SECTION 6A - ENGINE MECHANICAL

MAIN DATA AND SPECIFICATIONS

TORQUE SPECIFICATIONS

STANDARD BOLTS

FLARE NUTS

TORQUE SPECIFICATIONS

RECOMMENDED LIQUID GASKET

LOCTITE APPLICATION PROCEDURE

SERVICING

MODEL IDENTIFICATION

AIR CLEANER

LUBRICATING SYSTEM

FUEL SYSTEM

COOLING SYSTEM

VALVE CLEARANCE ADJUSTMENT

COMPRESSION PRESSURE MEASUREMENT

GENERAL DESCRIPTION

REMOVAL AND INSTALLATION

REMOVAL

INSTALLATION

COOLANT REPLENISHMENT

ENGINE WARM-UP

ENGINE REPAIR KIT

ENGINE OVERHAUL

REMOVAL

EXTERNAL PARTS

DISASSEMBLY

INTERNAL PARTS

MAJOR COMPONENTS

MINOR COMPONENTS

INSPECTION AND REPAIR

CYLINDER HEAD

ROCKER ARM SHAFT AND ROCKER ARM

CYLINDER BODY

CAMSHAFT

CRANKSHAFT AND BEARING

CRANKSHAFT BEARING SELECTION

CRANKSHAFT PILOT BEARING

FLYWHEEL AND RING GEAR

PISTON

CYLINDER HEAD GASKET SELECTION

CONNECTING ROD

IDLER GEAR SHAFT AND IDLER GEAR

TIMING GEAR CASE COVER

REASSEMBLY

INTERNAL PARTS

MINOR COMPONENT

MAJOR COMPONENT

INSTALLATION

EXTERNAL PARTS

LUBRICATION SYSTEM

LUBRICATING FLOW

OIL PUMP AND OIL FILTER

OIL PUMP

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

OIL FILTER AND OIL COOLER

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

INTER COOLER

REMOVAL AND INSTALLATION

REMOVAL

INSTALLATION

SPECIAL TOOLS

MAIN DATA AND SPECIFICATIONS

Item Data

Engine type Four-cycle, overhead valve, water cooled

Combustion chamber type Direct injection

Cylinder liner type

Timing gear train system Dry type, chrome plated

Gear drive

No. of cylinders-bore × stroke mm (in) 4 – 95.4 × 104.9 (3.76 × 4.13)

No. of piston rings Compression ring: 2 / Oil ring: 1

Total piston displacement litre

Compression ratio (to 1)

2,999

18.3

Compression pressure MPa (kg/cm2/psi) 3.0 (31.0/441) – 200 rpm

Engine weight kg (lb) 4 × 2MT & 4 × 4 : Approximately 249 (549)

4 × 2AT : Approximately 236 (520)

Fuel injection order 1 – 3 – 4 - 2

Specified fuel type JIS No.2 diesel fuel

Idling speed rpm 700 ± 25 (A/C OFF)

800 ± 25 (A/C ON)

Valve clearances (At cold): Intake mm (in)

Exhaust mm (in)

Intake valves Open at (BTDC) deg

Close at (ABDC) deg

Exhaust valves Open at (BBDC) deg

Close at (ATDC) deg

Fuel system

Injection pump type

0.4 (0.016)

24.5

55.5

54.0

26.0

BOSCH distributor VP44 type

Injection nozzle type

Injection nozzle opening pressure

(Design value) MPa(kg/cm2/psi)

Hole with 5 orifices

1st 19.5 (199/2,828)

2nd (Reference) 34.3 - 35.8 (350/4,980 - 365/5,197)

Main fuel filter type

Lubricating system

Lubricating method

Cartridge paper element and water separator

Pressure circulation

Specified engine oil (API grade) Refer to Section 0B - Lubrication

Oil pump type

Oil filter type

Gear

Cartridge paper element

Oil capacity lit (US/UK gal)

6.5 (1.7/1.4) (For 4 × 2)

7.3 (1.9/1.6) (For 4 × 4)

Oil cooler type Water cooled

Item Data

Cooling system

Water pump type

Thermostat type

Air cleaner type

Battery type/voltage × No. of units

Generator capacity V-A

Starter motor output V-kW

Turbocharger model

Turbine type

Compressor type

Centrifugal

Wax pellet with jiggle valve

Dry paper element

95D31R × 1

12 – 60/12 – 80

12 – 2.3

*IHI RHF5

Radial-inflow

Radial-outflow

*IHI: Ishikawajima-Harima Heavy Industries. Ltd.

TORQUE SPECIFICATIONS

STANDARD BOLTS

The torque values given in the following table should be applied whenever a particular torque is not specified.

N·m (kg·m/lb·ft)

8.8

4.8 (4T) (7T) Refined Non-Refined 9.8 (9T)

Strength

Class

Bolt

Identification

Bolt

Diameter ×

Pitch (mm)

M 6 × 1.0

M 8 × 1.25

M 10 × 1.25

M 12 × 1.25

M 14 × 1.5

M 16 × 1.5

M 18 × 1.5

M 20 × 1.5

M 22 × 1.5

M 24 × 2.0

* M 10 × 1.5

* M 12 × 1.5

* M 14 × 2.0

* M 16 × 2.0

5.88 ± 1.96

(0.60 ± 0.20/4.33 ± 1.44)

12.74 ± 4.90

(1.30 ± 0.50/9.40 ± 3.62)

27.44 ± 6.86

(2.80 ± 0.70/20.25 ± 5.06)

61.25 ± 12.25

(6.25 ± 1.25/45.21 ± 9.04)

95.55 ± 19.11

(9.75 ±1.95/70.52 ± 14.10)

130.34 ± 26.46

(13.30 ± 2.70/96.20 ± 19.53)

188.16 ± 37.24

(19.20 ± 3.80/138.87 ± 27.49)

257.74 ± 51.94

(26.30 ± 5.30/190.23 ± 38.33)

332.22 ± 81.34

(33.90 ± 8.30/245.20 ± 60.03)

448.84 ± 90.16

(45.80 ± 9.20/331.27 ± 66.54)

26.46 ± 6.86

(2.70 ± 0.70/19.53 ± 5.06)

56.84 ± 11.76

(5.80 ± 1.20/41.95 ± 8.68)

89.18 ± 17.64

(9.10 ± 1.80/65.82 ± 13.02)

124.46 ± 24.50

(12.70 ± 2.50/91.86 ± 18.08)

7.35 ± 2.45

(0.75 ± 0.25/5.43 ± 1.80)

17.15 ± 5.39

(1.75 ± 0.55/12.66 ± 4.00)

36.75 ± 9.31

(3.75 ± 0.95/27.12 ± 6.87)

75.95 ± 15.19

(7.75 ± 1.55/56.06 ± 11.21)

116.13 ± 23.03

(11.85 ± 2.35/85.71 ± 17.00)

169.54 ± 34.30

(17.30 ± 3.50/125.13 ± 25.32)

244.02 ± 49.00

(24.90 ± 5.00/180.10 ± 36.17)

337.12 ± 67.62

(34.40 ± 6.90/248.82 ± 49.41)

453.25 ± 90.65

(46.25 ± 9.25/334.53 ± 66.91)

570.36 ± 140.14

(58.20 ± 14.30/420.96 ± 103.43)

36.26 ± 8.82

(3.70 ± 0.90/26.76 ± 6.50)

70.56 ± 13.72

(7.20 ± 1.40/52.08 ± 10.13)

109.76 ± 21.56

(11.20 ± 2.20/81.01 ± 15.91)

161.70 ± 32.34

(16.50 ± 3.30/119.34 ± 23.87)

23.52 ± 6.86

(2.40 ± 0.70/17.36 ± 5.06)

49.98 ± 12.74

(5.10 ± 1.30/36.89 ± 9.40)

94.57 ± 19.11

(9.65 ± 1.95/69.80 ± 14.10)

142.10 ± 28.42

(14.50 ± 2.90/104.88 ± 21.00)

199.92 ± 40.18

(20.40 ± 4.10/147.55 ± 29.66)

287.14 ± 57.82

(29.30 ± 5.90/211.93 ± 42.67)

395.92 ± 79.38

(40.40 ± 8.10/292.21 ± 58.59)

530.18 ± 105.84

(54.10 ± 10.80/391.30 ± 78.12)

691.88 ± 138.18

(70.60 ± 14.10/510.65 ± 101. 99)

48.02 ± 11.76

(4.90 ± 1.20/35.44 ±8.68)

89.18 ± 17.64

(9.10 ± 1.80/65.82 ± 13.02)

133.28 ± 26.46

(13.60 ± 2.70/98.37 ± 19.53)

191.10 ± 38.22

(19.50 ± 3.90/141.04 ± 28.21)

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such

as casting. Those shown in parentheses in the strength class indicate the classification by the old standard.

FLARE NUTS

N·m (kg·m/lb·ft)

Pipe diameter mm

(in) Torque Pipe diameter mm

(in) Torque

4.76 (0.187)

6.35 (0.250)

8.00 (0.315)

15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8)

26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1)

44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6)

10.00 (0.394)

12.00 (0.472)

15.00 (0.591)

53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)

88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)

105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)

TORQUE SPECIFICATIONS

Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket N·m (kg·m/lb·ft)

W46AXF000501

Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,

Flywheel, and Oil Pan N m (kg·m/lb·ft)

RTW36AXF000101-a

Timing Gear Case, Pulley Housing, Timing Gear, and Camshaft N·m (kg·m/lb·ft)

RTW46AXF000601

Cooling and Lubricating System N·m (kg·m/lb·ft)

RTW46AXF000701

Intake Manifold and EGR Valve N·m (kg·m/lb·ft)

RTW36AXF000201

Exhaust Manifold, and Turbocharger N·m (kg·m/lb·ft)

RTW46AXF001001

Engine Electricals N·m (kg·m/lb·ft)

RTW36AXF000501

Fuel Injection System N·m (kg·m/lb·ft)

RTW46AXF001301

Engine Mounting Bracket

N·m (kg·m/lb·ft)

022R300001

RECOMMENDED LIQUID GASKET

Type Brand Name Manufacturer Remarks

RTV*

Silicon Base ThreeBond 1207B

ThreeBond 1207C Three Bond

Three Bond

Water Base ThreeBond 1141E

ThreeBond 1215 Three Bond

Three Bond

Solvent ThreeBond 1104

Belco Bond 4

Belco Bond 401

Belco Bond 402

Three Bond

Isuzu

Anaerobic LOCTITE 515

LOCTITE 518

LOCTITE 262

Loctite

Recommended for

transaxle repairs

* RTV: Room Temperature Vulcaniser

NOTE:

1. It is very important that the liquid gaskets listed abov e or their exact equivalent be used on the vehicle.

2. Be careful to use the specified amount of liquid gasket.

Follow the manufacturer’s instructions at all times.

3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before

applying the liquid gasket.

The connecting surfaces must be perfectly dry.

4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.

Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater

than 0.25 mm (0.01 in). Poor adhesion will result.

LOCTITE APPLICATION PROCEDURE

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242 Blue

LOCTITE 262 Red

LOCTITE 270 Green

LOCTITE 271 Red

1. Completely remove all lubricant and moisture from the bolts and the

female threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

2. Apply LOCTITE to the bolts.

3. Tighten the bolts to the specified torque.

4. Wait at least one hour before continuing the installation procedure.

LOCTITE 515 Violet

1. Completely remove lubricant and moisture from the connecting

surfaces.

The surfaces must be perfectly dry.

2. Apply a 2.0 – 2.5 mm bead of LOCTITE to one of the connecting

surfaces.

There must be no gaps in the bead.

3. Tighten the bolts to the specified torque.

4. Let the joined parts set for at least thirty minutes.

SERVICING

Servicing refers to general maintenance procedures to be performed by qualified service personnel.

RTW36ASH000401

MODEL IDENTIFICATION

Engine Serial Number

The engine number is stamped on the rear left hand side

of the cylinder body.

The engine number is stamped in the plate in front of the

engine room as well.

AIR CLEANER

Element cleaning procedures will vary according to the

condition of the element.

Dust Fouled Element

Rotate the element with your hand while applying

compressed air to the inside of the element. This will blow

the dust free.

Compressed air pressure kPa (kg/cm2/psi)

392 – 490 (4 – 5/57 – 71)

CAUTION:

Do not hit the element against another object in an

attempt to clean it. Damage to the element will result.

LUBRICATING SYSTEM

Main Oil Filter (Cartridge Type Paper Element)

Replacement Procedure

1. Drain the engine oil.

2. Retighten the drain plug.

3. Loosen the used oil filter by turning it counter

clockwise with a filter wrench.

Filter Wrench: 5-8840-0200-0

RTW36ASH000101

4. Clean the oil cooler fitting face. This will allow the new

oil filter to seat properly.

5. Apply a light coat of engine oil to the filter O-ring.

6. Turn in the new oil filter until the filter O-ring is fitted

against the sealing face.

7. Use the filter wrench to turn in the filter an additional

2/3 turns.

8. Check the engine oil level and replenish to the

specified level if required.

9. Start the engine and check for oil leakage from the

main oil filter.

130RY00003

6A-6

Techline

Replenished Engine Oil MAX lit (US/UK gal)

Condition

Model

Engine Dry

With oil filter

replacement

Without oil

filter

replacement

4 × 2 6.5 (1.7/1.4) 4.5 - 5.5

(1.19 - 1.45

/ 0.99 - 1.21)

3.5 - 4.5

(0.93 - 1.19

/ 0.77 - 0.99)

4 × 4 7.3 (1.9/1.6) 5.3 - 6.3

(1.40 - 1.66

/ 1.17 - 1.39)

4.3 - 5.3

(1.14 - 1.40

/ 0.95 - 1.17)

FUEL SYSTEM

Fuel Filter Replacement Procedure

1. Remove the fuel filter by turning it counter clockwise

with a filter wrench.

Filter Wrench: 5-8840-0253-0 (J-22700)

NOTE:

Be careful not to spill the fuel in the filter cartridge.

2. Clean the fuel filter cartridge fitting faces.

This will allow the new fuel filter to seat properly

3. Apply a light coat of engine oil to the O-ring.

4. Turn in the fuel filter until the sealing face comes in

contact with the O-ring.

5. Turn in the fuel filter an additional 2/3 of a turn with a

filter wrench.

Filter Wrench : 5-8840-0253-0 (J-22700)

6. Operate the priming pump until the air discharged

completely from fuel system.

7. Start the engine and check for fuel leakage.

NOTE:

The use of a HOLDEN genuine fuel filter is strongly

recommended.

6A-7

041RY00009

Draining Procedure

The indicator light will come on when the water level in the

water separator exceeds the specified level.

Drain the water and foreign material from the water

separator (inside chassis frame) with the following

procedure.

