannot be checked with a circuit tester. After re-assembling the generator, check it to make sure that regulator controls the voltage for generator.

Assembly Assembly can be performed in the reverse order of disassembly. However, be careful with the following. 1. Lubrication is not necessary. Bearing is filled with grease and is sealed. Caution: Keep a bearing with resin band for rotor shaft away from oil. Wipe off oil on bearing box area of rear bracket. Oil may cause creep. 2. Use a high temperature solder (melting point: 230°C {446°F}). Using a soldering iron (with 180 — 270 watt), soldering must be performed quickly (within five seconds) not to heat the rectifier. 3. Tightening torque • Pulley fixing nut: 132 — 162 N⋅m {13.5 — 16.5 kg⋅m/97 — 119 lb ft} • Through bolt: 12.8 — 18.6 N⋅m {1.3 — 1.9 kg⋅m/9 — 14 lb ft} • Bearing retainer fixing screw: 2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in} • Coil assembly fixing screw: 2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in} • Rectifier fixing screw: 2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in} • Regulator fixing screw: 2 — 5.3 N⋅m {20 — 54 kgf⋅cm/18 — 47 lb in} • Nut for B terminal bolt: 4.9 — 8.7 N⋅m {50 — 88 kgf⋅cm/43 — 77 lb in} 4. Assembly of rear bracket to stator assembly and front bracket to rotor assembly • The rotor bearing and rear bracket are engaged tightly. Heat the bearing box area of rear bracket to 50 — 60°C (122 — 140°F) prior to assembly. • After re-assembling the generator, rotate the pulley to confirm that the rotor rotates smoothly.

Engine Electrical Bench Testing Bench testing is performed as follows. Regulated voltage check 1. Wire as shown in the illustration. Use an ammeter with 100 A rating and a voltmeter with 30 V rating.

1D-23

4. Set the generator speed to approx. 5000 rpm and read an ammeter. If the value is 5 A or less, read indication on a voltmeter. This is regulated voltage. If an ammeter shows 5 A or more, keep charging for a while until it shows below 5 A or replace the battery with full-charged one. If regulated voltage is out of specified value, replace the regulator. Output current test

2

4

A B 1

V

8

3

6

L R 5

7

WSHK0100 Name 1. Voltmeter 2. Ammeter 3. Lamp (24 V, 3 W or less) 4. Key Switch 1 5. Battery (24 V) 6. Key Switch 2 7. Load Resistance 2. Close the switch 1. Leave the switch 2 open. In this time, the lamp comes on. If it does not, check the voltage on L terminal. If the voltage is almost the same as battery voltage, check the generator. If the voltage is low, lamp or the circuit is open. 3. Increase the generator speed gradually. Make sure that the lamp goes off before the speed reaches approx. 1300 rpm. Notice the voltage. If the voltage is not controlled and exceeds 30 V, the IC regulator may be faulty. If the voltage does not exceed battery voltage, the generator does not generate electric power. Check the generator again. If the lamp does not go off, check the generator again.

Output current test is performed to check if the generator generates rated output. 1. After checking regulated voltage, decrease the generator speed until it stops. 2. Close the switch 1. The lamp should come on. 3. Set the value of no load resistance to maximum (minimum current) and close the switch 2. 4. Increase the generator speed to 5000 rpm and keep it. Adjust the load resistance so that output current becomes maximum. Keep this condition 15 minutes and increase in temperature of the generator. 15 minutes later, set the generator speed to the specified speed (2500 and 5000 rpm) and then adjust the load resistance so that output current becomes maximum in this condition. In this time, if indication of ammeter is within specified value, the generator is normal. If it is less than specified value, check the generator again according to “Inspection” page.

1D-24 Engine Electrical Trouble Diagnosis Symptom

Trouble cause

No generation of electric power

a. Defective IC regulator b. Open circuit in field coil

Low output

a. Defective diode b. Defective stator coil c. Defective rectifier d. Internal short circuit in field coil

Too high regulated voltage

a. Defective IC regulator

Noise

a. Defective bearing b. Defective rectifier c. Foreign material in generator

Specifications Item

Standard value and limit

Isuzu Part No. Manufacturer code No. Rated output Output characteristic (hot)

(V-A)

1-81200-633-0

1-81200-603-2

A009TU3782

A004TU6285

24-90

24-50

Voltage

(V)

27

27

Current

(A)

105 or more

42 or more

2,500

2,500

Revolution speed

(r/min)

Voltage

(V)

27

27

Current

(A)

114 or more

50 or more

5,000

5,000

(Ω: at 20°C)

4.3-5.0

4.4-5.1

(V)

28-29

28-29

Clockwise

Clockwise

Revolution speed Field coil resistance

(r/min)

Regulated voltage by regulator Revolution direction (viewed from pulley side)

Engine Electrical

1D-25

Starting System General Description Starter and Glow Plug Relays The starter is a 5 kilowatt, reduction drive model. The gear housing and armature end bearing housings are aluminum. The brush ASM has replaceable brushes. The commutator bars are mica insulated and are undercut.

The starter circuit starts at the batteries. The battery cable goes to the large terminal on the starter. From that terminal wires lead to the engine control switch and the starter relay.

* 4HK1 is shown for illustration. Name 1. Starter 2. Nut Maintenance Keep the starter’s exterior clean. Remove corrosion from the terminals, leads, and connectors. Tighten the starter to engine mounting bolts and the electrical cable retaining nuts.

