Service Manual - Case 4HK1-6HK1 Isuzu Engine 9-44061na

UNITSOFMEASURE

ThismanualadoptstheunitsofmeasurebasedonInternationalSystem. TheMKSAsystemunitsofmeasureareindicatedwithinbracketsaftertheunitsofmeasureoftheInternational System.

Example:24.5MPa(250kgf/cm2)

ThefollowingtableconvertstheInternationalSystemunitsofmeasureinsomeofthemainunitsbelongingtoother system.

QuantityToconvert from(IS) Into (Others)MultiplybyQuantityToconvert from(IS) Into (Others)Multiplyby

Lenght mmin0.03937 PressureMPakgf/cm210.197 mmft0.003281MPapsi145.0

Volume LUSgal0.2642PowerkWCV-PS1.360 LUSqt1.057kWHP1.341 m3yd31.308Temperature°C°F°Cx1.8+32 Masskglb2.205Speedkm/hmph0.6214

ForceNkgf0.10197 min-1rpm1.0 Nlbf0.2248

CapacityL/minUSgpm0.2642

TorqueN.mkgf.m0.10197mL/revcc/rev1.0 N.mlbf.ft0.7375

GeneralInformation Contents

GeneralInformation.......................0A-2

ServicePrecautions......................0A-2

Readingthemodel.......................0A-6

Generalinformation......................0A-7

ServicePrecautions

Inordertocarryoutworksafely

1.Alwaysuseanenginestandwhentakingthe enginedownfromthevehicle. Donotplacetheenginedirectlyontotheground, orplaceinamannerthatinterfereswiththeoil pan.

2.Ifyouareworkingtogetherwithothers,alwayspay attentiontoeachother'ssafety.

3.Ifyouarerepairinganypartoftheelectrical system,alwaysremovetheminussidecablefrom thebatteryterminalbeforestartingwork.Ifyouare removingthebatterycover,alwaysremovethe coverinaplacethatisawayfromsourcesoffire/ heat.

4.Donotperformpaintingworkorleavetheengine runningforlongperiodsoftimeinanenclosedor badlyventilatedindoorworkshop.

5.Alwaysusethecorrectspecializedtoolindicatedin theinstructions.Usingtheincorrecttoolmay causedamagetothepartsorinjurytotheperson usingthetool.

6.Allregulartools,gaugesandspecialtoolsshould beregularlyinspected,andpreparedbefore startingwork.Donotusebentspanners,hammers withdamagededges,chippedchisels,oranyother faultyordamagedtools.

7.Alwayspaycloseattentiontosafetyandhandling requirementswhenusinggrinders,cranes, welders,andothersuchequipment. Moreover,alwayswearthecorrectprotective garmentsandusethenecessarysafetytoolsfor thejobinhand.

8.Alwayscheckthattherearenofuelleakswhen performingmaintenanceworkonthefuelsystem. (Itmaycauseafire.)

9.Paycloseattentiontotheriskofignitionifyouare handlingpartsthatcarryahighvoltage. Furthermore,anyoilorfatspiltontorubberparts mustbewipedoffimmediately,asitwillcause deteriorationoftherubber.

Replacementpartsandpartnumbers.

1.Alwaysreplacepacking,oilseals,o-rings,caulking locknuts,foldinglockplates,splitpinsandother suchpartswithbrandnewparts.

2.Thepartsnumberscontainedinthismanualmay notrepresentthesupplyconditionoftheparts,and thepartnumbersmaybechangeddueto revisions.Therefore,partsshouldalwaysbe checkedagainstapartscataloguebeforeuse.

Liquidgasket

1.Eachtimeyoudisassemblepartsthatuseliquid gasket,completelyremovetheoldgasketresidue fromeachofthepartsandmatchingsectionsusing ascraper,thencleaneachofthepartsto completelyremoveoil,water,anddirtetc.fromthe varioussurfaces.Usingthespecifiedtypeofliquid gasket,applynewliquidgaskettoeachofthe surfacesbeforereassemblingtheparts.

2.Inordertomakeiteasiertocleanliquidgasket surfaces,applygasketremoverliquid(Pando391DmadebyThreeBondCo.,Ltd.)andleave theparttostandforapproximately10minutes, afterwhichtheoldliquidgasketresiduewillbe easiertoremove.

However,thisshouldnotbeusedonresin componentsorpaintedcomponents.

3.Pleasetakecarenottoapplytoomuchortoolittle liquidgasket.