1. Place the drain pan under the drain plug.

2. Loosen the drain plug and drain water.

3. After draining the water, tighten the drain plug.

4. Operate the priming pump on the fuel filter several

times and check for fuel leakage.

5. Check the water separator indicator light. It should be

off.

041RY00011

041R300001

6A-8

Air Bleeding

1. Operate the priming pump until strong resistance is

felt.

2. Wait 1 minute, and operate the priming pump until

strong resistance is felt.

3. Once more wait, and operate the priming pump until

strong resistance is felt.

4. Turn the ignition switch to the "ON" position. Wait until

the glow indicator lamp turns off.

5. Turn the ignition switch to the "START" position and

crank the engine until it starts.

6. If the engine does not start, repeat Step 3 - 5.

7. Allow the engine to idle for 3 minutes to bleed air

completely form the fuel system and check for fuel

leakage.

NOTE:

Insufficient air bleeding may cause a Diagnostic Trouble

Code (DTC) to store, or improper engine performance.

111R300001

COOLING SYSTEM

Coolant Level

Check the coolant level and replenish the radiator reserve

tank as necessary.

If the coolant level falls below the “MIN” line, carefully

check the cooling system for leakage. Then add enough

coolant to bring the level up to the “MAX” line. Use only

50% water with 50% coolant to Holden HN2217

Specification.

Engine coolant filling procedure

NOTE:

Use only 50% water with 50% coolant to Holden HN2217

Specification.

1. Make sure that the engine is cool.

WARNING:

When the coolant is heated to a high temperature, be

sure not to loosen or remove the radiator cap,

otherwise you might get scalded by hot vapour or

boiling water. Wait until the coolant has become

cooler before opening the cap.

To open the radiator cap, put a piece of thick cloth on

the cap and loosen the cap slowly to reduce the

pressure.

2. Remove the radiator cap and add coolant up to the

filler neck.

3. Pour coolant into the reservoir tank up to “MAX” line.

4. Set the heater adjustment to the highest temperature

position to allow the coolant to circulate through the

heater system.

5. Tighten the radiator cap and start the engine. After

idling for 2 to 3 minutes, stop the engine and reopen

the radiator cap. If the coolant level is lower than the

filler neck, replenish the coolant level.

6. After replenishing the coolant, refit and tighten the

radiator cap. Warm up the engine at approximately

2000 rpm.

7. Continue to monitor the coolant temperature gauge.

When the coolant temperature gauge indicates that

the thermostat has opened, idle the engine for 5

minutes, then stop the engine.

8. When the engine has cooled, remove the radiator cap

and inspect that the coolant level is up to the filler

neck. Replenish if required. If there is an extreme

shortage of coolant, check the coolant system,

including the reservoir tank and hose, for leaks.

9. Pour coolant into the reservoir tank up to “MAX” line.

Cooling System Inspection

Install a radiator filler cap tester to the radiator. Apply

testing pressure to the cooling system to check for

leakage. The testing pressure must not exceed the

specified pressure.

Testing Pressure kPa (kg/cm2/psi)

150 (1.5/21)

Radiator Cap Inspection

The radiator filler cap is designed to maintain coolant

pressure in the cooling system at 103 kPa(1.05 kg/cm2,

15psi).

Check the radiator filler cap with a radiator filler cap tester.

The radiator filler cap must be replaced if it fails to hold

the specified pressure during the test procedure.

Radiator Cap Valve Opening Pressure

kPa (kg/cm2/psi)

90 – 120 (0.9 – 1.2/13 – 17)

Negative Valve (Reference) kPa (kg/cm2/psi)

1.9 – 4.9 (0.02 – 0.05/0.28 – 0.71)

Thermostat Operating Test

1. Completely submerge the thermostat in water.

2. Heat the water.

Stir the water constantly to avoid direct heat being

applied to the thermostat.

3. Check the thermostat initial opening temperature.

Thermostat Initial Opening Temperature °C (°F)

82 (180)

Oil Cooler Thermo Valve °C (°F)

76.5 (170)

4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature °C (°F)

95 (203)

Oil Cooler Thermo Valve °C (°F)

90 (194)

Valve Lift at Fully Open position mm (in)

9.5 (0.37)

Oil Cooler Thermo Valve mm (in)

4.5 (0.18)

030LX003

030LX002

030LX014

Drive Belt Adjustment

Check drive belts for wear or damage, and replace with

new ones as necessary. Check belts for tension, and

adjust as necessary.

1 Crankshaft damper pulley

2 Generator pulley

3 Cooling fan pulley

4 Oil pump pulley or idler pulley

5 Compressor pulley or idler pulley

Cooling Fan Pulley Drive Belt

Fan belt tension is adjusted by moving the generator.

Depress the drive belt mid-portion with a 98N (10 kg/22

Ib) force.

Cooling Fan Drive Belt Deflection mm (in)

New belt 4 - 7 (0.16 - 0.28)

Reuse belt 6 - 9 (0.24 - 0.35)

1 Crankshaft damper pulley

2 Generator pulley

3 Cooling fan pulley

A/C Compressor Drive Belt

Compressor belt tension is adjusted by moving the P/S

pump pulley.

Depress the drive belt mid-portion with a 98N (10 kg/22

Ib) force.

A/C Compressor Drive Belt Deflection mm (in)

New belt 9 - 10 (0.35 - 0.39)

Reuse belt 12 - 13 (0.47 - 0.51)

1 Crankshaft damper pulley

2 P/S pump pulley

3 A/C Compressor pulley

033RY00002

033RY00003

033RY00004

VALVE CLEARANCE ADJUSTMENT

1. Bring the piston in either the No. 1 cylinder or the No.

4 cylinder to TDC on the compression stroke by

turning the crankshaft until the crankshaft damper

pulley TDC line is aligned with the timing pointer.

2. Check the rocker arm shaft bracket nuts for

looseness.

Tighten any loose rocker arm shaft bracket nuts

before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque N·m (kg·m/lb·ft)

54 (5.5/40)

3. Check for play in the No. 1 intake and exhaust valve

push rods. If the No. 1 cylinder intake and exhaust

valve push rods have play, the No. 1 piston is at TDC

on the compression stroke. If the No. 1 cylinder intake

and exhaust valve push rods are depressed, the No. 4

piston is at TDC on the compression stroke.

Adjust the No.1 or the No. 4 cylinder valve clearances

while their respective cylinders are at TDC on the

compression stroke.

Valve Clearance (At Cold) mm (in)

0.4 (0.016)

4. Loosen each valve clearance adjusting screw as

shown in the illustration.

5. Insert a feeler gauge of the appropriate thickness

between the rocker arm and the valve stem end.

6. Turn the valve clearance adjusting screw until a slight

drag can be felt on the feeler gauge.

7. Tighten the lock nut securely.

8. Rotate the crankshaft 360°.

9. Realign the crankshaft damper pulley TDC notched

line with the timing pointer.

10. Adjust the clearances for the remaining valves as

shown in the illustration.

014RY00014

014RY00015

014RY00016

014RY00017

COMPRESSION PRESSURE MEASUREMENT

1. Start the engine and allow it to idle until the coolant

temperature reaches 70 – 80 °C (158 – 176 °F).

2. Remove the following parts.

• Leak off pipe

• Injection nozzle holder bracket

• Injection nozzle holder

3. Install the following parts.

• Set the adapter and compression gauge (SST) to

the No.1 cylinder injection nozzle hole.

• Injection nozzle holder bracket

Injection nozzle holder bracket Bolt Torque

N·m (kg·m/lb·ft)

37 (3.8/27)

Compression Gauge: 5-8840-2675-0

Adapter; Compression Gauge: 5-8531-7001-0

4. Turn the engine over with the starter motor and take

the compression gauge reading.

Compression Pressure MPa (kg/cm2/psi) at 200 rpm

Standard Limit

30 (31.0/441) 2.1 (21.7/309)

5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.

If the measured value is less than the specified limit,

refer to “Troubleshooting” in this Manual.

F06XL056

901R100003

GENERAL DESCRIPTION

RTW36AMF000101

The 4J series automotive diesel engine feature a unique design of combustion chamber in the top of each piston. This

design provides superior fuel economy over a wide range of driving conditions.

Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion, resulting in reduced engine noise

during the engine warm-up period.

Chrome plated dry type cylinder liners provide increased durability over the more conventional cast iron liners.

The laminated steel sheet cylinder head gasket increases head gasket reliability.

The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be

reground.

Engine is equipped with the BOSCH VP44-Type distributor injection pump, a turbocharger and Exhaust Gas

Recirculation (EGR) system.

REMOVAL AND INSTALLATION

Read this section carefully before performing any removal and installation procedure. This section gives you important

points as well as the order of operation. Be sure that you understand everything in this section before you begin.

REMOVAL

P1010011

1. Battery

1) Disconnect the battery cable and the grounding cable

from the battery terminals.

2) Remove the battery clamp. Take care not to

accidentally short the battery with the wrench or some

other tool.

3) Remove the battery.

4) Disconnect the battery cable at the starter motor and

the ground cable at the cylinder body.

2. Engine Hood

Apply setting marks to the engine hood and the engine

hood hinges before removing the engine hood. This will

facilitate reinstallation of the engine hood to its original

position.

3. Supporting the Vehicle

1) Jack up the vehicle.

2) Place chassis stands at the front and the rear of the

vehicle.

4. Under cover (for 4x4 model)

5. Rear propeller shaft

1) Remove the propeller shaft flange yoke at the rear

differential.

2) Remove the center bearing retainer bolts.

3) Remove the propeller shaft together with the center

bearing from the transmission mainshaft spline.

P1010002

F06R300006

6. Front propeller shaft (for 4x4 model)

Remove the spline yoke flange bolt at the transfer output

shaft.

Do not allow the spline yoke to fall away from the front

propeller shaft.

If the spline yoke should fall away from the front propeller

shaft, align the setting marks on the spline yoke and the

propeller shaft to reassemble the two marks. The setting

marks are punched circles approx. 3mm (0.12 in) in

diameter.

7. Clutch slave cylinder (for M/T model)

8. ATF pipe (for A/T model)

9. Shift control cable (for A/T model)

10. Transmission sensor harness

11. Remove the vehicle speed sensor connector, inhibitor

switch connector (A/T), ATF temperature sensor

connector, back up light switch connector (M/T) from

transmission.

11. Breather hose (for A/T model)

12. Transmission shift lever (for M/T model)

Remove the shift lever from the floor.

13. Transfer shift lever (for 4x4 model)

Remove the shift lever from the floor.

14. Transmission member

1) Support the transmission with the transmission jack.

2) Remove the transmission member mounting bolts

fixing the transmission member to the chassis frame.

15. Torque converter bolt (for A/T model)

1) Remove the under cover under the torque converter

housing.

2) Rotate the flywheel by using tire lever or some other

tool, and then remove the torque converter bolts.

16. Transmission coupling bolt

1) Support the engine with the garage jack.

2) Use the jack to slightly lower the transmission.

3) Remove the transmission coupling bolts.

17. Transmission (and transfer)

Separate the transmission (and transfer) from the engine.

Take care not to damage the transmission, the engine,

and their related parts.

P1010025

F06R300007

18. Radiator

1) Drain the engine coolant.

2) Remove the reservoir hose.

3) Remove the upper and lower hose.

4) Remove the fan guide.

5) Remove the radiator.

19. Fan

P1010034

20. Air cleaner

1) Remove the MAF sensor connector from air cleaner

duct.

2) Remove the air cleaner duct and the air cleaner box

from engine bay.

3) Remove the two air ducts from inter cooler.

21. Power Steering Pump

Loosen the power steering pump adjust plate bolt, then

remove the power steering pump assembly. Place the

power steering pump assembly along with piping on the

body side.

22. Air conditioner compressor

1) Remove air compressor magnet connector.

2) Remove the air conditioner compressor. Place the air

conditioner compressor along with piping on the body

side.

23. Engine Control Cable

Remove the engine control cable from its bracket.

24. Vacuum Piping

Remove the vacuum pipes from the vacuum pump, and

the EGR valve.

P1010009

25. Engine Harness

1) Remove following connectors from engine.

• TPS connector

• Oil pressure switch connector

• Thermo switch connector

• Injection pump connector

• Engine earth

• Engine Coolant Temperature sensor connector

• TDC sensor

2) Remove the clips fixing engine harness.

26. Fuel Hose

Remove the fuel hose from the fuel filter.

27. Exhaust Pipe

Remove the front exhaust pipe bolts and separate the

exhaust manifold and the front exhaust pipe.

28. Engine Assembly

1) Remove two right side engine foot bolts.

2) Remove two left side engine mount bolts.

3) Use the hoist to lift the engine from the engine

compartment.

INSTALLATION

To reassemble, follow the removal steps in the reverse

order.

140R300001

022R300002

F06R300008

COOLANT REPLENISHMENT

NOTE:

Use only 50% water with 50% coolant to Holden HN2217

Specification.

1. Make sure that the engine is cool.

WARNING:

When the coolant is heated to a high temperature, be

sure not to loosen or remove the radiator cap,

otherwise you might get scalded by hot vapour or

boiling water. Wait until the coolant has become

cooler before opening the cap.

To open the radiator cap, put a piece of thick cloth on

the cap and loosen the cap slowly to reduce the

pressure.

2. Remove the radiator cap and add coolant up to the

filler neck.

3. Pour coolant into the reservoir tank up to “MAX” line.

4. Set the heater adjustment to the highest temperature

position to allow the coolant to circulate through the

heater system.

5. Tighten the radiator cap and start the engine. After

idling for 2 to 3 minutes, stop the engine and reopen

the radiator cap. If the coolant level is lower than the

filler neck, replenish the coolant level.

6. After replenishing the coolant, refit and tighten the

radiator cap. Warm up the engine at approximately

2000 rpm.

7. Continue to monitor the coolant temperature gauge.

When the coolant temperature gauge indicates that

the thermostat has opened, idle the engine for 5

minutes, then stop the engine.

8. When the engine has cooled, remove the radiator cap

and inspect that the coolant level is up to the filler

neck. Replenish if required. If there is an extreme

shortage of coolant, check the coolant system,

including the reservoir tank and hose, for leaks.

9. Pour coolant into the reservoir tank up to “MAX” line.

Coolant Capacity lit (US/UK gal)

9.5 (2.5/2.1)

ENGINE WARM-UP

After completing the required maintenance procedures,

start the engine and allow it to idle until it is warm.

Check the following:

1. Engine idling speed.

2. Engine noise level.

3. Engine lubricating system and cooling system.

Carefully check for oil and coolant leakage.