3. Ground Cable 4. Bolt

1D-26 Engine Electrical Diagnosis of Starting System

On-machine Service: Starting System

No Cranking, No Sound

Maintenance

• Discharged batteries. Check for the cause of the discharged batteries. • Sulfated battery terminals. Clean all the battery terminals and cable ends. • A starter that draws too much current. • Starter relay won’t work. Attempt to start and listen for a “click” at the starter relay. If there is no “click,” check the starter relay control terminals with a test light. If the test light shows that power is getting to the starter relay, check the ground circuit with the test light. If the ground circuit is OK, replace the starter relay. • Engine control switch start circuit won’t close. With the engine control switch turned to start, check the starter relay with a test light. If the test light doesn’t come on, check the starter circuit at the engine control switch with the test light. If the test light comes on, check the harness for an open and repair. If the test light does not come on, replace the engine control switch. • Starter relay power circuit isn’t closing. Attempt to start. The starter relay “clicks.” Check the secondary terminals with a test light. If the test light lights on the battery side only, replace the starter relay. If the test light lights on both terminals, check for an open at the starter. • Starter clicks when start is attempted. Check all power connections for corrosion. Clean connections if corrosion is present. Terminal on starter should have at least 18 volts on it when cranking the engine. If voltage is OK, replace the starter. Slow Cranking, Solenoid Clicks or Chatters • Discharged batteries. Check for cause of discharged batteries. • Check the battery terminal for corrosion. Hint: Test for warm terminals. Clean all the battery terminals and connectors. • Loose or dirty connections. Measure the cranking voltage at the battery terminals. If the voltage is less than 18 volts, load test the battery. If the battery is bad, replace the battery. If the battery is good, repair the starter. If the voltage is 18 volts or more, measure the voltage from the battery NEGATIVE terminal to the engine block. If the voltage is 0.5 volt or more, repair the ground cable and connections. If the voltage is less than 0.5 volt, measure the voltage at the battery cable terminal on the starter. If the voltage is 18 volts or more, repair the starter. If the voltage is less than 18 volts, clean and tighten the positive cable connections. If the voltage is still less than 18 volts, replace the positive cable.

Keep starter terminals and all other terminals in the electrical system clean tight. A loose or corroded connection or terminal will cause excessive resistance in the system that will result in hard starting. At regular intervals, inspect the starting system to locate and correct potential causes of trouble before the system performance is affected. Starting motors do not require lubrication.

Engine Electrical

1D-27

Starter (4HK1)

Removal 1. 2. 3. 4.

Battery negative cable from the battery. Cables and electrical leads from the starter. Two mount nuts. Starter.

1D-28 Engine Electrical Installation 1. Starter 2. Two mount nuts. Tightening torque: Mount nuts 82.4 N⋅m (8.4 kg⋅m/61 lb ft)

Torque Specifications


3. Cables and electrical leads to the starter. 4. Battery negative cable to the battery.

Engine Electrical Main Data and Specifications Model (Manufacturer) Rating

Nikko Electric Industry Co., Ltd

Voltage Power output Time

V

24

kw

5

Sec.

30

Number of pinion teeth

11

Revolution direction (viewed from pinion side) Weight (approx.)

Clockwise N {kg}

78.4 {8}

No load characteristic

Current/Voltage

A/V

85 or less/24

Speed

rpm

3300 or more

Load characteristic

Current/Voltage

A/V

500 or less/18.5

Locking characteristic

Torque

N⋅m {kgf⋅m}

Speed

rpm

1250 or more

Current/Voltage

A/V

1400 or less/9

Torque

N⋅m {kgf⋅m}

28.4 {2.9} or more

88.2 {9.0} or more

1D-29

1D-30 Engine Electrical Connections (Nikko Electric Industry Co., Ltd)

S.S S B

P1

C

C3

P2 B C2

C1

M 2 Fc

Ar

E 1

4

3

WSHK0113 Name 1. Starter Relay 2. Battery S.S Ar Fc C1 C2 C3 P1 P2

Starter switch Armature Field coil Pressure coil Holding coil Starter relay coil Sub contactor Main contactor

3. Motor 4. Magnetic Switch

Engine Electrical

1D-31

Disassembly of starter 24 V

5.0KW (Nikko Electric Industry Co., Ltd) 5

19

18 27

21

17

16 12

20

13 14

4 1

15

26

2

25 24 22 23

3 7 6 8 9

10

11

Name 1. Clip Ring 2. Pinion Stopper, Pinion, Spring 3. Lead Wire 4. Bolt 5. Magnetic Switch 6. Screw 7. Bolt 8. Rear Bracket 9. Brush Holder ASM 10. Yoke ASM 11. Armature 12. Cover 13. Packing 14. Idle Gear

WSHK0114 15. Ball 16. Rubber Bushing 17. Plate 18. Spring 19. Pin 20. Holder 21. Shift Lever 22. E Clip 23. Overrunning Clutch ASM 24. Internal Gear 25. Washer 26. Drive Shaft ASM 27. Front Bracket ASM Assembly is the reverse order of disassembly.

1D-32 Engine Electrical Inspection and repair of starter 1. Magnetic switch Never perform operational check on magnetic switch as single unit. Inspection of coil • Check the pressure coil C1 and holding coil C2 for open circuit using a tester. Check the continuity between magnetic switch and M terminal. It has open circuit if no continuity. (Resistance approx. 1.6Ω)

Contact Point Check Service limit of contact point is judged by damaged condition on contact surface in the following procedure. Measure the load current on starter. Replace it if voltage drop between terminals B and M is 0.3 V or more per 100 A. Caution: Use a digital voltmeter to measure voltage drop. Using an analog voltmeter may damage itself.

WSHK0117 WSHK0115 • Supply 24 V between M terminal of magnetic switch and case, push the plunger by hand, and then release it. It is normal if it is not sucked. Coil is defective if it is sucked.

2. Armature Bentness measurement of shaft Measure with a dial gauge, and repair or replace if bentness is 0.05 mm (0.0020 in) or more.

Caution: Perform this while the magnetic switch is set up.

WSHK0118

WSHK0116

Engine Electrical Inspection of commutator • Check the surface of commutator. File the surface smooth with No.400 to 600 sand paper if it is rough. Repair with a lathe if deflection is 0.1 mm (0.004 in) or more.

WSHK0119 • Measure the depth of undercut and repair if it is 0.2 mm (0.008 in) or less. mm(in)

1D-33

Inspection of armature coil • Using a growler tester, put probe on a armature core. It is normal if probe does not vibrates. • Check with a tester. It is normal if there is no continuity between commutator and shaft.

WSHK0121 3. Field Coil • Check the field coil for open circuit with a tester. It is open circuit if there is no continuity between M terminal in field coil and lead wire on brush side. • Check between field coil and yoke with a tester. It is normal if there is no continuity between them.

2 3 1

0.5-0.8 (0.02-0.03)

WSHK0120

Name 1. Repair is needed 2. Improper repair 3. Good

WSHK0122

Outside diameter of commutator Measure the outside diameter of commutator with a slide-caliper. If the measured value is less than the limit, replace it. mm (in) Standard

Limit

32.4 (1.276)

31.4 (1.236)

4. Overrunning clutch • Rotate the pinion by hand. It is normal if it is rotated smoothly in one direction only. Check the pinion tooth surface. Replace if it has worn or damage. Caution: If the entire overrunning clutch is soaked in liquid when washing it, internal grease flows out, causing seizure.