Also,youshouldalwaysre-applytheliquidgasket uponitselfwhenyoustartandfinishapplication.

4.Makesurethattherearenogapswhenreinstallingtheliquidgasketpartstoeachother.If therearegapsbetweenthetwoparts,re-applythe liquidgasket.Someparts,especiallytheoilpan, usethesamesizestudsasaguidetoeliminatethe needforknockpinpositioningetc.

5.Re-installthesepartswithin7minutesofapplying theliquidgasket.

0A-4GeneralInformation

Ifmorethan7minutespasses,removethe previousliquidgasketandre-applyit.

6.Pleasewaitforatleast30minutessincethelast partisinstalledbeforestartingtheengine.

Liquidgasket

SealsectionProductnameManufacturer'sname

Betweencylinderblockand–Flywheelhousing1207BThreeBond Betweencylinderblockand–Flywheelhousingand– Crankcase 1207BThreeBond

Betweencylinderblockand–Crankcase1207BThreeBond Betweencylinderblockand–Frontcover1207BThreeBond Cylinderblock,headplugnipple,unit,switches262Loctite

•Alwaysusetheliquidgasketproductslistedabove, oraliquidgasketidenticaltotheoneslistedabove.

•Usethecorrectquantityofliquidgasket.Always followthehandlinginstructionsforeachproduct.

Applicationprocedure

1.Wipethecontactsurfacescleanofallwater,fator oil.Thecontactsurfacesshouldbedry.

2.Applyaregularbeadwidthofliquidgaskettoone ofthecontactsurfaces.Makesurethatthebead doesnotbreakatthispoint.

Notes:

Iftherearespecialregulationsconcerningthe applicationprocedureintherepairdocument,please followthoseregulations.

Workprocedure

1.Wipethejointsurfacesofthebolt,bolthole,and screwthreadsectioncleanofwater,fat,andoil. Thecontactsurfacesshouldbedry.

2.ApplyLoctitetothetop1/3ofthescrew.

3.Tightenthebolttothecorrecttighteningtorque.

Important:

Aftertighteningthebolt,donotapplyexcessivetorque ortrytorotatetheboltuntilatleastonehourhas passed,andtheLoctitehashardened.

ProcedureforusingthePlastiguage

TypeMeasurablerangemm(in)

PG-1(Green)0.025–0.076(0.001–0.003)

PR-1(Red)0.051–0.152(0.002–0.006)

PB-1(Blue)0.102–0.229(0.004–0.009)

Example:Procedureformeasuringtheclearance betweentheconnectingrodbearingandcrankpin.

•Cleantheconnectingrodandbearing,andinstall thebearingtotherod.

•Cuttheplastiguagetothesamewidthasthecrank pin,andwhileavoidingtheoilporeofthecrankpin laythegaugeparalleltothepin.

•Lineupthemarksontheconnectingrodandcap andinstallthecrankpin,applymolybdenum disulphidetothethreadsectionandbearing surfaceofthefasteningbolt,androtatebothcap andbolttothecorrecttorque.

Important:

Donotmovetheconnectingrodwhileusingthe plastiguage.

•Gentlyremovethecapandconnectingrod,and measurethecrushedwidthoftheplastiguage (clearancebetweenrodandpin)usingthescale printedonthebag.

Example:Measuringtheclearancebetweenthecrank bearingandcrankjournal

•Cleantheclampfaceofthecylinderblockand crankcasebearing,andalsothebearing,and installthecylinderblocktothecrankcase.

•Gentlyrestthecrankshaftonthecylinderblock, androtateitapproximately30degreetostabilizeit.

•Cuttheplastiguagetothesamesizeasthejournal width,andwhileavoidingtheoilporeofthejournal laythegaugeparalleltothejournal.

•Gentlyrestthecrankcaseonthecylinderblock, applymolybdenumdisulphidetothethreadsection andbearingsurfaceofthefasteningbolt,and tighteninsequencetothecorrecttorque.

Important:

Donotrotatethecrankshaftwhileusingthe plastiguage.

•Gentlyremovethecrankcase,andmeasurethe crushedwidthoftheplastiguage(clearance betweenbearingandjournal)usingthescale printedonthebag.

Readingthemodel

Enginenumberstampingposition

4HK1

Generalinformation

Terminology,descriptionofabbreviations

Terminologydefinitions

TermExplanation

MaintenancestandardThegenericnameforreferencevaluesrequiredformaintenance,suchasnominal dimension,selectionofareferencepoint,andlimit.