4. Clutch engagement.

5. Transmission operation.

6. Indicator warning light operation.

ENGINE REPAIR KIT

RTW36ALF000601

Removal Steps

1. Cylinder head gasket

2. Head cover gasket

3. Head cover cap nut gasket

4. Drain cock gasket

5. Crankshaft rear oil seal

6. Gear case gasket

7. Oil pan drain plug gasket

8. Oil pan gasket

9. Oil filter gasket

10. Joint bolt gasket

11. Vacuum pump gasket

12. Water pump O-ring

13. Water outlet pipe gasket

14. Intake pipe gasket

15. Thermostat housing gasket

16. Intake manifold gasket

17. Exhaust manifold gasket

18. Nozzle holder O-ring

19. Nozzle holder gasket

20. Crankshaft front oil seal

NOTE:

Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of these parts

will result in oil, water, and gas leakage.

ENGINE OVERHAUL

REMOVAL

EXTERNAL PARTS

RTW36AMF000401

Removal Steps

1. Clutch assembly or flex plate

2. Intake pipe and throttle body

3. EGR pipe

4. EGR valve

5. Oil level gauge

6. Fuel filter assembly

7. Fuel filter bracket

8. Fuel injection pipe with clip

9. Power steering oil pump bracket

10. Intake manifold

11. Engine mounting bracket and foot

12. Injection pump cover

13. Injection pump

14. Starter motor

15. Oil pressure warning switch

16. Fuel leak-off pipe

17. Oil cooler water pipe

18. Cooling fan pulley

19. Heat protector

20. Catalytic converter

21. Turbocharger

22. Compressor bracket

23. Vacuum pump oil return hose

24. Generator and adjusting plate

25. Water inlet pipe

26. Generator bracket

27. Oil cooler with oil filter

28. Exhaust manifold

Removal

1. Clutch Assembly or Flex Plate

Remove the clutch assembly or the flex plate.

RTW36ASH000201

2. Intake Pipe and Throttle Body

1) Loosen hose clamp between turbocharger and intake

duct.

2) Remove the rubber hose.

3) Remove the intake pipe and the throttle body.

RTW36ASH000301

3. EGR Pipe

1) Remove two bolts from the exhaust manifold.

2) Remove two nuts from the EGR valve adapter.

3) Remove the EGR pipe with gaskets.

4. EGR Valve

1) Remove four nuts and remove the EGR valve

assembly from the intake manifold.

2) Remove four bolts and remove the adapter from the

EGR valve assembly.

5. Oil Level Gauge

1) Disconnect PCV hose.

2) Remove two bolts and remove the engine oil level

gauge.

6. Fuel Filter Assembly

1) Disconnect fuel hose.

2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket

Remove three bolts and remove the fuel filter bracket with

leak pipe.

RTW36ASH001201

8. Fuel Injection Pipe with Clip

1) Loosen the injection pipe sleeve nuts at pump side

and nozzle side.

Do not apply excessive force to the injection pipes.

2) Loosen the injection pipe clips.

3) Remove the injection pipe.

NOTE:

Plug the delivery holder ports with the caps to prevent the

entry of foreign material.

9. Power Steering Oil Pump Bracket

RTW36ASH000701

10. Intake Manifold

1) Disconnect the PCV hose from the cylinder head

cover.

2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot

12. Injection Pump Cover

13. Injection Pump

Refer to Section 6C Injection Pump

14. Starter Motor

15. Oil Pressure Warning Switch

16. Fuel Leak Off Pipe

17. Oil Cooler Water Pipe

18. Cooling Fan Pulley

19. Heat Protector

20. Catalytic Converter

21. Turbocharger

1) Disconnect the water hose between thermostat

housing cover and turbocharger.

2) Disconnect the water hose between water inlet pipe

and turbocharger.

3) Remove the oil feed pipe.

4) Remove the oil return pipe.

5) Remove the turbocharger and the gasket.

NOTE:

Plug the turbocharger body oil ports and water ports after

removing the turbocharger assembly to prevent the entry of

foreign material.

22. Compressor Bracket

23. Vacuum Pump Oil Return Hose

24. Generator and Adjusting Plate

25. Water Inlet Pipe

26. Generator Bracket

27. Oil Cooler with Oil Filter

28. Exhaust Manifold

027R100007

037RY00001

DISASSEMBLY

INTERNAL PARTS

MAJOR COMPONENTS

011R300001

Disassembly Steps-1

1. Water bypass hose

2. Thermostat housing with thermo

switch

3. Cylinder head cover

4. Injection nozzle and bracket

5. Rocker arm shaft and rocker arm

6. Push rod

7. Cylinder head

8. Cylinder head gasket

RTW36ALF000701

Disassembly Steps-2

9. Crankshaft damper pulley

10. Timing gear case cover

11. Water pump

12. Idler gear "B" and shaft

13. Idler gear "A"

14. Idler gear shaft

15. Crankshaft timing gear

16. Injection pump

014R300005

Disassembly Steps-3

17. Flywheel

18. Crank case

19. Oil pump with oil pipe

20. Camshaft timing gear

21. Camshaft thrust plate

22. Camshaft

23. Timing gear case

24. Cylinder body rear plate

25. Piston cooling oil jet

26. Connecting rod bearing cap with

lower bearing

27. Piston and connecting rod with

upper bearing

28. Crankshaft bearing cap with lower

bearing

29. Crankshaft thrust bearing

30. Crankshaft

31. Crankshaft upper bearing

32. Tappet

33. Crankshaft rear oil seal

34. Cylinder body

Disassembly

1. Water Bypass Hose

2. Thermostat Housing with Thermo Switch

3. Cylinder Head Cover

4. Injection Nozzle and Bracket

1) Remove the injection nozzle bracket bolts.

2) Use the injection nozzle remover and the sliding

hammer to remove the injection nozzle together.

Injection Nozzle Remover: 5-8840-2723-0

Sliding Hammer: 5-8840-0019-0

5. Rocker Arm Shaft and Rocker Arm

Loosen the rocker arm shaft bracket bolts in numerical

order a little at a time.

NOTE:

Failure to loosen the rocker arm shaft bracket bolts in

numerical order a little at a time will adversely affect the

rocker arm shaft.

6. Push Rod

011R100002

011RY00005

011RY00006

7. Cylinder Head

Loosen the cylinder head bolts in numerical order a little

at a time.

NOTE:

Failure to loosen the cylinder head bolts in numerical order a

little at a time will adversely affect the cylinder head lower

surface.

8. Cylinder Head Gasket

9. Crankshaft Damper Pulley

10. Timing Gear Case Cover

The timing gear case is tightened together with the

injection pump at the 6 points indicated by the arrows in

the illustration.

11. Water Pump

12. Idle Gear B and shaft

Before removing the idle gear B, install bolt (M6,L=30) to

the hole marked with an arrow in the illustration to hold

the scissor gear in place.

13. Idler Gear "A"

1) Measure the camshaft timing gear backlash and the

crankshaft timing gear backlash before removing the

idler gear.

2) Measure the idler gear end play before removing the

idler gear.

NOTE:

Refer to the following items for details on the backlash and

end play measurement procedures.

011RY00007

020L200006

020L200020

020RY00019

Timing Gear Backlash Measurement

1. Set a dial indicator to the timing gear to measured.

Hold both the gear to be checked and the adjusting

gear stationary.

2. Move the gear to be checked as far as possible to

both the right and the left.

Take the dial indicator reading.

If the measured value exceeds the specified limit, the

timing gear must be replaced.

Timing Gear Backlash mm (in)

Standard: 0.10 - 0.17 (0.0039 - 0.0067)

Limit: 0.30 (0.012)

RTW36ASH000801

Idler Gear "A" End Play Measurement

Insert a feeler gauge between the idler gear and the thrust

collar to measure the gap and determine the idler gear

end play.

If the measured value exceeds the specified limit, the

thrust collar must be replaced.

Idler Gear End Play mm (in)

Standard: 0.07 (0.0028)

Limit: 0.2 (0.0079)

14. Idle Gear Shaft

15. Crankshaft Timing Gear

RTW36ASH001301

16. Injection Pump

1) Remove the injection pump cover.

2) Remove the injection pump bracket.

3) Pull the injection pump along with the injection pump

timing gear free toward the rear of the engine.

NOTE:

Plug the injection pump delivery ports with the caps to prevent

the entry of foreign material.

020RY00020

17. Flywheel

Loosen the flywheel bolts in numerical order a little at a

time.

Use the gear stoper to stop the flywheel gear.

Gear stoper: 5-8840-0214-0

18. Crank Case

19. Oil Pump With Oil Pipe

20. Camshaft Timing Gear

1) Use a dial indicator to measure the camshaft end

play.

This must be done before removing the camshaft

gear.

If the camshaft end play exceeds the specified limit,

the thrust plate must be replaced.

Camshaft End Play mm (in)

Standard: 0.050 - 0.114(0.002 - 0.0044)

Limit: 0.20(0.008)

2) Remove the camshaft timing gear bolt from the

camshaft.

NOTE:

Hold the camshaft stationary to prevent the camshaft from

turning.

3) Remove the sensor rotor plate.

4) Use the universal puller to pull out the camshaft

timing gear.

Universal Puller: 5-8521-0002-0

5) Remove the thrust plate.

21. Camshaft Thrust Plate

015RY00001

014RT0001

901R100008

22. Camshaft

Jiggle the camshaft with your hand as you pull it free from

the front of the engine.

23. Timing Gear Case

24. Cylinder Body Rear Plate

25. Piston Cooling Oil Jet

The oiling jet uses thin steel tubing which is easily bent.

Accidental contact between the oiling jet and the cylinder

body, piston, or a tool will damage the oiling jet.

Never attempt to repair a damaged oiling jet. Replace it

with a new one.

26. Connecting Rod Bearing Cap with Lower Bearing

If the connecting rod lower bearings are to be reinstalled,

mark their fitting positions by tagging each bearing with

the cylinder number from which it was removed.

27. Piston and Connecting Rod with Upper Bearing

1) Remove carbon deposits from the upper portion of the

cylinder wall with a scraper before removing the piston

and connecting rod.

2) Move the piston to the top of the cylinder and tap it

with a hammer grip or a similar object from the

connecting rod lower side to drive it out.

RTW36ASH001501

3) If the connecting rod upper bearings are to be

reinstalled, mark their fitting positions by tagging each

bearing with the cylinder number from which it was

removed.

014RY00019

052RY00001

014LX056

015LX018

28. Crankshaft Bearing Cap with Lower Bearing

1) Measure the crankshaft end play at the center journal

of the crankshaft.

Do this before removing the crankshaft bearing caps.

If the measured value exceeds the specified limit, the

crankshaft thrust bearing must be replaced.

Crankshaft End Play mm (in)

Standard: 0.10 (0.004)

Limit: 0.30 (0.012)

2) Loosen the crankshaft bearing cap bolts in numerical

order a little at a time.

If the crankshaft bearings are to be reinstalled, mark

their fitting positions by tagging each bearing with the

cylinder number from which it was removed.

29. Crankshaft Thrust Bearing

30.Crankshaft

31. Crankshaft Upper Bearing

If the crankshaft upper bearings are to be reinstalled,

mark their fitting positions by tagging each bearing with

the cylinder number from which it was removed.

015RY00002

015RY00003

015RY00004

32. Tappet

If the tappets are to be reinstalled, mark their fitting

positions by tagging each tappet with the cylinder number

from which it was removed.

33. Crankshaft Rear Oil Seal

• With the oil seal pushed in deep, install the special

tool as shown in the illustration and remove the oil

seal.

Oil Seal Remover: 5-8840-2360-0

34. Cylinder Body

015RY00005

015LV002

MINOR COMPONENTS

ROCKER ARM SHAFT AND ROCKER ARM

011RY00009

Disassembly Steps

1. Rocker arm shaft snap ring

2. Rocker arm

3. Rocker arm shaft bracket

4. Rocker arm

5. Rocker arm shaft spring

6. Rocker arm shaft snap ring

7. Rocker arm shaft

Disassembly

1. Rocker Arm Shaft Snap Ring

2. Rocker Arm

3. Rocker Arm Shaft Bracket

1) Use a pair of pliers to remove the snap rings.

2) Remove the rocker arms.

3) Remove the rocker arm shaft brackets.

If the rocker arms and rocker arm shaft brackets are

to be reinstalled, mark their installation positions by

tagging each rocker arm and rocker arm shaft bracket

with the cylinder number from which it was removed.

4. Rocker Arm

5. Rocker Arm Shaft Spring

6. Rocker Arm Shaft Snap Ring

7. Rocker Arm Shaft

011RY00010

CYLINDER HEAD

RTW36ALF000901

Disassembly Steps

1. Intake manifold

2. Intake manifold gasket

3. Split collar

4. Valve spring upper seat

5. Valve spring

6. Intake and exhaust valve

7. Valve stem oil seal

8. Valve spring lower seat

9. Cylinder head

Disassembly

1. Intake Manifold

2. Intake Manifold Gasket

3. Split Collar

1) Place the cylinder head on a flat wooden surface.

2) Use the spring compressor to remove the split collars.

Do not allow the valve to fall from the cylinder head.

Spring Compressor: 9-8523-1423-0

4. Valve Spring Upper Seat

5. Valve Spring

6. Intake and Exhaust Valve

If the intake and exhaust valves are to be reinstalled, mark

their installation positions by tagging each valve with the

cylinder number from which it was removed.

If the intake and exhaust valves are to be replaced, the

valve guides must also be replaced.

7. Valve Stem Oil Seal

8. Valve Spring Lower Seat

9. Cylinder Head

011RY00011

011LX022

PISTON AND CONNECTING ROD

RTW36ALF0001301

Disassembly Steps

1. Connecting rod bearing

2. Piston ring

3. Piston pin snap ring

4. Piston pin

5. Connecting rod

6. Piston

RTW36ASH001501

Disassembly

1. Connecting Rod Bearing

If the connecting rod bearings are to be reinstalled, mark

their fitting positions by tagging each bearing with the

cylinder number from which it was removed.

2. Piston Ring

1) Clamp the connecting rod in a vice.

Take care not to damage the connecting rod.

2) Use a piston ring replacer to remove the piston rings.

NOTE

Piston Ring Replacer

Do not attempt to use some other tool to remove the piston

rings. Piston ring stretching will result in reduced piston ring

tension.

3. Piston Pin Snap Ring

Use a pair of pliers to remove the piston pin snap rings.

RTW36ASH001601

4. Piston Pin

5. Connecting Rod

6. Piston

Tap the piston pin out with a hammer and a brass bar.

If the pistons and piston pins are to be reinstalled, mark

their installation positions by tagging each piston and

piston pin with the cylinder number from which it was

removed.

015RW041

F06MV015

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during

inspection.

CYLINDER HEAD

Cylinder Head Lower Face Warpage

1. Use a straight edge and a feeler gauge to measure the

four sides and the two diagonals of the cylinder head

lower face.