1D-34 Engine Electrical 6. Bearing • Check if the bearing outer race rotates smoothly by hand.

WSHK0123 5. Reduction gear • Check the reduction gear. It is normal if it has no wear.

WSHK0125 7. Brush height • Measure the brush height. If it is less than the limit, replace the brush. mm (in)

WSHK0124

Standard

Limit

17 — 18 (0.669 — 0.709)

10 (0.394)

Engine Electrical Handling of starter 1. Precautions on handling • Improper gap between pinion and ring gear causes faulty mesh. (Gap 2 — 5 mm {0.079 — 0.197 in}) • Also, the front bracket is installed on the engine side securely. • Be sure to turn off the battery switch before removal/installation of stater. • Tightening/inserting wiring must be performed properly. Improper work causes starting trouble due to high contact resistance. 2. Precautions on starting • Be careful with charging status of battery. Insufficiently-charged battery causes starting trouble. • After checking engine starting, turn off the stater switch immediately. • One continuous use should be less than 10 seconds. If re-starting is needed, wait until the pinion stops completely. • If the starter does not stop rotating when the starter switch is turned off, turn off the battery switch immediately. In this case, check the wiring, switch, etc.

1D-35

1D-36 Engine Electrical Trouble countermeasure Trouble symptom Starter does not operate when starter switch is turned on.

Pinion moves forward but it does not engage with ring gear.

Trouble cause 1.

Full discharge of battery

2.

Open circuit, poor contact

3.

Poor contact in starter switch or improper tightening of terminal

4.

Poor contact in starter relay or plug terminal

5.

Short or open circuit in magnetic switch coil

1.

Insufficient capacity of battery

2.

Improper gap of pinion and ring gear

3.

Wear of pinion or ring gear tooth edge

4.

Dust on pinion shaft

5.

Insufficient auxiliary rotation of armature due to insufficient thrust gap of motor

Pinion engages and rotates motor but it does not run engine.

1.

Slippage of clutch

2.

Breakage of reduction gear

Pinion engages but it does not run engine.

1.

Insufficient capacity of battery

2.

Too high rotational resistance of engine

3.

Improper tightening of wiring circuit terminal

4.

Short circuit of armature or field coil

5.

Contamination of commutator

6.

Fatigue or wear of brush spring

7.

Locking of bearing

8.

Poor contact in magnetic switch

When turning starter switch off, starter does not stop after engine starts.

1.

Retuning failure of starter switch contact

2.

Retuning failure of starter relay contact

3.

Short circuit in magnetic switch coil

Engine Electrical

Starter (6HK1) Specifications Manufacturer

Mitsubishi Electric Co.

Isuzu Part No.

181100-4140

Manufacturer code No.

M008T60971

Power output Rating Outside diameter of yoke

(V-kw)

24-5.0

(Sec)

30

(mm/in)

Revolution direction

Right

Protection

Dust-proof, drip-proof

Reduction mechanism

Internal gear

Weight Pinion

(kg) Module

14.5

The number of teeth

11

Gear ratio {ring gear/pinion gear}

12.8 {129/11}

Voltage

(V)

23

Current

(A)

85 or less

Revolution speed Restraint

7.2 3

Pressure angle

No load

85/3.346

(rpm)

3,300 or more

Voltage

(V)

9

Current

(A)

1,400 or less

Torque

N⋅m {kgf⋅m}

Pinion engagement voltage

(V)

88 {9} or more 16.0 or less

1D-37

1D-38 Engine Electrical Sectional view (reference)

5

6

4

7 8

3 2

9 1

13

12

11

10

WSHK0069 Name 1. Through Bolt 2. Bearing 3. Rear Bracket 4. Brush Holder 5. Magnetic Switch 6. Shift Lever 7. Gear Shaft

8. 9. 10. 11. 12. 13.

Pinion Bearing Front Bracket Gear Yoke Armature

Engine Electrical

1D-39

Output Characteristic (reference)

Rotation Rotation speed force

Output Terminal voltage

r/min

N.m

kW

V

6000

120

6

24

5000

100

5

20

4000

80

4

16

3000

60

3

12

2000

40

2

8

Output

Rotation force

Rotation speed

Terminal voltage 1000

20

1

4

0

0

0

0 0

200

400

600

800

1000

1200

1400

1500

Current (A)

WSHK0070


Disassembly and Inspection of Starter Disassembly diagram: disassemble in the order of the numbers.

7

18 27

21

19 9

6

28 29 14 16 17 15 20

4 1

2

5 8

26

3

22

10

25 13

24 12

23 30 11 12

WSHK0071 Name 1. Snap Ring 2. Stop Ring 3. Pinion 4. Pinion Spring 5. Lead Wire with Terminal 6. Screw 7. Magnetic Switch 8. Screw 9. Through Bolt 10. Rear Bracket 11. Yoke Assembly 12. O-Ring 13. Brush Holder 14. Armature 15. Ball

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Plate Packing Packing Plate Planetary Gear Lever E-shaped Retaining Ring Overrunning Clutch Internal Gear Washer Gear Shaft Front Bracket Bearing Washer Brush

Engine Electrical

1D-41

Disassembly Caution: • Before disassembling the starter, put alignment marks on each magnet switch, yoke front bracket and rear bracket to facilitate re-assembly. • In normal condition, if tap the pinion or stop ring toward the front bracket side, the front bracket will be broken. Therefore, tap the stop ring when the pinion come out to cranking position. 1. Connect the starter to battery as shown in the illustration. When closing the switches SW1 and SW2, the pinion move forward to the cranking position and the armature rotates. Then, open the switch SW2 to stop the armature rotating. Caution: Remove the pinion within 10seconds since heat is generated during electric discharge.

SW 1

B SW 2

S M

Battery 24V

5 4 3 2

6

1

WSHK0073 Name 1. Pinion 2. Clutch Shaft 3. Snap Ring 4. Stop Ring 5. Pipe 6. Pinion Spring 3. Remove the nut on M terminal of magnet switch and remove the lead wire with terminal.

Wiring diagram to move pinion forward

Caution: Tightening screw is tight. Use a shock driver to loosen. 4. Remove the brush holder-tightening screw and through bolt. Then, remove the rear bracket and O-ring together.

2. Apply the pipe, which just fits the stop ring, on the ring and tap the pipe with a hammer to remove the stop ring toward the pinion side once. Then, remove the snap ring and remove the stop ring, pinion and pinion spring.