NominaldimensionShowsthestandardvalueatthepointofmanufacturethatdoesnotincludethe commondifference.

SelectionofareferencepointShowsthestandardvalueafterassembling,repairing,oradjusting.

LimitWhenthisvalue(dimensions)isreached,itshowsthattheparthasreacheditsfull limitandmustbereplacedorrepaired.

Frontrear,leftright,upper lower Theseshoweachorientationsofpartsinstalledtothevehiclewhenlookingfrom thevehicle'sforwarddirection.

UnitUnitswrittentoSIconventions(mainlytorque,pressure,force) [Example]Length:mm,Torque:Nm{kgfm}

WarningItemsthatcarrythewarningmarkposeadangertolifeorthreatofseriousinjuryif notstrictlyobserved.

CautionItemsthatcarrythecautionmarkmaycauseinjuryorleadtoaccidentsifnotstrictly observed.

ImportantItemsthatcarrytheimportantmarkmaycausethevehicletobreakdown,ormay preventtheguaranteednormaloperationofthesystemorrelatedpartsifnotstrictly observed.

0A-8GeneralInformation

TermExplanation

NotesItemsthatshouldreceivespecialmentionwithinaworkprocedure.

Descriptionofabbreviations

AbbreviationDescription

ACAlternatingCurrent AlternatingCurrent

ACCAccessory Accessory

ACGAlternatingCurrentGenerator Alternatingcurrentgenerator

APIAmericanPetrolInstitute AmericanPetroleumInstitute

ASM(Assy)Assembly Assembly

ATDCAfterTopDeadCenter AfterTopDeadCenter

BAT,BATTBattery Battery

BRG,BrgBearing Bearing

BKT,BRKTBracket Bracket

BTDCBeforeTopDeadCenter BeforeTopDeadCenter

COCarbonOxide CarbonMonoxide

CONNConnector Connector

CPUCentralProcessingUnit Centralprocessingunit

C/UControlUnit Controlunit

DCDirectCurrent Directcurrent

DIDirectInjection Directinjection

ECUEngineControlUnit/ElectronicControl Unit

Enginecontrolunit/controlunit

ECMEngineControlModule Enginecontrolmodule

EGRExhaustGasRecirculation

Exhaustgasrecirculation

Exh,EXHExhaust Exhaust

Ft,FRTFront Front

AbbreviationDescription

FWDForward Forward

F/CFuelCut FuelCut

GNDGround Earth

ICIntegratedCircuit Integratedcircuit

IDPlateIdentificationplate Identificationplate,IDplate

INIntake,Intake Intake

ISOInternationalOrganizationfor Standardization InternationalOrganizationfor Standardization

I/PUMPInjectionPump InjectionPump

JISJapaneseIndustrialStandard JapaneseIndustrialStandard

L/H,LHLeftHand Lefthandside

M/VMagneticValve Magneticvalve

NOxNitrogenOxide NitrogenOxide

N-TDCNumber-TopDeadCenter Topdeadcenterrotationalfrequency

OPTOption Option

PPole(S) Pole

PCVPumpControlValve/Positive CrankcaseVentilation Pumpcontrolvalve/Positivecrankcase ventilation

PMParticulateMatter Particulatematter

PSPre-Stroke Pre-stroke

PTOPowerTakeOff Powertakeoff

QOSQuickOnSystem Rapidpreheatingsystem

Rr,RRRear

Rear

AbbreviationDescription

R/H,RHRightHand Righthandside

R/LRelay

Relay

STDStandard Standard

SWSwitch Switch

TICSTiming&InjectionrateControlSystem

Atypeofinjectionsystem

VGSTurboVariableGeometryturbocharger System

Adjustableturbo,VGSturbo

W/LWarningLamp Warninglamp

SI(InternationalSystemofUnits)

WithregardstheconversiontoSI(International SystemofUnits)

TheintroductionoftheSIsystemsaimsto internationallyunifythemetricsystemandthevarious unitsusedbydifferentcountries(traditionalweights andmeasures,thefootpoundmethodetc.),andto curbtheconfusionthatoccursbetweenthedifferent units(conversioncalculationsetc.).

ThenewcalculatingmethodwhichadoptedSIunits wascompletelyadoptedinJapanin1992,andis standardizedbyJIS-Z-8203.

Alloftheunitsinthismanualarewritteninlinewiththe InternationalSystemofUnitsSIunits,andconventional unitsarewrittenin{}brackets.