2. The cylinder head lower surface warpage is more than the

limit, it should be replaced.

Cylinder Head Lower Face Warpage mm (in)

Standard Limit

0.05

(0.002) or less 0.20

(0.0079)

NOTE:

The cylinder head lower face cannot be reground.

Cylinder Head Height (H) (Reference) mm (in)

Standard

91.95 – 92.05

(3.620 – 3.624)

Positive Crankcase Ventilation (PCV) Valve

1. Remove PCV valve assembly from cylinder head cover.

2. Inspect the diaphragm for broken.

3. Inspect the spring for broken or weaken.

4. If find any abnormal condition, replace the PCV valve

assembly.

011RY00012

011RY00013

011RY00014

Manifold Fitting Face Warpage

Use a straight edge and a feeler gauge to measure the

manifold cylinder head fitting face warpage.

Regrind the manifold cylinder head fitting surfaces if the

measured values are greater than the specified limit but less

than the maximum grinding allowance.

If the measured values exceed the maximum grinding

allowance, the cylinder head must be replaced.

Manifold Fitting Face Warpage mm (in)

Standard Limit

Maximum Grinding

Allowance

0.05

(0.002) or less 0.20

(0.008) 0.40

(0.016)

Exhaust Manifold Warpage

Use a straight edge and a feeler gauge to measure the

manifold cylinder head fitting face warpage.

If the measured values exceed the specified limit, the manifold

must be replaced.

Exhaust Manifold Warpage mm (in)

Standard Limit

0.05 (0.002) or less 0.20 (0.008)

Valve Stem and Valve Guide Clearance

Measuring Method-I

1. With the valve stem inserted in the valve guide, set the dial

indicator needle to "0".

2. Move the valve head from side to side.

Read the dial indicator.

Note the highest dial indication.

If the measured values exceed the specified limit, the valve

and the valve guide must be replaced as a set.

Valve Stem Clearance mm (in)

Standard Limit

Intake Valve 0.039 - 0.071

(0.0015 - 0.0028) 0.200

(0.008)

Exhaust Valve 0.064 - 0.096

(0.0025 - 0.0038) 0.250

(0.0098)

027RY00001

027RY00002

011RY00022

Measuring Method-II

1. Measure the valve stem outside diameter.

Refer to the Item "Valve Stem Outside Diameter".

2. Use a calliper calibrator or a telescoping gauge to

measure the valve guide inside diameter.

Valve Guide Replacement

Valve Guide Removal

Use a hammer and the valve guide replacer to drive out the

valve guide from the cylinder head lower face.

Valve Guide Replacer: 9-8523-1212-0

Valve Guide Installation

1. Apply engine oil to the valve guide outer circumference.

2. Attach the valve guide installer to the valve guide.

3. Use a hammer to drive the valve guide into position from

the cylinder head upper face.

Valve Guide Replacer: 9-8523-1212-0

4. Measure the height of the valve guide upper end from the

upper face of the cylinder head.

Valve Guide Upper End Height (H) (Reference) mm (in)

12.8-13.2 (0.50-0.52)

NOTE:

If the valve guide has been removed, both the valve and

the valve guide must be replaced as a set.

011RY00023

011LX029

011RY00024

011RY000025

Valve Stem Outside Diameter

Measure the valve stem diameter at three points.

If the measured value is less than the specified limit, the valve

and the valve guide must be replaced as a set.

Valve Stem Outside Diameter mm (in)

Standard Limit

Intake Valve 7.946 - 7.961

(0.3128 - 0.3134) 7.880

(0.3102)

Exhaust Valve 7.921 - 7.936

(0.3119 - 0.3124) 7.850

(0.3090)

Valve Thickness

Measure the valve thickness.

If the measured value is less than the specified limit, the valve

and the valve guide must be replaced as a set.

Intake and Exhaust Valve Thickness mm (in)

Standard Limit

Inlet 1.34 (0.054)

Exhaust 1.36 (0.055)

1.1 (0.045)

Valve Depression

1. Install the valve (1) to the cylinder head (2).

2. Use a depth gauge or a straight edge with steel rule to

measure the valve depression from the cylinder head

lower surface.

If the measured value exceeds the specified limit, the valve

seat insert must be replaced.

Valve Depression mm (in)

Standard Limit

1.17 (0.048) 1.67 (0.068)

011LX027

014RY00020

014RY00021

Valve Contact Width

1. Check the valve contact faces for roughness and

unevenness. Make smooth the valve contact surfaces.

2. Measure the valve contact width.

If the measured value exceeds the specified limit, the valve

seat insert must be replaced.

Valve Contact Width mm (in)

Standard Limit

Intake 1.7 (0.067) 2.2 (0.087)

Exhaust 2.0 (0.079) 2.5 (0.078)

Valve Seat Insert Replacement

Valve Seat Insert Removal

1. Arc weld the entire inside circumference (1) of the valve

seat insert (2).

2. Allow the valve seat insert to cool for a few minutes.

This will invite contraction and make removal of the valve

seat insert easier.

3. Use a screwdriver (3) to pry the valve seat insert free.

Take care not to damage the cylinder head (4).

4. Carefully remove carbon and other foreign material from

the cylinder head insert bore.

Valve Seat Insert Installation

1. Carefully place the attachment (1) (having a smaller

outside diameter than the valve seat insert) on the valve

seat insert (2).

NOTE:

The smooth side of the attachment must contact the valve

seat insert.

2. Use a bench press (3) to gradually apply pressure to the

attachment and press the valve seat insert into place.

NOTE:

Do not apply an excessive amount of pressure with the

bench press. Damage to the valve seat insert will result.

014RY00027

011LX039

014RY00026

Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface.

2. Use a valve cutter (15°, 45°, and 75° blades) to minimize

scratches and other rough areas. This will bring the

contact width back to the standard value.

Remove only the scratches and rough areas. Do not cut

away too much. Take care not to cut away unblemished

areas of the valve seat surface.

Valve Seat Angle Degree

NOTE:

Use an adjustable valve cutter pilot.

Do not allow the valve cutter pilot to wobble inside the

valve guide.

3. Apply abrasive compound to the valve seat insert surface.

4. Insert the valve into the valve guide.

5. Turn the valve while tapping it to fit the valve seat insert.

6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in contact with

the entire circumference of the valve.

Valve Spring Free Height

Use a vernier calliper to measure the valve spring free height.

If the measured value is less than the specified limit, the valve

spring must be replaced.

Spring Free Height mm (in)

Standard Limit

48.0 (1.89) 47.1 (1.85)

011LX063

011LX037

011LX038

011LX024

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.

Spring Squareness mm (in)

Limit 1.7 (0.070)

Valve Spring Tension

Use a spring tester to measure the valve spring tension.

If the measured value is less than the specified limit, the valve

spring must be replaced.

Valve Spring Tension N (kg/lb)

Compressed Height Standard Limit

38.9mm

(1.53in) 296.0

(30.2/66.4) 257.7

(26.3/57.9)

ROCKER ARM SHAFT AND ROCKER ARM

Rocker Arm Shaft Run-Out

1. Place the rocker arm shaft on a V-block.

2. Use a dial indicator to measure the rocker arm shaft

central portion run-out.

If the run-out is very slight, correct the rocker arm shaft

run-out with a bench press. The rocker arm must be at

cold condition.

If the measured rocker arm shaft run-out exceeds the

specified limit, the rocker arm shaft must be replaced.

Rocker Arm Shaft Run-Out mm (in)

Limit

0.3 (0.012)

014RY00025

011LX026

015LX008

Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting portion

outside diameter.

If the measured value is less than the specified limit, the

rocker arm shaft must be replaced.

Rocker Arm Shaft Outside Diameter mm (in)

Standard Limit

18.98–19.00 (0.747–0.748) 18.90 (0.744)

Rocker Arm Shaft and Rocker Arm Clearance

1. Use either a vernier calliper or a dial indicator to measure

the rocker arm inside diameter.

Rocker Arm Inside Diameter mm (in)

Standard Limit

19.010–19.030

(0.748–0.749) 19.100 (0.752)

2. Measure the rocker arm shaft outside diameter.

If the measured value exceeds the specified limit, replace

either the rocker arm or the rocker arm shaft.

Rocker Arm Shaft and Rocker Arm Clearance mm (in)

Standard Limit

0.01–0.05

(0.0004–0.0020) 0.20 (0.008)

3. Check that the rocker arm oil port is free of obstructions.

If necessary, use compressed air to clean the rocker arm

oil port.

Rocker Arm Correction

Inspect the rocker arm valve stem contact surfaces for step

wear (1) and scoring (2).

If the contact surfaces have light step wear or scoring, they

may be honed with an oil stone.

If the step wear or scoring is severe, the rocker arm must be

replaced.

015LX009

014RY00024

014RY00023

CYLINDER BODY

Cylinder Body Upper Face Warpage

1. Remove the cylinder body dowel.

2. Remove the cylinder liner.

Refer to "Cylinder Liner Replacement".

3. Use a straight edge (1) and a feeler gauge (2) to measure

the four sides and the two diagonals of the cylinder body

upper face.

If the measured values exceeds the limit, the cylinder body

must be replaced.

Cylinder Body Upper Face Warpage mm (in)

Standard Limit

0.05 (0.002) or less 0.20 (0.008)

Cylinder Body Height (H) (Reference) mm (in)

Standard

269.945-270.055 (10.6277-10.6320)

4. Reinstall the cylinder liner.

Refer to "Cylinder Liner Replacement".

5. Reinstall the cylinder body dowel.

Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder bore at

measuring point (1) in the thrust (2-2) and axial (3-3) directions

of the crankshaft.

Measuring Point (1): 20 mm (0.79 in)

If the measured value exceeds the specified limit, the cylinder

liner must be replaced.

Cylinder Liner Bore mm (in)

Standard Limit

95.40 (3.7559) 95.48 (3.7590)

NOTE:

The inside of the dry type cylinder liner is chrome plated. It

cannot be rebored or honed.

If the inside of the cylinder liner is scored or scorched, the

cylinder liner must be replaced.

012R100001

012RY00009

012RY00010

Cylinder Liner Projection Inspection

1. Hold a straight edge along the top edge of the cylinder

liner to be measured.

2. Use a feeler gauge to measure each cylinder liner

projection.

Cylinder Liner Projection mm (in)

Standard

0-0.1 (0-0.004)

The difference in the cylinder liner projection height

between any two adjacent cylinders must not exceed 0.03

mm (0.0012 in).

Cylinder Liner Replacement

Cylinder Liner Removal

1. Insert the cylinder liner remover (1) into the cylinder body

(from the lower side of the cylinder body) until it makes

firm contact with the cylinder liner.

Cylinder Liner Remover: 5-8840-2304-0

2. Use a bench press (2) to slowly force the cylinder liner

from the cylinder body.

NOTE:

Take care not to damage the cylinder body upper face

during the cylinder liner removal procedure.

3. Measure the cylinder body upper face warpage.

Refer to "Cylinder Body Upper Face Warpage".

Cylinder Liner Grade Selection

Subtract the average cylinder body bore from the average

cylinder liner outside diameter to obtain the fitting interference.

Fitting Interference mm (in)

Standard

-0.0010*-0.019 (-0.00004*-0.0007)

* A minus (-) value indicates that the cylinder body bore is

smaller than the liner outside diameter.

012LX016

012RY00012

012RY00013

Cylinder Body Bore Measurement

1. Take measurements at measuring point (1) across

positions 1-1 and 2-2.

Measuring Point (1):

18,53,88,123,158 mm (0.71,2.09,3.46,4.84,6.22 in)

Cylinder Liner Grade Selection and Standard Fitting

Interference

Accurately measured fitting interference and proper cylinder

liner grade selection are extremely important.

If the cylinder liner fitting interference is too small, engine

cooling efficiency will be adversely affected.

If the cylinder liner fitting interference is too large, it will be

difficult to insert the cylinder liner into the cylinder body.

012RY00022

A mark was stamped on the upper side of the cylinder block

during production to indicate the correct liner.

The liner grade (i.e.1.2.3.4) is indicated in metal stamp.

012RY00014

012R300001

Cylinder Liner Grade

4JH1T mm (in)

Liner

Outside

Grade

Cylinder Body

Bore Diameter Liner Outside

Diameter Liner Bore

Grade Service Liner Bore Measurement

AX 95.435-95.450 (3.7573-3.7579)

1 97.001-97.010

(3.8189-3.8193) 97.011-97.020

(3.8193-3.8197) CX 95.451-95.466 (3.7579-3.7585)

AX 95.435-95.450 (3.7573-3.7579)

2 97.011-97.020

(3.8193-3.8197) 97.021-97.030

(3.8197-3.8200) CX 95.451-95.466 (3.7579-3.7585)

AX 95.435-95.450 (3.7573-3.7579)

3 97.021-97.030

(3.8197-3.8200) 97.031-97.040

(3.8200-3.8205) CX 95.451-95.466 (3.7579-3.7585)

AX 95.435-95.450 (3.7573-3.7579)

4 97.031-97.040

(3.8200-3.8205) 97.041-97.050

(3.8205-3.8209) CX 95.451-95.466 (3.7579-3.7585)

Cylinder Liner Installation

Cylinder Liner Installation Using the Special Tool

1. Use new kerosene or diesel oil to thoroughly clean the

cylinder liners and bores.

2. Use compressed air to blow-dry the cylinder liner and

bore surfaces.

NOTE:

All foreign material must be carefully removed from the

cylinder liner and the cylinder bore before installation.

3. Insert the cylinder liner (1) into the cylinder body (2)

from the top of the cylinder body.

4. Set the cylinder liner installer (3) to the top of the

cylinder liner.

5. Cylinder Liner Installer 5-8840-2313-0 (3) is directly

beneath the bench press shaft center (4).

NOTE:

Check that the cylinder liner is set perpendicular to the

bench press and that there is no wobble.

6. Use the bench press to apply a seating force of 4,900

N (500 kg/1,100 Ib) to the cylinder liner.

7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully

seat the cylinder liner.

8. After installing the cylinder liner, measure the cylinder

liner projection.

Refer to "Cylinder Liner Projection Inspection".

012RY00017

012RY00018

Piston Grade Selection

Measure the cylinder liner bore after installing the cylinder

liner. Then select the appropriate piston grade for the installed

cylinder liner.

1. Measure the cylinder liner bore.

Refer to "Cylinder Liner Bore Measurement"

Cylinder Liner Bore (Service Part) Grade mm (in)

Grade Bore measurement

AX 95.435-95.450

(3.7573-3.7579)

CX 95.451-95.466

(3.7579-3.7585)

NOTE:

It is most important that the correct piston grade be used.

Failure to select the correct piston grade will result in

engine failure. Always measure the cylinder bore and

select the correct piston grade.