Caution: Do not reuse the removed O-ring. Also, do not reuse also O-ring on tightening screw. 5. Apply a socket (outside diameter 32 mm {1.260 in}) on a commutator of armature. Then, slide the brush on the socket to yoke assembly and O-ring. This facilitates to re-assemble.

Disconnect the lead wire (attached with terminal) from the M terminal.

WSHK0072

Caution: Do not reuse the snap ring.

Caution: Do not reuse the removed O-ring. 6. Remove the brush from brush holder by pulling up the brush spring, and then remove the brush holder. 7. Remove the armature. Remove a bearing using a general puller. 8. Remove the plate in planetary gear and remove the packing. Then, remove the packing and plate on the lever support. 9. Remove the internal gear, gearshift, overrunning clutch and lever as a unit from front bracket.

1D-42 Engine Electrical 10. Remove the lever. Caution: Remember the direction of lever. 11. Remove the two E-shaped retaining ring. To remove the overrunning clutch, rotate the spline by one tooth to remove it from gearshift assembly.

• Check the armature coil for grounding (faulty insulating) with a circuit tester. Replace the armature if grounding is present.

Caution: Do not reuse removed E-shaped retaining ring. 12. Remove the internal gear. In this time, take out one washer which adjusts axial play of gearshift.

Inspection and maintenance 1. Armature • Check the armature coil for internal short circuit with a growler tester. Replace the armature if internal circuit is present.

WSHK0075 • Check the outside of commutator for wear. Replace the armature if wear exceeds limit.

WSHK0074 WSHK0076

Engine Electrical • Check the depth (undercut) of insulating mold of commutator. Remove abrasion powder on brush, and repair if faulty.

1D-43

• Check the coil for grounding (faulty insulating) with a circuit tester. Repair or replace the yoke assembly if grounding is present.

2 3

1

4

WSHK0077 Name 1. Good 2. Insulating 3. Commutator Segment 4. Defective • Check the gears for wear or damage. Replace the armature if fault is present. • Check the bearings for noise, rattle or grease leakage. 2. Field coil • Check the coil for open circuit with a circuit tester. Replace the yoke assembly if open circuit is present.

WSHK0078

WSHK0079 3. Brush • Measure the length of the brush. If it is worn to the limit, replace the brush holder assembly on the brush holder as a unit and only brush on the yoke assembly side. • Make sure the brush moves smoothly in the brush holder. Also, check the brush spring pressure.

1D-44 Engine Electrical • Check the brush holder for grounding (faulty insulating) with a circuit tester. Clean the brush holder before checking. Replace the brush holder assembly if the continuity is present when putting one probe of circuit tester to brush holder plate (metal part) and another one to insulated holder.

2

1

WSHK0081

WSHK0080 Name 1. Brush Length 2. Insulated Holder 4. Overrunning clutch and pinion Hold the housing of overrunning clutch by hand. Make sure that the pinion can be rotated by hand with a light resistance in one direction and cannot be in the opposite direction. Replace the overrunning clutch if faulty. Check the pinion, and replace it if wear or scratch is present.

5. Front bracket Check the bearing and oil seal, and replace the front bracket assembly (including bearing, oil seal) if faulty. 6. Internal gear and planetary gear Check the internal gear and planetary gear, and replace them if excessive wear or damage is present. 7. Lever It the portion which contacts the overrunning switch is worn, the protruded position of pinion will be faulty. (Refer to “4. Assembly” section to adjust the protruded position of pinion.)

Caution: Grease is present in overrunning clutch. Do not use wash oil or cleaning agent for cleaning. Wipe off stain on overrunning clutch with a cloth.

1

WSHK0082 Name 1. Worn Part

Engine Electrical 8. Magnetic switch Check the continuity between the M terminal and the body, and replace the magnet switch if no continuity is present. Then, make sure that no continuity is present between B terminal and M terminal. Replace the magnet switch if continuity is present.

2

1

3

WSHK0083 Name 1. M Terminal 2. S Terminal 3. B Terminal

1D-45


Assembly of Starter Assembly diagram: Assemble in the order of the numbers.

24

13 4

10

12 22

25

3 2 17 15 14 16 11

27 30

29

26 23

5

28

9

21

6 18

7 19

8 1 20 19

WSHK0084

Name 1. Brush 2. Washer 3. Bearing 4. Front Bracket 5. Gear Shaft 6. Washer 7. Internal Gear 8. Overrunning Clutch 9. E-shaped Retaining Ring 10. Lever 11. Planetary Gear 12. Plate 13. Packing 14. Packing 15. Plate

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Ball Armature Brush Holder O-Ring Yoke Assembly Rear Bracket Through Bolt Screw Magnetic Switch Screw Lead Wire with Terminal Pinion Spring Pinion Stop Ring Snap Ring

Engine Electrical 1.

1D-47

Lubricant locations and tightening torque N m(kg m/lb ft)

4.9~8.8 (0.5~0.9 / 3.6~6.5)

I

19.6~25.5 (2.0~2.6 / 14.4~18.8)

C

B

H

F

G

2.4~4.4 (0.25~0.45 / 1.8~3.2)

7.8~12.7 (0.8~1.3 / 5.8~9.4)

E

A

D

WSHK0085

Lubricant locations Shown in the illustration

Lubricant locations

Lubricant agent

A

Sleeve bearing and ball

B

Clutch shaft sliding surface

MULTEMP 6129

C

Spline portion and sliding portion of gearshift

MULTEMP 6129

D

Sliding portion of lever and overrunning clutch

Molycote AG650

E

Armature shift gear, planetary gear, internal gear

Molycote AG650

F

Under pinion

MULTEMP 6129

G

Outer surface of armature bearing (tiny amount)

MULTEMP 6129

H

Oil seal

MULTEMP 6129

I

Surface of plunger (tiny amount)

MULTEMP 6129

2. Axial play of armature shift Adjustment is unnecessary (assemble the ball into a tip of shaft.) 3. Axial play of gear shaft Adjustment is unnecessary Appropriate gap will be obtained automatically when one washer (removed in step 12 of disassembly procedure) is inserted between internal gear and gearshift. 4. Assembly of gearshift

Molycote AG650

Pass the gear shaft through washer, internal gear and overrunning clutch. Then move the overrunning clutch by one tooth of spline to make sure that the clutch cannot be pulled out. Assemble the E-shaped retaining ring. Caution: • Do not reuse removed E-shaped retaining ring.