SI

French)AbbreviatednameofLeSystemeInternational d’Unites

ConnectionbetweenmainSIunitsandconventionalunits

SIConventionalUnitItem,unitconversion

LengthmmSameastheconventionalunit

Weight(Mass)kgkgSameastheconventionalunit

ForceN*kg,kgf1kgf=9.80665N

TorqueNm*kgm,gfm1kgfm=9.80665Nm

PressurePa*kg/cm2,mmHg1kgf/cm2=9.80665kPa,1mmHg=133.3Pa

Dynamicforce,horsepowerWPS1PS=0.74kW

Capacity,airvolumedisplacementm3Litle,L,cc1Litle=1dm3,1cc=1mLitle=1cm3

Fuelconsumptiong/(kWh)g/(PSh)1g/(PSh)=1.360g/(kWh)

*1Publishedservicedatamayconvenientlyusekgfor forceandmass(weight)insteadofkgf.

*2Someconversionresultsmayberoundedoffto1or 2decimalplaces.

Convertingexpressionsofquantity

Whenconverting,prefixessuchask(kilo)orm(mili) areused.

•200kgf/cm2=19,620kPa=19.6MPa

•40mmHg=5,332Pa=5.3kPa

TableofstandardIsuzutighteningtorque

Thetighteningtorquevaluesinthetablebelowapplyto allsituationsunlessaspecialtighteningtorqueis specified.

Isuzustandardbolts,nuts

Bolthead sectionshapeHexagonheadboltFlangeboltHexagonheadboltFlangebolt

*M101.519.6~33.3{2.0~3.4}22.3~37.2{2.3~3.8}27.5~45.1{2.8~4.6}30.3~50.4{3.1~5.1}

M121.2549.0~73.5{5.0~7.5}54.9~82.3{5.6~8.4}60.8~91.2{6.2~9.3}68.1~102.1{6.9~ 10.4}

*M121.7545.1~68.6{4.6~7.0}51.0~76.5{5.2~7.8}56.9~84.3{5.8~8.6}62.7~94.0{6.4~9.6} M141.576.5~114.7{7.8~ 11.7} 83.0~124.5{8.5~ 12.7}

*M14271.6~106.9{7.3~ 10.9} 77.2~115.8{7.9~ 11.8} 88.3~131.4{9.0~ 13.4} 94.9~142.3{9.7~ 14.5}

M161.5104.0~157.0{10.6~ 16.0} 115.6~173.3{11.8~ 17.7}

23.0}

*M162100.0~149.1{10.2~ 15.2} 109.4~164.2{11.2~ 16.7} 129.4~194.2{13.2~ 19.8} 142.5~213.8{14.5~ 21.8}

M181.5151.0~225.6{15.4~ 23.0}

*M182.5151.0~225.6{15.4~ 23.0}

M201.5206.0–310.0{21.0~ 31.6}

*M202.5190.2~286.4{19.4– 29.2}

M221.5251.1–413.8{25.6~ 42.2}

*M222.5217.7~327.5{22.2~ 33.4}

M242358.9~539.4{36.6~ 55.0}

*M243338.3~507.0{34.5~ 51.7}

195.2~293.2{19.9~ 29.9}

196.1~294.2{20.0~ 30.0}

269.7~405.0{27.5~ 41.3}

249.1~374.6{25.4~ 38.2}

362.8~544.3{37.0~ 55.5}

338.3~507.0{34.5~ 51.7}

430.5~711.0{43.9~ 72.5}

406.0~608.0{41.4~ 62.0}

The*markindicateswheresoftmaterialshavebeenusedforinternalthreadsections,suchascastings.

Strengthclassification8.8

The*markindicateswheresoftmaterialshavebeenusedforinternalthreadsections,suchascastings. Nm{kgfm}