2. Measure the piston diameter.

iston Measuring Point mm (in)

70 (2.76)

Piston Grade (Service Part) mm (in)

AX 95.359-95.374

(3.7542-3.7548)

CX 95.375-95.390

(3.7548-3.7555)

Cylinder Liner and Piston Clearance mm (in)

0.047-0.065 (0.0019-0.0026)

NOTE:

Cylinder liner kit clearances are preset. However, the

cylinder liner installation procedure may result in slight

decreases in cylinder liner clearances. Always measure

the cylinder liner clearance after installation to be sure

that it is correct.

015LX021

TAPPET AND PUSH ROD

Visually inspect the tappet contact surfaces for pitting,

cracking, and other abnormal conditions. The tappet must be

replaced if any of these conditions are present.

Refer to the illustration at the left.

1. Normal contact

2. Cracking

3. Pitting

4. Irregular contact Uneven contact

5. Irregular contact One-sided contact

NOTE:

The tappet surfaces are spherical. Do not attempt to grind

them with an oil stone or similar tool in an effort to repair

the tappet. If the tappet is damaged, it must be replaced.

Tappet Outside Diameter

Measure the tappet outside diameter with a micrometer.

If the measured value is less than the specified limit, the

tappet must be replaced.

appet Outside Diamete

mm (in)

Standard Limit

12.97 - 12.99

(0.510 - 0.511) 12.95 (0.510)

appet and Cylinder Body Clearance mm (in)

Standard Limit

0.01 - 0.046

(0.0004 - 0.0018) 0.10 (0.004)

Push Rod Curvature

1. Lay the push rod on a surface plate.

2. Roll the push rod along the surface plate and measure the

push rod curvature with a thickness gauge.

If the measured value exceeds the specified limit, the push

rod must be replaced.

Pushrod Curvature mm (in)

Limit

0.3 (0.012)

3. Visually inspect both ends of the push rod for excessive

wear and damage. The push rod must be replaced if these

conditions are discovered during inspection.

014RY00028

014RY00029

012LX014

014RY00031

CAMSHAFT

Visually inspect the journals, the cams, the oil pump drive

gear, and the camshaft bearings for excessive wear and

damage. The camshaft and the camshaft bearings must be

replaced if these conditions are discovered during inspection.

Camshaft Journal Diameter

Use a micrometer to measure each camshaft journal diameter

in two directions (1 and 2). If the measured value is less than

the specified limit, the camshaft must be replaced.

Camshaft Journal Diamete

mm (in)

Standard Limit

49.945 - 49.975

(1.9663 - 1.9675) 49.60 (1.953)

Cam Height

Measure the cam height (H) with a micrometer. If the

measured value is less than the specified limit, the camshaft

must be replaced.

Cam Height (H) mm (in)

Standard Limit

42.016 (1.6542) 41.65 (1.640)

Camshaft Run-Out

1. Mount the camshaft on V-blocks.

2. Measure the run-out with a dial indicator.

If the measured value exceeds the specified limit, the

camshaft must be replaced.

Camshaft Run-Out mm (in)

Standard Limit

0.02 (0.0008) 0.10 (0.004)

014RY00032

014RY00033

014LX092

Camshaft and Camshaft Bearing Clearance

Use an inside dial indicator to measure the camshaft bearing

inside diameter.

Crankshaft Bearing Inside Diamete

mm (in)

Standard Limit

50.00 - 50.03

(1.968 - 1.970) 50.08 (1.972)

If the clearance between the camshaft bearing inside diameter

and the journal exceeds the specified limit, the camshaft

bearing must be replaced.

Camshaft Bearing Clearance mm (in)

Standard Limit

0.055 (0.0022) 0.12 (0.005)

Camshaft Bearing Replacement

Camshaft Bearing Removal

1. Remove the cylinder body plug plate.

2. Use the bearing replacer to remove the camshaft bearing.

Bearing Replacer: 5-8840-2038-0

Camshaft Bearing Installation

1. Align the bearing oil holes with the cylinder body oil holes.

2. Use the replacer to install the camshaft bearing.

Bearing Replacer: 5-8840-2038-0

CRANKSHAFT AND BEARING

Inspect the surface of the crankshaft journals and crankpins

for excessive wear and damage.

Inspect the oil seal fitting surfaces for excessive wear and

damage.

Inspect the oil ports for obstructions.

NOTE:

To increase crankshaft strength, tufftriding (Nitrizing

Treatment) has been applied, and because of this, it is not

possible to regrind the crankshaft surfaces.

Therefore, under size bearings are not available.

014RY00034

014RY00035

014RY00036

Crankshaft Run-Out

1. Set a dial indicator to the center of the crankshaft journal.

2. Gently turn the crankshaft in the normal direction of

rotation.

Read the dial indicator as you turn the crankshaft.

If the measured value exceeds the specified limit, the

crankshaft must be replaced.

Crankshaft Run-Out mm (in)

Standard Limit

0.05 (0.002) or less 0.08 (0.003)

Bearing Spread

Use a vernier calliper to measure the bearing spread.

If the measured value is less than the specified limit, the

bearing must be replaced.

Bearing Spread mm (in)

Limit

Crankshaft Bearing 74.5 (2.93)

Connecting Rod Bearing 56.5 (2.22)

Crankshaft Journal and Crankpin Diameter

1. Use a micrometer to measure the crankshaft journal

diameter across points 1 - 1 and 2 - 2.

2. Use the micrometer to measure the crankshaft journal

diameter at the two points (3 and 4).

3. Repeat Steps 1 and 2 to measure the crankpin diameter.

If the measured values are less than the specified limit, the

crankshaft must be replaced.

Crankshaft Journal and Diameter mm (in)

Standard Limit

69.917-69.932

(2.7526-2.7532) 69.91(2.7524)

Crankpin Diamete

mm (in)

Standard Limit

52.915 - 52.930

(2.0833 - 2.0839) 52.90 (2.083)

Crankshaft Journal and Crankpin Uneven Wear mm (in)

Standard Limit

0.05 (0.002) or less 0.08 (0.003)

015LX061

015RY00007

015RY00008

Crankshaft Journal and Crankpin Diameter

If the clearance between the measured bearing inside

diameter and the crankshaft journal diameter exceeds the

specified limit, the bearing and/or the crankshaft must be

replaced.

Crankshaft Journal and Bearing Clearance mm (in)

Standard Limit

0.032 - 0.077

(0.0013 - 0.0030) 0.110 (0.0043)

Connecting Rod Bearing Inside Diameter

1. Install the bearing to the connecting rod big end.

2. Tighten the bearing cap to the two step of angular

tightening method.

Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)

1st step ; 29 (3.0/22)

2nd step ; 45°-60°

3. Use an inside dial indicator to measure the connecting rod

bearing inside diameter.

Crankpin and Bearing Clearance

If the clearance between the measured bearing inside

diameter and the crankpin exceeds the specified limit, the

bearing and/or the crankshaft must be replaced.

Crankpin and Bearing Clearance mm (in)

Standard Limit

0.029-0.083

(0.0011-0.033) 0.100 (0.0039)

Clearance Measurements (With Plastigage)

Crankshaft Journal and Bearing Clearance

1. Clean the cylinder body, the journal bearing fitting surface,

the bearing caps, and the bearings.

2. Install the bearings to the cylinder body.

3. Carefully place the crankshaft on the bearings.

4. Rotate the crankshaft approximately 30° to seat the

bearing.

5. Place the Plastigage (arrow) over the crankshaft journal

across the full width of the bearing.

6. Install the bearing caps with the bearing.

015RY00009

015RY00011

015RY00012

7. Tighten the bearing caps to the specified torque.

Crankshaft Bearing Cap Bolt Torque mm (in)

167 (17/123)

Do not allow the crankshaft to turn during bearing cap

installation and tightening.

8. Remove the bearing cap.

9. Compare the width of the Plastigage attached to either the

crankshaft or the bearing against the scale printed on the

Plastigage container.

If the measured value exceeds the limit, perform the

following additional steps.

1) Use a micrometer to measure the crankshaft

outside diameter.

2) Use an inside dial indicator to measure the

bearing inside diameter.

3) If the crankshaft journal and bearing clearance

exceeds the limit, the crankshaft and/or the

bearing must be replaced.

Crankshaft Journal and Bearing Clearance mm (in)

Standard Limit

0.032-0.077

(0.0013-0.0030) 0.110 (0.0043)

015RY00013

015LX129

015LX060

Crankpin and Bearing Clearance

1. Clean the crankshaft, the connecting rod, the bearing cap,

and the bearings.

2. Install the bearing to the connecting rod and the bearing

cap.

Do not allow the crankshaft to move when installing the

bearing cap.

3. Prevent the connecting rod from moving.

4. Attach the Plastigage to the crankpin.

Apply engine oil to the Plastigage to keep it from falling.

5. Install the bearing cap and tighten it to the two step of

angular tightening method.

Do not allow the connecting rod to move when installing

and tightening the bearing cap.

Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)

1st step ; 29 (3.0/22)

2nd step ; 45°-60°

6. Remove the bearing cap.

7. Compare the width of the Plastigage attached to either the

crankshaft or the bearing against the scale printed on the

Plastigage container.

If the measured value exceeds the specified limit, perform

the following additional steps.

1) Use a micrometer to measure the crankpin

outside diameter.

2) Use an inside dial indicator to measure the

bearing inside diameter.

3) If the crank pin and bearing clearance exceeds

the specified limit, the crankshaft and/or the

bearing must be replaced.

Crankpin and Bearing Clearance mm (in)

Standard Limit

0.029-0.083

(0.0011-0.0033) 0.100 (0.0039)

CRANKSHAFT BEARING SELECTION

Crankshaft bearing selection is based on the measured

diameters of the crankshaft journals and the bearing inserts.

Match the crankshaft bearing housing grade marks and the

crankshaft journal grade marks in the table below to determine

the correct crankshaft bearing size.

Crankshaft Bearing Housing Grade Mark Position

Crankshaft bearing housing grade marks 1, 2 or 3 are

stamped on the rear right hand side of the cylinder body.

Crankshaft Journal Grade Mark Position

The crankshaft journal grade marks (1 or -, 2 or --, 3 or ---) are

stamped on each crankshaft journal web.

The crankshaft journal and bearing clearance must be the

same for each position after installation of the crankshaft and

the crankshaft bearings.

NOTE:

The crankshaft journal mark No. 4 is stamped on

crankshaft No. 4 journal web front side or rear side.

RTW46ASH002501

REFERENCE

MY2003 mm (in)

Crankshaft

Bearing Housing Crankshaft Journal

Grade

Mark Diameter Grade

Mark Diameter

Crankshaft

Bearing

Size Color

Code

1 or

- 69.927-69.932

(2.7530-2.7532)

2 or

- - 69.922-69.927

(2.7528-2.7530)

Yellow

73.992-

74.000

(2.9131-

2.9134) 3 or

- - - 69.917-69.922

(2.7556-2.7528) Red

1 or

- 69.927-69.932

(2.7530-2.7532) Black

2 or

- - 69.922-69.927

(2.7528-2.7530) Blue

73.983-

73.992

(2.9127-

2.9131) 3 or

- - - 69.917-69.922

(2.7556-2.7528) Yellow

1 or

- 69.927-69.932

(2.7530-2.7532) Green

2 or

- - 69.922-69.927

(2.7528-2.7530)

73.975-

73.983

(2.9124-

2.9127) 3 or

- - - 69.917-69.922

(2.7526-2.7528)

Black

015LX060

015RY00016

015RY00017

RTW46ASH002501

MY2004 mm (in)

Crankshaft

Bearing Housing Crankshaft Journal

Grade

Mark Diameter Grade

Mark Diameter

Crankshaft

Bearing

Size Code

1 or

- 69.927-69.932

(2.7530-2.7532)

2 or

- - 69.922-69.927

(2.7528-2.7530)

73.992-

74.000

(2.9131-

2.9134) 3 or

- - - 69.917-69.922

(2.7556-2.7528) 5

1 or

- 69.927-69.932

(2.7530-2.7532) 2

2 or

- - 69.922-69.927

(2.7528-2.7530) 3

73.983-

73.992

(2.9127-

2.9131) 3 or

- - - 69.917-69.922

(2.7556-2.7528) 4

1 or

- 69.927-69.932

(2.7530-2.7532) 1

2 or

- - 69.922-69.927

(2.7528-2.7530)

73.975-

73.983

(2.9124-

2.9127) 3 or

- - - 69.917-69.922

(2.7526-2.7528)

CRANKSHAFT PILOT BEARING

Check the crankshaft pilot bearing for excessive wear and

damage and replace it if necessary.

Crankshaft Pilot Bearing Replacement

Crankshaft Pilot Bearing Removal

Use the pilot bearing remover to remove the crankshaft pilot

bearing.

Pilot Bearing Remover: 5-8840-2000-0

Sliding Hammer: 5-8840-0019-0

Crankshaft Pilot Bearing Installation

1. Place the crankshaft pilot bearing right angle across the

crankshaft bearing installation hole.

2. Tap around the edges of the crankshaft pilot bearing outer

races with a brass hammer to drive the bearing into the

crankshaft bearing installation hole.

Pilot Bearing Installer: 5-8522-0024-0

NOTE:

Strike only the crankshaft pilot bearing outer race with the

hammer. Do not strike the bearing inner race. Bearing

damage and reduced bearing service life will result.

015RY00018

015RY00010

FLYWHEEL AND RING GEAR

Flywheel

1. Inspect the flywheel friction surface for excessive wear

and heat cracks.

2. Measure the flywheel friction surface depth.

If the measured value is within the specified limit, the

flywheel may be reground.

If the measured value exceeds the specified limit, the

flywheel must be replaced.

Flywheel Friction Surface Depth (1) mm (in)

Standard Limit

18 (0.7087) 19 (0.7480)

Ring Gear

Inspect the ring gear.

If the ring gear teeth are broken or excessively worn, the ring

gear must be replaced.

Ring Gear Replacement

Ring Gear Removal

Strike around the edges of the ring gear with a hammer and

chisel to remove it.

Ring Gear Installation

1. Heat the ring gear evenly with a gas burner to invite

thermal expansion.

Do not allow the temperature of the gas burner to exceed

200°C (390°F).

2. Install the ring gear when it is sufficiently heated.

The ring gear must be installed with the chamfer facing the

clutch.

PISTON

Piston Grade Selection and Cylinder Bore Measurement

Refer to the Section "Cylinder Body", Item

"Cylinder Liner Bore Measurement" for details on piston

grade selection and cylinder liner bore measurement.

015RY00019

020LX008

020LX009

Piston Ring Gap

1. Insert the piston ring horizontally (in the position it would

assume if it were installed to the piston) into the cylinder

liner.