1D-48 Engine Electrical • If assembling the E-shaped retaining ring prior to the overrunning clutch, the clutch cannot be assembled. Be careful with it. 4 3

3

2

2

5 1

4 5

WSHK0087

1

WSHK0086 Name 1. Overrunning Clutch 2. Washer 3. Gear Shaft 4. E-shaped Retaining Ring 5. Internal Gear 5. Assembly of pinion Assemble the pinion spring, pinion and stop ring to clutch shaft in this order, then assemble the snap ring to the groove of clutch shaft at the end. Then, pull strongly the stop ring toward the snap ring side with a gear puller and fix both of them. Caution: • Assemble the pinion before assembling the magnet switch to front bracket. • Do not reuse the removed snap ring.

Name 1. Pinion 2. Clutch Shaft 3. Snap Ring 4. Stop Ring 5. Pinion Spring 6. Check of the pinion protruded position After assembling the starter, check the protruded position of pinion. How to measure and adjust • Connect the starter to battery. When closing the switches SW1 and SW2, the pinion move forward to the cranking position and the armature rotates. Then, open the switch SW2 to stop the armature rotating.

Engine Electrical • Push into or pull back a tip of the crankshaft lightly by hand and measure the moving distance of it. Adjust by using one or two packings (0.5 mm {0.020 in}) of magnet switch and front bracket so that this measurement value is between 0.5 — 2.0 mm (0.020 — 0.079 in). If this adjustment cannot be done, replace the lever.

SW 1

B SW 2

S M 1

WSHK0088 Name 1. Battery 24 V

Amount of shaft moved

Push back the clutch shaft lightly by hand.

Check of pinion moving out position

WSHK0089

1D-49

1D-50 Engine Electrical No Load Test 1.

After adjusting the protruded position of pinion, connect the starter as shown in the illustration above.

Caution: Use a thick electric wire and tighten the connected portion securely. 2. Close the switch and read the speed, current and voltage. If the measured values are out of specified value, disassemble and inspect again.

2

A

SW

B S M

1

V

3

WSHK0090 Name 1. Battery 24 V 2. Ammeter 3. Voltmeter

Specifications Item No load characteristic

Voltage

(V)

23

Current

(A)

85 or less

Speed Commutator

Standard value or limit

(rpm)

3,300 or more

Outside diameter

(mm/in)

32/1.260

Limit

(mm/in)

31.4/1.236

Undercut

(mm/in)

0.5/0.020

Limit

(mm/in)

0.2/0.008

Length

(mm/in)

18/0.709

Limit

(mm/in)

11/0.433

Pressure

(N)

29 — 39

Limit

(N)

13.7

Protruded position of pinion

(mm/in)

Commutator Brush Brush spring

0.5 — 2.0/0.020 — 0.079

Engine Electrical

1D-51

Preheating System Glow Plug Replacement Precautions during maintenance Adequate care should be taken as over-tightening the glow plug could lead to damage. Removal Procedure 1. Remove the engine harness, the EGR valve, the pressure sensor, and all of the fuel injector connectors. 2. Remove the EGR valve and the EGR adapter. 3. Tape the EGR case holes shut to prevent the entry of foreign material.

Installation Procedure 1. Install the glow plug. Tightening torque: 20 N⋅m (2.0 kg⋅m/15 lb ft) 2. Install and tighten the glow connector with the designated torque. Tightening torque: 1.2 N⋅m (0.1 kg⋅m/11 lb in) 3. Install the EGR valve and the EGR adapter. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft)

* 4HK1 is shown for illustration. Name 1. EGR Adapter 2. EGR Valve 4. Remove the glow plug connector. 5. Remove the glow plug.

* 4HK1 is shown for illustration. Name 1. EGR Adapter 2. EGR Valve 4. Attach the engine harness connectors. Each composite connector should make a loud click when it is securely attached.

1D-52 Engine Electrical Precautions on Service Work Adequate care should be taken as over-tightening the glow plug could lead to damage. Explanations on functions and operation The preheating system consists the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and make the engine easy to start. Glow plug check • Use the circuit tester and measure the resistance of the glow plug. • If the measured value deviates from the specified value, then replace the glow plug. • Resistance value of glow plug is approximately less than 5Ω. Caution: Use glow plugs from the same manufacturer.

A List of Defective Phenomena • The glow indicator lamp does not light up. • Preheating does not work. • Preheating time is too long or too short.

Engine Electrical

1D-53

Trouble Shooting The glow indicator lamp does not light up. Condition

Possible Cause

The glow indicator lamp does not light up.

Correction

Slow blow fuse has blown.

Replace the slow blow fuse.

Fuse is unavailable.

Replace the fuse.

Indicator valve is burnt out.

Replace the indicator valve.

Engine control system is faulty.

Refer to the “Engine Control System”

Preheating does not work. Condition

Possible Cause

Preheating does not work.

Correction

Slow blow fuse has blown.

Replace the slow blow fuse.

Defective or faulty glow plug relay connector contact.

Re-mount or replace the glow plug relay.



Preheating time is too long or too short. Condition

Possible Cause

Preheating time is too long or too short.

Correction

Thermo-sensor fault and break in circuit or short circuit.

Replace the thermo-sensor. Repair the circuit.

Fault in glow plug.

Replace or tighten the glow plug.



Main Data and Specifications Item

Model

Preheating device model Glow plug rated voltage/ current

Glow plug (V-A)

23 – 3.5


Exhaust System

ENGINE Exhaust System TABLE OF CONTENTS EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2 Precautions on Service Work. . . . . . . . . . . . . . . 1F-2 Explanations on Functions and Operation . . . . . 1F-2 EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . . 1F-3 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . 1F-5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6 A List of Defective Phenomena . . . . . . . . . . . . . 1F-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 1F-6 Turbocharger (6HK1) . . . . . . . . . . . . . . . . . . . . . . 1F-7 Table of Specifications . . . . . . . . . . . . . . . . . . . . 1F-7 Turbocharger Structured Diagram . . . . . . . . . . . 1F-8 Disassembly and Inspection of Turbocharger . . 1F-9 Assembly of Turbocharger . . . . . . . . . . . . . . . . 1F-15 Turbocharger (4HK1) . . . . . . . . . . . . . . . . . . . . . 1F-20 Measurement Tool. . . . . . . . . . . . . . . . . . . . . . . . 1F-21 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-21

1F-2

Exhaust System and Turbocharger


1F-1

1F-2 Exhaust System

EGR System Precautions on Service Work

Explanations on Functions and Operation

Perform EGR related assembly according to the usual procedure of temporarily fitting and then permanently tightening the parts so that unnecessary stresses are not applied on the parts.