2. Push the piston ring into the cylinder bore until it reaches

the measuring point 1 or 2 where the cylinder liner bore is

the smallest.

Do not allow the piston ring to slant to one side or the

other. It must be perfectly horizontal.

Measuring Point 1 10 mm (0.4 in)

Measuring Point 2 120 mm (4.7 in)

3. Use a feeler gauge to measure the piston ring gap.

If the measured value exceeds the specified limit, the

piston ring must be replaced.

Standard Limit

1st Compression Ring

2nd Compression Ring 0.3-0.5

(0.0118-0.0197)

Oil Ring 0.250-0.450

(0.0098-0.0177)

1.5

(0.059)

Piston Ring and Piston Ring Groove Clearance

Use a feeler gauge to measure the clearance between the

piston ring and the piston ring groove at several points around

the piston.

If the clearance between the piston ring and the piston ring

groove exceeds the specified limit, the piston ring must be

replaced.

Piston Ring and Piston Ring Groove Clearance mm (in)

Standard Limit

1st Compression Ring 0.09-0.130

(0.0035-0.0051)

2nd Compression Ring 0.05-0.090

(0.0020-0.0035)

Oil Ring 0.03-0.070

(0.0012-0.0028)

1.5

(0.0059)

015LX023

015RY00020

015RY00021

015LX025

4. Visually inspect the piston rings.

If a piston ring groove is damaged or distorted, the piston

must be replaced.

Piston Pin Diameter

Use a micrometer to measure the piston pin diameter at

several points.

If the measured value is less than the specified limit, the piston

pin must be replaced.

Piston Pin Diameter mm (in)

Standard Limit

30.995-31.000

(1.2202-1.2204) 30.97

(1.2193)

Piston Pin and Piston Clearance

Use an inside dial indicator to measure the piston pin hole (in

the piston).

Piston Pin Hole mm (in)

31.005-31.013 (1.2207-1.2210)

Piston Pin and Piston Pin Hole Clearance mm (in)

0.005-0.018 (0.0002-0.0007)

CYLINDER HEAD GASKET SELECTION

Cylinder head gasket is determined by the piston head

projection from the cylinder body upper surface, in order to

improve engine performance.

Three types of gasket are provided by the difference of

thickness. Select the adequate one out of three grades of

gasket, according to the following procedure.

Before measurement, clear off carbon from the piston head

and cylinder body surface and also clean the place where a

gasket was installed.

RTW36ASH001701

Piston Head Projection Measuring Point

1. Use a dial indicator to measure the piston projection

amount.

2. Refer to the illustration for the piston head projection

measuring positions.

All measuring positions should be as close as possible to

the cylinder liner.

015LX026

015RW048

011LX011

3. Measure the points 1, 2, 3, 4 and obtain two differences 1-

2 and 3-4 on each cylinder.

Calculate the average value of the piston head projection

on each cylinder.

4. Obtain the maximum value in the four cylinders.

5. Determine the gasket grade required to the maximum

value described above in accordance with the following

table.

Cylinder Head Gasket Combination mm (in)

Gasket Grade Mark Piston Projection Gasket Thickness

(Reference)

A 0.215-0.265

(0.0085-0.0104) 1.3

(0.5118)

B 0.265-0.315

(0.0104-0.0124) 1.35

(0.5315)

C 0.315-0.365

(0.0124-0.0144) 1.4

(0.5512)

NOTE:

Difference of the each piston projection and must be

equal or within 0.1 mm (0.004 in).

CONNECTING ROD

Connecting Rod Alignment

Use a connecting rod aligner to measure the distortion and the

parallelism between the connecting rod big end hole and the

connecting rod small end hole.

If either the measured distortion or parallelism exceed the

specified limit, the connecting rod must be replaced.

Connecting Rod Alignment Per Length of 100 mm (3.94 in)

mm (in)

Standard Limit

Distortion 0.08 (0.003) or Less 0.20 (0.008)

Parallelism 0.05 (0.002) or Less 0.15 (0.006)

011RY00027

011RY00030

015LX034

Connecting Rod Side Face Clearance

1. Install the connecting rod to the crankpin.

2. Use a feeler gauge to measure the clearance between the

connecting rod big end side face and the crankpin side

face.

If the measured value exceeds the specified limit, the

connecting rod must be replaced.

Connecting Rod Big End and Crankpin Side Face Clearance

mm (in)

Standard Limit

0.23 (0.009) 0.35 (0.014)

Piston Pin and Connecting Rod Small End Bushing

Clearance

Use a calliper calibrator and a dial indicator to measure the

piston pin and connecting rod small end bushing clearance.

If the clearance between the piston pin and the connecting rod

small end bushing exceeds the specified limit, replace the

piston pin and/or the connecting rod.

Piston Pin and Connecting Rod Small End

Bushing Clearance mm (in)

Standard Limit

0.005-0.018

(0.0002-0.0007) 0.050 (0.002)

IDLER GEAR SHAFT AND IDLER GEAR

Idler Gear "A" Shaft Outside Diameter

Use a micrometer to measure the idler gear shaft outside

diameter.

If the measured value is less than the specified limit, the idler

gear shaft must be replaced.

Idler Gear "A" Shaft Outside Diameter mm (in)

Standard Limit

44.945-44.975

(1.7695-1.7707) 44.845 (1.755)

011RY00029

015LX028

020RY00025

Idler Gear "A" Shaft inside Diameter

1. Use an inside dial indicator or an inside micrometer to

measure the idler gear inside diameter.

Idler Gear Inside Diamete

mm (in)

Standard Limit

45.0-45.03

(1.7717-1.7718) 45.10 (1.7756)

If the clearance between the idler gear shaft outside diameter

and the idler gear inside diameter exceeds the limit, the idler

gear must be replaced.

Idler Gear Shaft and Idler Gear Clearance mm (in)

Standard Limit

0.025-0.085

(0.0010-0.0033) 0.200 (0.0079)

TIMING GEAR CASE COVER

Replace the crankshaft front oil seal if it is excessively worn or

damaged.

Crankshaft Front Oil Seal Replacement

Oil Seal Removal

Use a plastic hammer and a screwdriver to tap around the oil

seal to free it from the gear case cover.

Take care not to damage the oil seal lip surfaces.

Oil Seal Installation

Use the special tool to install the front oil seal.

Front Oil Seal Installer: 5-8840-2361-0

1. With the oil seal attached to the sleeve, insert it into the

front end section of the crankshaft.

2. With the oil seal end section attached securely to the

crankshaft, tighten up the center bolt until the sleeve hits

the front end reference plane of the crankshaft securely.

3. Remove the sleeve.

4. With the seal pressed in, check the dimension of the oil

seal section.

Standard Dimension = 1.0 ± 0.03mm

NOTE:

Install the oil seal after assembling the timing pulley

housing. The oil seal lip section is applied with oil.

Take notice of the press-in direction of the oil seal.

014LX022

020R300004

020R300005

REASSEMBLY

INTERNAL PARTS

MINOR COMPONENT

ROCKER ARM SHAFT AND ROCKER ARM

020

RY00029

Reassembly Steps

1. Rocker arm shaft 5. Rocker arm

2. Rocker arm shaft snap ring 6. Rocker arm shaft spring

3. Rocker arm 7. Rocker arm shaft snap ring

4. Rocker arm shaft bracket

Reassembly

1. Rocker Arm Shaft

1) Position the rocker arm shaft with the large oil hole (4

φ) facing the front of the engine.

2) Install the rocker arm shaft together with the rocker

arm, the rocker arm shaft bracket, and the spring.

2. Rocker Arm Shaft Snap Ring

3. Rocker Arm

4. Rocker Arm Shaft Bracket

5. Rocker Arm

6. Rocker Arm Shaft Spring

7. Rocker Arm Shaft Snap Ring

014RY00037

CYLINDER HEAD

RTW36ALF001001

Reassembly Steps

1 .Cylinder head 6. Valve spring upper seat

2. Valve spring lower seat 7. Split collar

3. Valve stem oil seal 8. Intake manifold gasket

4. Intake and exhaust valve 9. Intake manifold

5. Valve spring

Reassembly

1. Cylinder Head

2. Valve Spring Lower Seat

3. Valve Stem Oil Seal

1) Apply a coat of engine oil to the oil seal inner face.

2) Use an oil seal installer to install the oil seal to the

valve guide.

Oil Seal Installer: 5-8840-2033-0

4. Intake and Exhaust Valve

1) Apply a coat of engine oil to each valve stem before

installation.

2) Install the intake and exhaust valves.

3) Turn the cylinder head up to install the valve springs.

Take care not to allow the installed valves to fall free.

5. Valve Spring

Install the valve spring with their fine pitched end (painted)

facing down.

6. Valve Spring Upper Seat

7. Split Collar

1) Use the spring compressor to compress the valve

spring into position.

Spring Compressor: 9-8523-1423-0

2) Install the split collars to the valve stem.

3) Set the split collars by tapping around the head of the

collar with a rubber hammer.

RTW36ASH001101

8. Intake manifold gasket

9. Intake manifold

1) Install the manifold gasket with the end having the

sharp corners facing the front of the engine.

2) Install the intake manifold to the cylinder head.

3) Tighten the manifold bolt/nuts to the specified torque.

Manifold Bolt/Nut Torque N·m (kg·m/lb·ft)

Bolt 19 (1.9/14)

Nut 24 (2.4/17)

011RW027

011LX055

014RY00039

PISTON AND CONNECTING ROD

RTW36ALF001401

Reassembly Steps

1. Piston 5. Piston pin snap ring

2. Connecting rod 6. Piston ring

3. Piston pin snap ring 7. Connecting rod bearing

4. Piston pin

Reassembly

1. Piston

2. Connecting Rod

1) Clamp the connecting rod in a vice. Take care not to

damage the connecting rod.

2) Use a pair of pliers to install the piston pin snap ring to

the piston.

RTW36ASH001801

Install the piston to the connecting rod so that the piston

head front mark (1) and the connecting rod mark (2) are

facing in the same direction.

3. Piston Pin Snap Ring

RTW36ASH001901

4. Piston Pin

1) Apply a coat of engine oil to the piston pin and the

piston pin hole.

2) Use your fingers to force the piston pin into the piston

until it makes contact with the snap ring.

5. Piston Pin Snap Ring

1) Use your fingers to force the piston pin snap ring into

the piston snap ring groove.

2) Check that the connecting rod moves smoothly on the

piston pin.

F06MV015

015R100001

RTW36ASH002001

6. Piston Ring

1) Use a piston ring replacer to install the three piston

rings.

Piston Ring Replacer

Install the piston rings in the order shown in the

illustration.

1. Oil ring

2. 2nd compression ring

3. 1st compression ring

NOTE:

Install the compression rings with the stamped side facing

up.

Insert the expander coil into the oil ring groove so that

there is no gap on either side of the expander coil before

installing the oil ring.

2) Apply engine oil to the piston ring surfaces.

3) Check that the piston rings rotate smoothly in the

piston ring grooves

7. Connecting Rod Bearing

Carefully wipe any oil or other foreign material from the

connecting rod bearing back face and the connecting rod

bearing fitting surface.

015R100006

POSITIVE CRANKCASE VENTILATION (PCV) VALVE

RTW36AMF000601

Reassembly Steps

1. Positive Crankcase Ventilation (PCV)

Valve 4. Breather pipe

2. Rubber spacer 5. Fixing bolt

3. Cylinder head insulator cover 6. Oil filler cap

Reassembly

1. PCV Valve

Install the PCV valve and tighten the bolts to specified

torque.

PCV Valve Bolts Torque N·m (kg·m/lb·in)

2 (0.2/17)

2. Rubber Spacer

3. Cylinder Head Insulator Cover

RTW36ASH001401

4. Breather Hose

Apply LOCTITE 262 or equivalent to the new breather

pipe.

Do not reuse the breather pipe.

5. Fixing Bolt

Fixing Bolt Torque N·m (kg·m/lb·in)

19 (1.9/14)

6. Oil Filler Cap

010R100014

MAJOR COMPONENT

014R300004

Reassembly Steps-1

1. Cylinder body 11. Piston and connecting rod with upper bearing

2. Tappet 12. Connecting rod bearing cap with lower

bearing

3. Crankshaft upper bearing 13. Piston cooling oil pipe

4. Crankshaft 14. Oil pump with oil pipe

5. Crankshaft thrust bearing 15. Crankshaft rear oil seal

6. Crankshaft bearing cap with lower bearing 16. Crank case

7. Camshaft 17. Cylinder body rear plate

8. Timing gear case 18. Flywheel

9. Camshaft thrust plate

10. Camshaft timing gear

RTW36ALF000801

Reassembly Steps-2

19. Crankshaft timing gear 23. Injection pump

20. Idler gear shaft 24. Water pump

21. Idler gear "A" 25. Timing gear case cover

22. Idler gear "B" and shaft 26. Crankshaft damper pulley

011R300002

Reassembly Steps-3

27. Cylinder head gasket 32. Water by-pass hose

28. Cylinder head 33. Injection nozzle and bracket

29. Push rod 34. Cylinder head cover with gasket

30. Rocker arm shaft and rocker arm

31. Thermostat housing with thermo switch

Reassembly

1. Cylinder Body

Use compressed air to thoroughly clean the inside and

outside surfaces of the cylinder body, the oil holes, and the

water jackets.

2. Tappet

1) Apply a coat of engine oil to the tappet and the

cylinder body tappet insert holes.

2) Locate the position mark applied at disassembly (if the

tappet is to be reused).

NOTE:

The tappet must be installed before the camshaft

installation.

3. Crankshaft Upper Bearing

The crankshaft upper bearings have an oil hole and an oil

groove. The lower bearings do not.

1) Carefully wipe any foreign material from the upper

bearing.

NOTE:

Do not apply engine oil to the bearing back faces and the

cylinder body bearing fitting surfaces.

2) Locate the position mark applied at disassembly if the

removed upper bearings are to be reused.

4. Crankshaft

Apply an ample coat of engine oil to the crankshaft

journals and the crankshaft bearing surfaces before

installing the crankshaft.

015R100003

014LX088

015LX125

015R100004

5. Crankshaft Thrust Bearing

Apply an ample coat of engine oil to the thrust bearings

before installation.

Install the thrust bearings to the crankshaft center journal.

The thrust bearing oil grooves must be facing the sliding

faces.

6. Crankshaft Bearing Cap With Lower Bearing

Before the crankshaft bearing installation, select the

appropriate bearings in accordance with the description in

CRANK BEARING SELECTION of INSPECTION AND

REPAIR.

1) Apply the recommended liquid gasket or its equivalent

to the No. 5 crankshaft bearing cap cylinder body

fitting surfaces at the points shown in the illustration.

NOTE:

Be sure that the bearing cap fitting surface is completely

free of oil before applying the liquid gasket. Do not allow

the liquid gasket to obstruct the cylinder thread holes and

bearings.

2) Install the bearing caps with the bearing cap head

arrow mark facing the front of the engine. The bearing

cap numbers must be facing up.

3) Apply engine oil to the crankshaft bearing cap bolts.

4) Tighten the crankshaft bearing cap bolts to the

specified torque a little at time in the sequence shown

in the illustration.

Crankshaft Bearing Cap Torque N·m (kg·m/lb·ft)

167 (17/123)

5) Check to see the crankshaft turns smoothly by

rotating it manually.

015LX115

015LX127

015LX128

015LX129

7. Camshaft

1) Apply a coat of engine oil to the camshaft and the

camshaft bearings.

2) Install the camshaft to the cylinder body. Take care

not to damage the camshaft bearings.

8. Timing Gear Case

Tighten the timing gear case with timing gear case gasket

to the specified torque.

Timing Gear Case Bolt Torque N·m (kg·m/lb·ft)

19 (1.9/14)

9. Camshaft Thrust Plate

Install the thrust plate to the cylinder body and tighten the

thrust plate bolts to the specified torque.

Thrust Plate Bolt Torque N·m (kg·m/lb·ft)

19 (1.9/14)

RTW36ASH000901

10. Camshaft Timing Gear

1) Install the camshaft timing gear to the camshaft. The

timing gear mark must be facing outward.

2) Tighten the timing gear to the specified torque.

Timing Gear Bolt Torque N·m (kg·m/lb·ft)

110 (11.2/82)

014RY00019

020R300003

020RY00032

RTW36ASH002001

11. Piston and Connecting Rod with Upper Bearing

12. Connecting Rod Bearing Cap with Lower Bearing

1) Apply a coat of engine oil to the circumference of each

piston ring and piston.

2) Position the piston ring gaps as shown in the

illustration.

a) Oil ring

b) 2nd compression ring

c) 1st compression ring

3) Apply a coat of molybdenum disulfide grease to the

two piston skirts. This will facilitate smooth break-in

when the engine is first started after reassembly.

4) Apply a coat of engine oil to the upper bearing

surfaces.

5) Apply a coat of engine oil to the cylinder wall.

6) Position the piston head front mark so that it is facing

the front of the engine.

7) Use the piston ring compressor to compress the

piston rings.

Piston Ring Compressor: 5-8840-9018-0

8) Use a hammer grip to push the piston in until the

connecting rod makes contact with the crankpin.

At the same time, rotate the crankshaft until the

crankpin is at BDC.

9) Align the bearing cap cylinder number marks and the

connecting rod cylinder number marks.

The cylinder number marks must be turned toward the

exhaust manifold.

10) Apply a coat of engine oil to the threads and setting

faces of each connecting rod cap bolt.

11) Tighten the connecting rod caps to the two step of

angular tighten method.

Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/lb·ft)

1st step 29 (3.0/22)

2nd step 45° - 60°

015R100006

015LX096

015R100007

015LX130

13. Piston Cooling Oil Jet

1) Install the piston cooling oil jet to the cylinder body.

2) Tighten the oil jet bolts and relief valve to the specified

torque.

Oil Jet Bolt Torque N·m (kg·m/lb·ft)

M8 × 1.25 19 (1.9/14)

M6 × 1.00 8 (0.8/6)

Relief Valve Torque N·m (kg·m/lb·ft)

29 (3.0/22)

NOTE:

Check that there is no interference between the piston

and the oiling jet by slowly rotating the crankshaft.

14. Oil Pump with Oil Pipe

Install the oil pump with the oil pipe and tighten the bolts to

the specified torque.

Oil Pump Bolt Torque N·m (kg·m/lb·ft)

19 (19/14)

NOTE:

Take care not to damage the O-rings when tightening the

oil pipe bolts.

15. Crankshaft Rear Oil Seal

Use a oil seal install to install the crankshaft rear oil seal.

Oil Seal Installer : 5-8840-2359-0

052LX010

051R100004

015LX112

16. Crank Case

1) Apply the recommended liquid gasket (Three bond

1207B) or its equivalent to arch gasket fitting surface

as shown in the illustration.

2) Install the crank case front gasket (1) to the timing

gear case arches.

The gasket projection (2) must be facing forward.

NOTE:

ThreeBond 1207B is a fast-drying liquid gasket. Install the

arch packing to the crankcase immediately after applying

the gasket.

3) Install the rear arch gasket (2) to the No. 5 bearing

cap. Use your fingers to push the arch gasket into the

bearing cap groove. Take care not to scratch the arch

gasket outer surface.

Also apply the recommended liquid gasket (1207C) or

its equivalent to arch gasket fitting area as indicated in

the illustration.

4) Apply the recommended liquid gasket or its equivalent

to groove of the crank case fitting surface as shown in

the illustration.

NOTE:

Be sure that the crank case fitting surface is completely

free of oil and dust before applying the liquid gasket.

5) Install the crank case to the cylinder body.

6) Tighten the crank case bolts to the specified torque a

little at a time in the sequence shown in the

illustration.

Crank Case Bolt Torque N·m (kg·m/lb·ft)

19 (1.9/14)

013RW012

013RW011

013LV003

013R100001

17. Cylinder Body Rear Plate

1) Align the rear plate with the cylinder body knock pins.

2) Tighten the rear plate to the specified torque.

Rear Plate Torque N·m (kg·m/lb·ft)

82 (8.4/61)

18. Flywheel

1) Apply a coat of engine oil to the threads of the

flywheel bolts.

2) Align the flywheel with the crankshaft dowel pin.

3) Tighten the flywheel bolts in the numerical order

shown in the illustration.

Gear stopper: 5-8840-0214-0

Flywheel Bolt Torque N·m (kg·m/lb·ft)

118 (12/87)

19. Crankshaft Timing Gear

Use the crankshaft timing gear installer (1) to install the

crankshaft timing gear (2).

The crankshaft timing gear setting mark must be facing

outward.

Crankshaft Timing Gear Installer: 9-8522-0020-0

020R100001

015LX113

020RY00034

20. Idler Gear Shaft

21. Idler Gear "A"

1) Turn the crankshaft clockwise to set the DTC of the

No.1 piston.

2) Apply engine oil to the idler gear and the idler gear

shaft.

The idler gear shaft oil hole (A) must be facing up.

3) Position the idler gear setting marks so that they are

facing the front of the engine.

4) Align the idler gear setting mark with the crankshaft

timing gear (1) setting mark.

5) Align the idler gear setting mark with the camshaft

timing gear (2) setting mark.

6) Install the thrust collar and bolts to the cylinder body

through the shaft.

The thrust collar oil hole must be facing up, and the

thrust collar chamfered must be outward.

7) Tighten the idler gear bolt to the specified torque.

Idler Gear "A" Bolt Torque N·m (kg·m/lb·ft)

30 (3.1/22)

020R300006

22. Idler Gear "B" and Shaft

1) Apply engine oil to the idler gear and the idler gear

shaft.

2) Align the idler gear "B" (3) setting mark with the idler

gear "A" (4) setting mark.

3) Tighten the idler gear bolt to the specified torque.

4) Be sure to remove the lock bolt (5) from idle gear “B”.

Idler Gear "B" Bolt Torque N·m (kg·m/lb·ft)

76 (7.7/56)

020RY00035

020RY00036

020L200019

5) If the idle gear "B" is disassembled, reassemble in the

following procedure.

a) Drive pins into the main gear, the front gear, and

the rear gear.

020L200007

b) Install the main gear bearing from the front side of

the main gear (the side with the groove).

c) Place the main gear in a vice with copper plate so

that the rear side of the main gear facing up.

RTW31BSH000101

d) Set the spring as shown in the illustration.

RTW31BSH000201

e) Position the rear gear so that the pin is aligned

with the receiving end of the spring.

RTW31BSH000301

f) Install the snap ring to the main gear groove.

RTW31BSH000501

g) Install suitable bolts, nuts and washers to special

tool as shown in the illustration to rotate the

scissors gear.

End yoke holder: 5-8840-2447-0

RTW31BSH000401

h) Insert the bolts of the special tool into the rear

gear setting hole. Rotate the rear gear to mesh the

teeth of main gear and rear gear.

i) Insert a lock bolt (M6 × 1 L=30) into scissors gear

fixing hole to prevent the scissors gear from

turning.

j) Place the main gear in a vice with copper plate so

that the front side of the main gear facing up.

k) Repeat steps 4 to 8 to install the front gear.

l) Lock the front gear, the main gear, and the rear

gear with lock bolt (inserted at Step 8).

23. Injection Pump

1) Install the O-ring (1) to the injection pump flange (2).

2) Attach the noise insulator rubber to the cylinder body.

3) Install the injection pump to the timing gear case.

Align the idler gear "B" (3) mark with the injection

pump timing gear (4) mark.

RTW36AMH000101

4) Tighten the injection pump bolts (5) to the specified

torque.

Injection Pump Bolt Torque N·m (kg·m/lb·ft)

19 (1.9/14)

5) Install the injection pump bracket (6) and the bracket

bolts (7) and (8) to the cylinder body.

6) Temporarily tighten the bracket bolts.

7) Tighten the bracket bolts (7) to the specified torque.

8) Tighten the bracket bolts (8) to the specified torque.

NOTE:

Tighten the bracket bolt (7) first.

Injection Pump Bracket Bolt Torque N·m (kg·m/lb·ft)

19 (1.9/14)

020RY00039

030RY00007

24. Water Pump

1) Apply the recommended liquid gasket or its equivalent

to the water pump at the position shown in the

illustration.

Do not apply an excessive amount of liquid gasket.

2) Tighten the water pump bolts to the specified torque.

Water Pump Bolt Torque N·m (kg·m/lb·ft)

20 (2.0/14)

25.Timing Gear Case Cover

1) Align the gear case with the timing gear case knock

pin and then install the timing gear case cover.

2) Tighten the gear case cover bolts to the specified

torque.

Gear Case Cover Bolt Torque N·m (kg·m/lb·ft)

M8 19 (1.9/14)

M12 76 (7.7/56)

26. Crankshaft Damper Pulley

Tighten the crankshaft damper pulley bolt to the specified

torque.

NOTE:

Hold the flywheel ring gear stationary to prevent the

crankshaft from turning when tightening the damper pulley

bolt.

Crankshaft Damper Pulley Bolt Torque N·m (kg·m/lb·ft)

235 (24/174

Take care not to damage the crankshaft damper pulley

boss.

27. Cylinder Head Gasket

The cylinder head gasket "TOP" mark must be facing up.

NOTE:

Before the gasket installation, measure the piston head

projection and select the appropriate head gasket.

Refer to "INSPECTION AND REPAIR", "Cylinder Head

Gasket Selection".

020R300004

014R100014

28. Cylinder Head

1) Align the cylinder body dowels and the cylinder head

dowel holes.

Carefully place the cylinder head on the cylinder head

gasket.

2) Apply a coat of engine oil to the cylinder head bolt

threads and setting faces.

3) Tighten the cylinder head bolts in three steps of

angular tightening method.

Follow the numerical sequence shown in the

illustration.

Cylinder Head Bolt Torque N·m (kg·m/lb·ft)

1st step 49 (5.0/36)

2nd step 60° - 75°

3rd step 60° - 7 5°

30. Rocker Arm Shaft and Rocker Arm

Tighten the rocker arm shaft bracket bolts in the numerical

order shown in the illustration.

Rocker Arm Shaft Bracket Bolt Torque N·m (kg·m/lb·ft)

54 (5.5/40)

31. Thermostat Housing

1) Install the thermostat housing.

2) Tighten the thermostat housing bolts to the specified

torque.

Thermostat Housing Bolt Torque N·m (kg·m/lb·ft)

19 (1.9/14)

011LX073

014LX083

031R300002

33. Injection Nozzle Holder

1) Install the injection nozzle gasket and the O-ring to the

injection nozzle holder.

Be sure that the O-ring fits snugly in the injection

nozzle groove.

2) Install the nozzle holder together with the nozzle

holder bracket to the cylinder head.

3) Tighten the nozzle holder bracket bolt to the specified

torque.

Injection Nozzle Holder Bracket Bolt

Torque N·m (kg·m/lb·ft)

37 (3.8/28)

Note on Valve Clearance Adjustment

Valve clearances must be adjusted before the cylinder

head cover is reinstalled. Refer to "Valve Clearance

Adjustment" in the "Servicing" Section of this manual.

Valve Clearance (At Cold) mm (in)

0.4 (0.0157)

34. Cylinder Head Cover

1) Apply engine oil to the rocker arm and the valve

spring.

2) Install the cylinder head cover gasket to the head

cover. Check to see that the head cover gasket has

no loose areas.

3) Tighten the cylinder head cover nuts in the numerical

order shown in the illustration.

Cylinder Head Cover Bolt Torque N·m (kg·m/lb·ft)

13 (1.3/9.4)

4) Connect the positive crankcase ventilation (PCV)

hose to the cylinder head cover.

040R100013

014RY00015

010R100018

INSTALLATION

EXTERNAL PARTS

RTW36AMF000701

Installation Steps

1. Exhaust manifold 15. Starter motor

2. Oil cooler with oil filter 16. Injection pump

3. Generator bracket 17. Injection pump cover

4. Water inlet pipe 18. Engine mounting bracket and foot

5. Generator and adjusting plate 19. Intake manifold

6. Vacuum pump oil return hose 20. Power steering oil pump bracket

7. Compressor bracket 21. Fuel injection pipe with clip

8. Turbocharger 22. Fuel filter bracket

9. Catalytic converter 23. Fuel filter assembly

10. Heat protector 24. Oil level gauge

11. Cooling fan pulley 25. EGR valve

12. Oil cooler water pipe 26. EGR pipe

13. Fuel leak off pipe 27. Intake pipe and throttle body

14. Oil pressure warning switch 28. Clutch assembly or flex plate

Installation

1. Exhaust Manifold

1) Install the exhaust manifold to the cylinder head with

the manifold gasket.

2) Tighten the exhaust manifold bolts and nuts to the

specified torque a little at a time.

Exhaust Manifold Bolt and Nuts

Torque N·m (kg·m/Ib·ft)

27 (2.8/20)

3) Install the exhaust manifold bracket to the manifold

and the cylinder body.

Manifold Bracket Bolt Torque N·m (kg·m/Ib·ft)

19 (1.9/14)

RTW46ASH001301

2. Oil Cooler with Oil Filter

1) Install the O-ring to the oil filter body flange groove.

2) Install the oil filter body to cylinder block and tighten to

the specified torque.

Oil Filter Body Bolt and Nut

Torque N·m (kg·m/Ib·ft)

Bolt 19 (1.9/14)

Nut 24 (2.4/17)

3. Generator Bracket

Install the generator bracket to the cylinder body and

tighten the bracket bolts to the specified torque.