Re-circulate a part of the exhaust gas of the EGR system in the intake manifold. Reduce the combustion temperature and inhibit NOx generation since inert gases may be mixed up in the intake air. An electronic control system is used in this EGR to balance the requirements of operability and low emissions. A DC motor is operated using the control current of the Engine Control Module (ECM) to control the EGR. Refer to the chapter on Engine Control System for details on fault diagnosis of the EGR system.

Name 1. EGR Cooler 2. Engine Control Module (ECM)

3. EGR Valve DC Motor

Exhaust System 1F-3

EGR Valve and EGR Cooler Components

Name 1. EGR Adapter 2. Cooling Water Pipe (out) 3. EGR Cooler

Removal 1. Drain the coolant. 2. Disconnect the EGR valve connector. 3. Remove the EGR pipe.

4. EGR Pipe 5. Cooling Water Pipe (in) 6. EGR Valve

1F-4 Exhaust System 2. Install the EGR cooler. • Temporarily fit the EGR cooler to the bracket. Notice: Temporarily tighten the bolts. 3. Install the EGR adapter. • Temporarily fit the EGR adapter between the EGR cooler and exhaust manifold. Notice: Temporarily tighten the bolts. 4. Install the EGR pipe. • Insert the gasket between the two ends of the EGR pipe and temporarily fit it.


Notice: Temporarily tighten the bolts. During temporary assembly, tighten the nuts and bolts to the specified torque in the order shown in the illustration.

Name 1. EGR Adapter 2. Cooling Water Pipe (out) 3. EGR Cooler 4. EGR Pipe 5. Cooling Water Pipe (in) 4. 5. 6. 7.

Remove the cooling water pipes. Remove the EGR adapter. Remove the EGR cooler. Remove the EGR valve.

Caution: After removing the EGR valve and EGR adapter, seal so that foreign matter does not enter.

Inspection Gas leak check • Check for gas leak in various parts of the EGR gas line. If the results of the check show abnormalities, repair or replace the defective parts. EGR valve check • Refer to the chapter on Engine Control System for details on the method of checking the EGR valve.

Installation 1. Mount the EGR valve. • Insert the gasket and temporarily fit the EGR valve. Notice: Temporarily tighten the bolts.

* 4HK1 is shown for illustration. Name 1 ~ 9 Show the Order of Tighten Bolts and Nuts. Tightening torque 1, 2: 3, 4, 5, 6:

28 N⋅m (2.9 kg⋅m/21 lb ft) 24 N⋅m (2.4 kg⋅m/18 lb ft)

Exhaust System 1F-5 Torque Specifications


1F-6 Exhaust System

Exhaust System A List of Defective Phenomena • Vibration or rattling noise from the exhaust system • Clogging of exhaust system • Exhaust leakage or noise

Troubleshooting Vibration or rattling noise from the exhaust system Condition Vibration or rattling noise from the exhaust system

Possible Cause Loose or misaligned components

Correction Match the joints and then re-tighten. Or, check for damage in the hanger, mounting brackets and clamps.

Clogging of exhaust system Condition Clogging of exhaust system

Possible Cause Clogging or deformation of the exhaust piping

Correction Repair or replace the exhaust piping.

Exhaust leakage or noise Condition Exhaust leakage or noise

Possible Cause

Correction

Defect or misalignment in mounting

Match the joints and then re-tighten.

Damage or burn-out of exhaust piping or silencer

Replace the damaged part.

Defective components in the exhaust system (clamps, pipes, silencer)

Replace the defective part.

Internal damage to silencer

Replace the silencer

Exhaust System 1F-7

Turbocharger (6HK1) Table of Specifications Item Turbine shaft

Assembly specifications

Service limit

Axial play

mm (in)

0.06 — 0.09 (0.00236 — 0.00354)

0.11 (0.00433)

Radial play

mm (in)

0.10 — 0.17 (0.00394 — 0.00669)

0.205 (0.00807)

Journal outside diameter

(A) mm (in)

—

11.380 (0.44803)

Sealing groove width

(B) mm (in)

—

1.33 (0.05236)

mm (in)

—

0.11 (0.00433)

Runout Sealing insertion part

Turbine side (bearing housing)

(F) mm (in)

—

17.03 (0.67047)

Compressor side (seal plate)

(H) mm (in)

—

14.05 (0.55315)

Oil thrower

Sealing groove width

(G) mm (in)

—

1.52 (0.05984)

Bearing housing

Bearing housing inner diameter

(B) mm (in)

—

16.11 (0.63425)

Thrust bearing inside diameter for press-fit portion

(L) mm (in)

—

23.020 (0.90630)

Thrust bearing

Bearing pad height at compressor side

(J) mm (in)

—

0.0 — 0.060 (0.0 — 0.00236)

Thrust collar thickness

(K) mm (in)

—

2.950 (0.11614)

J

H

F B

L

A K

E

G

WSHK0126

1F-8 Exhaust System Turbocharger Structured Diagram

4 2

5

3

6

7

10 1

9 8

WSHK0127 Name 1. Turbine Housing 2. Heat Protector 3. Floating Metal 4. Oil Thrower 5. Compressor Housing

6. 7. 8. 9. 10.

Seal Plate Compressor Impeller Seal Ring Seal Ring Turbine Shaft

Exhaust System 1F-9 Disassembly and Inspection of Turbocharger Disassembly diagram: disassemble in the order of the numbers. 1

2

4

3

6 14 17 16

13

5

16

15

8 18 7 11 12 10 9

WSHK0128 Name 1. Compressor Housing 2. Nut 3. Compressor Impeller 4. Seal Plate 5. Oil Thrower 6. Seal Ring 7. G Coupling 8. Turbine Housing 9. Turbine Shaft

10. 11. 12. 13. 14. 15. 16. 17. 18.

Seal Ring Gasket Heat Protector Thrust Bearing Thrust Collar Snap Ring Floating Metal Thrust Bearing Bearing Housing

1F-10 Exhaust System Disassembly Caution: If you perform inspection with the turbocharger removed from the engine, plug the oil port opening before work. Inspection Prior to Disassembly • Measurement of axial play of turbine shaft Axial play

mm (in)


0.06 — 0.09 (0.0024 — 0.0035)

Service limit

0.11 (0.0043)

If it exceeds the service limit, check the thrust metal, the thrust bushing, and the oil thrower.