Bracket Bolt Torque N·m (kg·m/Ib·ft)

40 (4.1/30)

4. Water Inlet Pipe

1) Tighten the water inlet pipe bolts to the specified

torque.

Suction Pipe Bolt Torque N·m (kg·m/Ib·ft)

19 (1.9/14)

027R100003

027R100004

066RY00001

032R300001

5. Generator and Adjusting Plate

1) Install the generator to the bracket (1).

2) Temporarily tighten the generator bolt (2) and

adjusting plate bolts (3).

The bolts will be finally tightened after installation of

the cooling fan drive belt.

3) Connect the vacuum pump rubber hose (4) to the

vacuum pump (5), and the oil pan (6).

6. Vacuum Pump Oil Return Hose

Connect the vacuum oil pipe (7) to the vacuum pump, and

the cylinder body

052R30000

7. Compressor Bracket

1) Install the compressor bracket to the cylinder head.

2) Tighten the bracket bolts to the specified torque.

Bracket Bolt Torque N·m (kg·m/Ib·ft)

M8×1.25 19 (1.9/14)

M10×1.25 40 (4.1/30)

066RY00002

042RY00003

8. Turbocharger

1) Install the turbocharger and the gasket.

2) Temporarily tighten the turbocharger nuts at this time.

They will be fully tightened after the installation of the

turbocharger oil pipe.

Always install new nuts and new gasket.

3) Install the oil return pipe with gasket to the

turbocharger.

4) Tighten the turbocharger oil return pipe to the

specified torque.

Bracket Bolt Torque N·m (kg·m/Ib·ft)

8 (0.8/6)

5) Before installing the oil feed pipe, supply 10 - 20 cc of

clean engine oil to the turbocharger centre housing

through the oil feed opening.

6) Turn the rotating assembly with your hand to

thoroughly lubricate the internal parts.

7) Tighten the oil feed pipe to the specified torque.

Turbocharger Oil Feed Pipe Joint

Bolt Torque N·m (kg·m/Ib·ft)

M10×1.5 22 (2.25/16)

M14×1.5 54 (5.5/40)

8) Tighten the turbocharger nut to the specified torque.

Turbocharger Nut Torque N·m (kg·m/Ib·ft)

27 (2.8/20)

027R100002

036R100001

036R300001

027R100005

9) Install the water return adapter with the gaskets to

turbocharger and tighten to the specified torque.

Adapter Torque N·m (kg·m/Ib·ft)

39 (4.0/29)

10) Install the water return pipe with the gaskets and

tighten to the specified torque.

Water Return Pipe Torque N·m (kg·m/Ib·ft)

39 (4.0/29)

11) Install the water feed pipe with the gaskets and

tighten to the specified torque.

Water Feed Torque N·m (kg·m/Ib·ft)

39 (4.0/29)

12) Clamp the water feed pipe to the oil return pipe of the

turbocharger.

Fixing Bolt (3) Torque N·m (kg·m/Ib·ft)

8 (0.8/6)

13) Install the hoses for the water feed and return.

RTW46ASH001601

9. Catalytic Converter

Install the catalytic converter with gasket and tighten the

nut to the specified torque.

Catalytic converter Nut Torque N·m (kg·m/Ib·ft)

27 (2.8/20)

Do not install the catalytic converter, if drop down it.

10. Heat Protector

Install the heat protector and tighten the bolt to the

specified torque.

Heat Protector Bolt Torque N·m (kg·m/Ib·ft)

9 (0.9/78 Ib in)

033R300002

11. Cooling Fan Pulley

1) Install the cooling fan pulley to the water pump with

spacer.

2) Tighten the cooling fan pulley nuts to the specified

torque.

Pulley Nut Torque N·m (kg·m/Ib·ft)

8 (0.8/6)

12. Oil Cooler Water Pipe

13. Fuel Leak Off Pipe

14. Oil Pressure Warning Switch

027R100007

15. Starter Motor

Tighten the starter motor bolts to the specified torque.

Starter Motor Bolt Torque N·m (kg·m/Ib·ft)

85 (8.7/63)

16. Injection Pump

Refer to Section 6C Fuel System; Injection Pump

17. Injection Pump Cover

18. Engine Foot

Install the engine foot to the cylinder body and tighten the

bracket bolts to the specified torque.

Engine Foot Bolt Torque N·m (kg·m/Ib·ft)

Right Side M10×1.25 40 (4.1/30)

M10×1.25 40 (4.1/30)

Left Side M14×1.50 127 (13/93)

RTW36ASH001001

19. Intake Manifold

1) Install the manifold gasket to the intake manifold.

2) Connect the intake rubber hose to the intake duct.

3) Tighten the intake manifold bolts and the flange nuts

to the specified torque.

Intake Manifold Bolt Torque N·m (kg·m/Ib·ft)

19 (1.9/14)

Intake Manifold Flange Nut Torque N·m (kg·m/Ib·ft)

24 (2.4/18)

4) Connect the PCV hose to the cylinder head cover.

5) Install the fan drive belt and adjust the belt tension

referring SERVICING of this section

022R300003

20. Power Steering Oil Pump Bracket

Oil Pump Bracket Nut and Bolt Torque N·m (kg·m/Ib·ft)

1M10×1.25 37 (3.8/28)

3M8×1.25 18 (1.8/13) (Bolt ID:8)

040R300005

21. Fuel Injection Pipe with Clip

1) Temporarily tighten the injection pipe sleeve nut.

2) Set the clip in the illustrated position.

NOTE:

Make absolutely sure that the clip is correctly positioned.

An improperly positioned clip will result in injection pipe

breakage and fuel pulsing noise.

3) Tighten the injection pipe sleeve nut to the specified

torque.

Torque

Injection Pump Side N·m (kg·m/Ib·ft)

40 (4.1/30)

Injection Pipe Sleeve Nuts N·m (kg·m/Ib·ft)

29 (3.0/22)

Injection Pipe Clip Nuts N·m (kg·m/Ib·ft)

8 (0.8/6)

22. Fuel Filter Bracket

Install the fuel filter bracket and tighten fixing bolts to the

specified torque.

Fuel Filter Bracket Bolt Torque N·m (kg·m/Ib·ft)

21 (2.1/15)

23. Fuel Filter Assembly

Install the fuel filter assembly and tighten fixing bolts to the

specified torque.

Fuel Filter Assembly Bolt Torque N·m (kg·m/Ib·ft)

21 (2.1/15)

431RY00013

24. Oil Level Gauge

Install the oil level gauge and tighten fixing bolts to the

specified torque.

Oil Level Gauge Bolt Torque N·m (kg·m/Ib·ft)

M8 19 (1.9/14)

M6 8 (0.8/6)

25. EGR Valve

Install the EGR valve assembly to the intake manifold with

the two gasket.

Tighten the four nuts to the specified torque.

Nut Torque N·m (kg·m/Ib·ft)

31 (3.1/23)

Connector the vacuum hose.

RTW36ASH000301

26. EGR Pipe

Install the EGR valve adapter with the gasket to the EGR

valve assembly and install the EGR pipe with the gasket.

Tighten fixing bolts and nuts to the specified torque.

ECM Valve Adapter Bolts N·m (kg·m/Ib·ft)

24 (2.4/17)

EGR Pipe Bolts and Nuts N·m (kg·m/Ib·ft)

27 (2.8/20)

27. Intake Pipe and Throttle Body

Install the throttle body with the gasket to the intake

manifold and install the intake duct with the gasket.

Tighten the two bolts and the two nuts to the specified

torque.

Throttle Body and Intake Duct N·m (kg·m/Ib·ft)

Bolt 19 (1.9/14)

Nut 24 (2.4/17)

RTW36ASH000201

28. Clutch Assembly or Flex Plate

LUBRICATION SYSTEM

LUBRICATING OIL FLOW

1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8 kg/cm2 (608 - 764 Kpa)

2. Regulating Valve Operating Pressure: 5.7 - 6.3 kg/cm2 (558.6 - 617.4 Kpa)

3. Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4 kg/cm2 (270 - 330 Kpa)

4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2 kg/cm2 (78.4 - 117.6 Kpa)

5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5 kg/cm2 (29.4 - 49.0 Kpa)

6. Regulating Valve: 1.8 - 2.2 kg/cm2 (176 - 216 Kpa)

The 4J series engine has a full flow type lubricating system.

Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is

then delivered to the vital parts of the engine from the cylinder body oil gallery.

Oiling jets installed on the cylinder body spray engine oil to the piston backside faces to achieve maximum piston

cooling effect.

OIL PUMP AND OIL FILTER

RTW46ALF001501

The 4J series engine is equipped with a gear type oil pump.

The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.

OIL PUMP

DISASSEMBLY

051R100005

Disassembly Steps

1. Oil pipe 5. Driven gear

2. Strainer 6. Relief valve assembly

3. Pump cover 7. Pinion gear

4. Driven gear with bushing 8. Oil pump body

Disassembly procedure is shown in the illustration above in numerical order.

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during

inspection. Gear Teeth and Body Inner Wall Clearance

Use a feeler gauge to measure the clearance between the

gear teeth and the body inner wall.

If the clearance between the gear teeth and the body

inner wall exceeds the specified limit, either the gear or

the body must be replaced.

Gear teeth and body inner wall clearance mm (in)

Standard Limit

051RY00001

0.14 (0.0055) 0.20 (0.0079)

Gear and Body Clearance

Use a feeler gauge to measure the clearance between the

body and the gear.

If the clearance between the gear and the body exceeds

the specified limit, the body must be replaced.

Gear and body clearance mm (in)

Standard Limit

RTW46ASH002701

0.06 (0.024) 0.15 (0.0059)

Drive Shaft and Oil Pump Body Clearance

Use a micrometer to measure the drive shaft outside

diameter.

Use an inside dial indicator to measure the pump body

inside diameter.

If the clearance between the drive shaft and the oil pump

body exceeds the specified limit, the oil pump assembly

must be replaced.

Drive shaft and oil pump body clearance mm (in)

Standard Limit

0.04 (0.0016) 0.20 (0.0079)

051RY00003

REASSEMBLY

051R100006

Reassembly Steps

1. Oil pump body 5. Pinion gear

2. Drive gear 6. Strainer

3. Driven gear 7. Relief valve assembly

4. Pump cover 8. Oil pipe

Reassembly procedure is shown in the illustration above in numerical order.

Pump cover fixing bolts torque: 16 N·m (1.6 kg·m/12 lb·ft)

OIL FILTER AND OIL COOLER

DISASSEMBLY

050R300004

Disassembly Steps

1. Oil filter cartridge 5. Body

2. Bolt 6. Oil cooler relief valve

3. Gasket 7. Regulating valve

4. Oil cooler

Disassembly procedure is shown in the illustration above in numerical order.

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during

inspection.

Oil Cooler

Water Leakage at Water Passage

1. Plug one side of the oil cooler water passage.

2. Submerge the oil cooler in water.

3. Apply compressed air (200 kPa (2 kg/cm2 /28 psi)) to

the other side of the oil cooler water passage.

Check for air bubbles escaping from the oil cooler. Air bubbles

indicate the presence of a leak in the oil cooler's water

passage. If the oil cooler is leaking, it must be replaced.

050RY00002

REASSEMBLY

050R300003

Reassembly Steps

1. Body 5. Gasket

2. Regulating valve 6. Bolt

3. Oil cooler relief valve 7. Oil filter cartridge

4. Oil cooler

The numbers in the above illustration represent the order of reassembly.

RTW46ASH001701

1. Body

2. Oil Filter Safety Valve

3. Oil Cooler Safety Valve

Tighten the oil filter A and oil cooler B relief valve to the

specified torque.

Regulating Valve N·m (kg·m/lb·ft)

A 64 (6.5/48)

4. Oil Cooler

5. Gasket

6. Bolt

Tighten bolt with gasket and oil cooler to the specified

torque.

Bolt Torque N·m (kg·m/lb·ft)

40 (4.1/30)

7. Oil Filter Cartridge

1) Apply engine oil to the O-ring.

2) Tighten the oil filter cartridge to the specified torque.

Filter wrench: 5-8840-0201-0

Oil Filter Cartridge Torque N·m (kg·m/lb·ft)

18 (1.8/13)

050R300006

050RY00004

INTER COOLER

REMOVAL AND INSTALLATION

RTW46ALF001001

Removal Steps

1. Radiator grille

2. Front bumper fascia

3. Front bumper impact support assembly

4. Inter cooler

Installation Steps

4. Inter cooler

3. Front bumper impact support assembly

2. Front bumper fascia

1. Radiator grille

RTW36ASH000601

REMOVAL

1. Radiator Grille

• Refer to removal procedure in Sheet Metal section.

RTW36ASH000501

2. Front Bumper Fascia

• Remove the nine clips and four screws.

• Disconnect the fog light harness connectors.

RTW46ASH002101

3. Front Bumper Impact Support Assembly

• Remove the nut and two bolts.

4. Inter Cooler

• Remove the nut and two bolts.

• Disconnect the air hose.

INSTALLATION

4. Inter Cooler

• Tighten the nut and two bolts.

3. Front Bumper Impact Support Assembly

• Tighten the nut and two bolts.

2. Front Bumper Fascia

• Install the nine clips and four screws.

• Connect the fog light harness connectors.

1. Radiator grille

• Refer to installation procedure in Sheet Metal section.

SPECIAL TOOLS

Illustration Tool Number Tool Name

5-8840-0201-0 Filter Wrench

5-8840-0253-0 Filter Wrench

5-8840-2675-0 Compression Gauge

5-8531-7001-0 Adapter; Compression Gauge

5-8840-2723-0 Nozzle Holder Remover

5-8840-0019-0 Sliding Hammer

5-8521-0002-0 Universal Puller

5-8840-2360-0 Oil Seal Remover

9-8523-1423-0 Spring Compressor

9-8523-1212-0 Valve Guide Replacer

Illustration Tool Number Tool Name

5-8840-2040-0

(4JA1L/TC)

5-8840-2313-0 (4JH1TC) Cylinder Liner Installer

5-8840-2038-0 Bearing Replacer; Camshaft

5-8840-2000-0 Pilot Bearing Remover

5-8522-0024-0 Pilot Bearing Installer

5-8840-2033-0 Oil Seal Installer

5-8840-9018-0 Piston Ring Compressor

5-8840-2359-0 Oil Seal Installer

9-8522-0020-0 Crankshaft Timing Gear Installer

5-8840-0266-0 Angle Gauge

5-8840-0214-0 Gear Stopper

5-8840-2039-0

(4JA1L/TC)

5-8840-2304-0 (4JH1TC)

Cylinder Liner Remover

5-8840-2361-0 Front Oil Seal Installer