WSHK0130 • Measurement on the machine of radial play of turbine shaft Insert a thickness gauge into the gap between the compressor impeller and housing, and measure the clearance. The thickness gauge to be inserted must be 0.2 mm (0.0078 in) or less. 1. Compressor housing • Put alignment marks between the compressor housing and the seal plate, and tap the compressor housing to drive it out. • Liquid gasket is applied to the mating surfaces of the compressor and the seal plate.

WSHK0129

Caution: Take care not to damage the impeller during removal of the compressor housing.

• Measurement of radial play of turbine shaft Radial play

mm (in)


0.10 — 0.17 (0.00394 — 0.00669)

Service limit

0.205 (0.00807)

If it exceeds the service limit, check the floating metal.

1

WSHK0131 Name 1. Alignment Mark

Exhaust System 2. Compressor impeller • Attach the box spanner to the turbine-side shaft end of the turbine shaft, and remove the nut. The nut is left-hand screw. • Remove the impeller from the turbine shaft. • Washing of impeller Soak in the cleaning solvent until the foreign matters soften, and clean it with a plastic scraper or hard brush. Caution: Do not use a wire brush.

1F-11

4. • 5. •

Oil thrower Remove the oil thrower from the seal plate. G coupling Loosen the nut and remove the G coupling from the turbine housing and the center housing. 6. Turbine housing • Remove the center housing from the turbine housing. • Washing of turbine housing Soak in the cleaning solvent to remove the foreign matters.

1

WSHK0132 Name 1. Left-hand Thread 3. Seal plate • Loosen the pot small screw. • Lightly tap the bearing housing in the seal plate with a wooden hammer. • Liquid gasket is applied to the mating surfaces of the seal plate and the bearing housing.

WSHK0134 7. Turbine shaft • Hold the heat protector lightly by hand, and take out the turbine shaft. • If it is hard to remove, lightly tap the compressorside shaft end with a wooden hammer. • Washing of turbine shaft Soak in the cleaning solvent until the foreign matters soften, and clean it with a plastic scraper or hard brush. Caution: • Do not use a wire brush. • Foreign matters remaining on the surface causes the unbalance of weight. Therefore, wash it thoroughly. • Take care not to damage the floating metal contact surface of the shaft and the seal ring groove.

WSHK0133

1F-12 Exhaust System Inspection Compressor housing • Check the compressor housing for crack or damage, and replace if defective.

WSHK0135 8. Heat protector • Remove the heat protector from the bearing housing. 9. Thrust bearing (compressor side) • Loosen the Plate small screw with a screwdriver, and remove the thrust bearing and the thrust collar. 10. Floating metal • Remove the turbine-side snap ring with snap ring pliers. • Draw out the floating metal from the bearing housing. 11. Thrust bearing (turbine side) • Using a brass bar, push out the compressor-side floating metal from the turbine-side bearing housing, together with the thrust bearing.

WSHK0136 Turbine housing • Check the turbine housing for crack or damage, and replace if defective. Impeller • Check the impeller for scratch, dent or crack.

Caution: While pushing out with a bar, take care that they do not run on to damage the snap ring. 12. Snap ring • Remove the 2 snap rings from the bearing housing with snap ring pliers. 13. Seal ring • Remove the seal rings from turbine shaft and oil thrower.

WSHK0137

Exhaust System Heat protector

1F-13

• Measurement of turbine shaft runout

• Check the heat protector for damage, thermal deformation or corrosion.

Turbine shaft runout

mm (in)

Service limit

0.011 (0.00043)

WSHK0138 Turbine shaft

WSHK0140

• Measure the journal outer diameter of the turbine shaft, and the groove width of the seal ring insertion part. Journal outer diameter

mm (in) φ 11.38 (0.4480)

Service limit Groove width of the seal ring insertion part

Seal plate • Inspection of damage on the seal plate, measurement of inner diameter of the seal ring insertion part Inner diameter of the seal ring insertion part

mm (in) Service limit

mm (in) H

Service limit

14.05 (0.5531)

1.33 (0.0524)

2

H

1

WSHK0139 Name 1. Journal outer diameter 2. Ring groove width

WSHK0141 Oil thrower • Inspection of damage on the oil thrower sliding surface, measurement of the seal ring groove width

1F-14 Exhaust System Seal ring groove width G


G

1.52 (0.0598)

Thrust collar • Measure the thrust collar thickness (K), and replace with new one if it exceeds the service limit. F

Thickness of thrust collar

B

L


K

2.950 (0.11614)

WSHK0143 G coupling G

• Replace with new one. Seal ring

K

• Replace with new one. Others • Check the bolts for deformation, and replace with new ones if faulty. Also, replace the Plate small screw with new one.

WSHK0142 Thrust bearing • Replace the compressor-side and the turbine-side thrust bearings with new ones. Floating metal • Replace the floating metal with new one. Bearing housing • Check the casting surface for peeling from oxidation-deterioration, dent or crack. Replace with new one if faulty. mm (in) Location

Service limit

Bearing housing inner diameter

(B)

16.11 (0.6343)

Turbine-side seal ring insertion part

(F)

17.03 (0.6705)

Turbine-side thrust bearing press-fit part inner diameter

(L)

23.02 (0.9063)

Exhaust System

1F-15

Assembly of Turbocharger Assembly diagram: Assemble in the order of the numbers. 18

17

15

16

13

3

4

8

9

14

3

2

11 1 12 10 6 5 7

WSHK0144 Assembly Procedure 1. Bearing Housing 2. Snap Ring 3. Floating Metal 4. Thrust Bearing 5. Seal Ring 6. Heat Protector 7. Turbine Shaft 8. Thrust Collar 9. Thrust Bearing

10. 11. 12. 13. 14. 15. 16. 17. 18.

Gasket Turbine Housing G Coupling Seal Ring Oil Thrower Seal Plate Compressor Impeller Nut Compressor Housing

1F-16 Exhaust System Assembly 1. Bearing housing • Check that the bearing housing is free of damage and foreign matters. 2. Snap ring • Install the 2 snap rings to the bearing housing with snap ring pliers. • After assembling the floating metal (turbine side), install the snap ring at the position shown in the figure.

1

WSHK0146 Name 1. Apply Oil.

1

WSHK0145 Name 1. Turbine-Side Floating Metal 3. Floating metal • Apply oil to the floating metal, and assemble it to the bearing housing. After securing it with a snap ring, assemble the compressor-side floating metal. Caution: • Place the snap ring with its rounded-side facing to the floating metal. • Assemble the inner snap ring with its end gap facing to the oil outlet-direction of the housing, to prevent it from blocking the oil path. • Assemble the turbine-side snap ring to the housing with its end gap facing to the direction as shown in the illustration. • Apply oil to the floating metal before assembly. Besco super engine oil

4. Thrust bearing a. Press-fitting of turbine-side thrust bearing • Press-fit the turbine-side thrust bearing into the bearing housing. • Position the pawl of the turbine-side thrust bearing for more than 2 mm (0.0787 in) apart from the existing press-fitting part. • Do not press the thrust bearing pad surface during press-fitting. • The press-fit pressure must be between 215.6 N {22.0 kgf} and 1862 N {190 kgf}. • After press-fitting, remove the dust powder using vacuum.

Exhaust System

1F-17

b. After press-fitting, check the depth and flatness of the turbine-side thrust bearing. (Depth 3.08±0.02 mm {0.1213±0.0008 in}, Flatness is below 0.01 mm {0.0004 in}: See illustration) mm(in)

0

1 12

3.08 0.02 (0.1213 0.0008)

1

WSHK0149 Name 1. Apply Oil.

120

WSHK0147

Name 1. Common Tolerance 5. • • 6. • 7. •

Seal ring Insert the seal ring to the turbine shaft. Use new seal ring. Heat protector Install the heat protector to the bearing housing. Turbine shaft Apply engine oil to the journal portion of the turbine shaft, and insert it from the turbine side of the bearing housing. • Take care not to damage the floating metal with the turbine shaft. Also, insert with the end gap of the seal ring facing to the oil inlet side so that its core matches with the turbine shaft.

8. Thrust collar • Apply engine oil to the thrust collar, and install ti to the turbine shaft. 9. Thrust bearing • Apply engine oil to the metal portion of the thrust bearing, and insert it to the bearing housing. • Apply Loctite to the Plate small screw threads, and install it using torque screwdriver. Tightening torque: 3.7 N⋅m (0.38 kgf⋅m/33 lb in)

1

WSHK0150 Name 1. Apply Oil. 10. Gasket • Set the gasket to the turbine housing, and install it to the bearing housing.

1F-18 Exhaust System 11. Turbine housing • Assemble by aligning the phase of the turbine housing and the bearing housing with the turbine housing positioning pin and the bearing housing hole.

2

1

3

A

3 1

2 6

4

5

WSHK0152

WSHK0151 12. G coupling a. Check that it does not run on the turbine housing or the bearing housing. b. Tighten temporarily to the specified torque using a torque wrench.

Name 1. Approx. 60° 2. Approx. 60° 3. Torque Wrench Hammering procedure 1)

Using a metal hammer (Approx. 250g in weight), lightly tap 2 to 3 times (same place), from the outer portion toward the center.

2)

Do not hammer the G coupling directly. Place brass bar between as shown in the illustration.

Tightening torque: 83 N⋅m (8.5 kgf⋅m/61 lb ft) c. Hammering: Perform the hammering of (1) to (6) in the numerical order, using the following procedure. d. Tighten to the specified torque using a torque wrench. Tightening torque: 83 N⋅m (8.5 kgf⋅m/61 lb ft) e. Perform (c) and (d) of the above step again.

150 ~ 200 mm (6 ~ 8 in)

2

3

4 5

1

7

6

WSHK0153

Name 1. Approx. φ 13 mm (0.5 in) 2. Hammer 3. G Coupling 4. Bearing Housing 5. Gasket 6. Heat Shield Plate 7. Turbine Housing

Exhaust System 13. • • 14. • •

Seal ring Install the seal ring to the oil thrower. Use new one. Oil thrower Insert the oil thrower into the seal plate. Insert with the end gap of the seal ring facing to the oil inlet side. 15. Seal plate • Apply liquid gasket to the turbine-side flange surface. Application thickness 0.1 — 0.2 mm (0.004 — 0.008 in) (B)

1F-19

• Align the alignment marks that marked during the disassembly, and assemble the compressor housing to the seal plate. Tightening torque: 7.9 N⋅m (0.81 kgf⋅m/70 lb in)

ThreeBond No. 1207 • Install the seal plate to the bearing housing. • Apply Loctite (B) to the Pot small screw threads, and install it using torque screwdriver. Tightening torque: 23 N⋅m (2.3 kgf⋅m/17 lb ft)

WSHK0156 Check after assembly • Make sure that the axial play and radial play of rotor are within the specified value. Refer to the section on inspection.

B

A

WSHK0154 16. • 17. •

Compressor impeller Insert the compressor impeller to the turbine shaft. Nut Attach the box spanner to the turbine-side shaft end of the turbine shaft, and tighten the nut. • The nut is left-hand thread. Make sure the turning direction.

Tightening torque: 7.8 N⋅m (0.80 kgf⋅m/69 lb in) 18. Compressor housing • Apply liquid gasket to the compressor-side flange surface of the seal plate. Illustration shown in the previous page (A) Application thickness 0.1 — 0.2 mm (0.004 — 0.008 in) ThreeBond No. 1207

1F-20 Exhaust System

Turbocharger (4HK1) Inspection of Turbocharger Inspection Caution: Turbocharger on 4HK1 engine cannot be overhauled structurally. Perform only the following inspection. • Measurement of axial play of turbine shaft Axial play Service limit

mm (in) 0.11 (0.004)

WSHK0129 • Inspection of radial play of turbine shaft Insert a thickness gauge into the gap between the compressor impeller and housing, and measure the clearance. The thickness gauge to be inserted must be 0.2 mm (0.0078 in) or less.

Exhaust System

1F-21

Measurement Tool Shape

Name

Part number

Usage

—

Measurement of the seal ring groove width Measurement of inner diameter of the seal ring insertion part Measurement of turbine shaft journal outer diameter Measurement of thrust bushing groove clearance Measurement of thrust bearing thickness Measurement of floating metal inner/outer diameter Measurement of inner diameters of the center housing metal portion and ring portion

Caliper

WSHK0157

Dial gauge

Measurement of turbine shaft axial gap, radial gap and runout —

WSHK0158

Other Material Name

Usage

Besco super engine oil

Floating metal sliding portion Thrust bushing sliding portion Thrust bearing sliding portion Turbine shaft journal portion

ThreeBond No. 1207

Housing installing surface of the seal plate Flange of the compressor housing

Loctite No. 242

Seal plate tightening screw thread

1F-22


4HK1 & 6HK1 manual

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