M61 5.6~11.2{0.6~ 1.1} 6.6~12.2{0.6~ 1.2}

M81.2513.4~25.7{1.4~ 2.6}

2.9}

3.1}

3.4} M101.2531.3~52.5{3.2~ 5.4}

*M121.7564.8~96.1{6.6~ 9.8} 71.4~107.2{7.3~ 10.9}

12.2} M141.5106.2~158.8{10.8 ~16.2} 114.9~172.3{11.7 ~17.6}

*M142100.6~149.8{10.3 ~15.3} 108.2~162.2{11.1 ~16.6}

M161.5154.3~232.5{15.7 ~23.7} 171.1~256.7{17.4 ~26.2}

*M162147.6~221.4{15.0 ~22.6} 162.5~243.8{16.6 ~24.9}

M181.5222.5~334.3{22.7 ~34.1}

*M182.5223.6~335.4{22.8 ~34.2}

M201.5307.4~461.7{31.4 ~47.1}

*M202.5284.0~472.1{29.0 ~43.5}

M221.5413.6~620.5{42.2 ~63.3}

*M222.5385.7~578.0{39.3 ~58.9}

M242490.8~810.5{50.0 ~82.7}

*M243462.8~693.1{47.2 ~70.7}

~17.4}

~16.3}

~24.5}

~18.9}

~17.7}

~27.1}

~23.4} 168.5~252.7{17.2 ~25.8}

229.5~345.2{23.4 ~35.2}

230.5~346.2{23.6 ~35.3}

316.8~475.6{32.3 ~48.5}

293.2~440.3{29.2 ~44.9}

424.6~636.5{43.3 ~64.9}

394.2~592.3{40.0 ~60.4}

554.1~830.6{56.5 ~84.7}

520.7~781.6{53.1 ~79.7}

DesignationsforIsuzustandardboltheads

Legend

1.Hexagonheadbolt(4.8,4T)

2.Hexagonheadbolt(4.8,4T)

3.Flangebolt(4.8,4T)

4.Flangebolt(4.8,4T)

5.Hexagonheadbolt(7T)

6.Flangebolt(7T)

7.Hexagonheadbolt(refined8.8)

8.Hexagonheadbolt(refined8.8)

Flarenut

9.Hexagonheadbolt(Un-refined8.8)

10.Hexagonheadbolt(Un-refined8.8)

11.Flangebolt(8.8)

12.Flangebolt(8.8)

13.Hexagonheadbolt(9.8,9T)

14.Hexagonheadbolt(9.8,9T)

15.Flangebolt(9.8,9T)

16.Flangebolt(9.8,9T)

Pipediametertighteningtorque (formediumandlarge sizevehicles)

Flarenut2sidewidth(mm)

Flarenuttighteningtorque(service standardvalue)Nm{kgfm} 4.76mm12.8~18.6{1.3~1.9}1414 6.35mm23.5~49{2.4~5.0}1717 8.0mm23.5~49{2.4~5.0}1917 10.0mm44.1~93.2{4.5~9.5}2219 12.0mm58.8~137.3{6.0~14.0}2724 15.0mm78.5~156.9{8.0~16.0}3030

Taperscrewfromconnectors(brass) Nm{kgfm}

ScrewsizePT(R)1/8PT(R)1/4PT(R)3/8PT(R)1/12

—2.0~14.7 (0.2~1.5)

(0.5~1.6)

ENGINE

ENGINEMECHANICAL(4HK1,6HK1)

TABLEOFCONTENTS

ISUZUDIESELENGINE(4HK1,6HK1).......1A-3

1A-2ENGINEMECHANICAL(4HK1,6HK1)

ISUZUDIESELENGINE(4HK1,6HK1)

PrecautionsonServiceWork

Mattersthatrequireattentionintermsof maintenance

Topreventdamagetotheengineandensurereliability ofitsperformance,payattentiontothefollowingin maintainingtheengine:Whentakingdowntheengine ontheground,donotmakethebearingsurfaceofthe oilpantouchdirectlytheground.Useawoodframe,for example,tosupporttheenginewiththeenginefootand theflywheelhousing.

Becausethereisonlyasmallclearancebetweenthe oilpanandtheoilpumpstrainer,itcandamagethe oilpanandtheoilstrainer.

•Whentheairductoraircleanerisremoved,cover theairintakeopeningtopreventforeignmatter fromgettingintothecylinder.Ifitgetsintoit,itcan considerablydamagethecylinderandotherswhile theengineisoperating.

•Whenmaintainingtheengine,neverfailtoremove thebatterygroundcable.Ifnot,itmaydamagethe wireharnessorelectricalparts.Ifyouneed electricityonforthepurposeofinspection,for instance,watchoutforshortcircuitsandothers.

•Applyengineoiltotheslidingcontactsurfacesof theenginebeforereassemblingit.Thisensures adequatelubricationwhentheengineisfirst started.

•Whenvalvetrainparts,pistons,pistonrings, connectingrods,connectingrodbearingsor crankshaftjournalbearingsareremoved,putthem inorderandkeepthem.

•Wheninstallingthem,putthembacktothesame locationastheywereremoved.

•Gaskets,oilseals,O-rings,etc.mustbereplaced withnewoneswhentheengineisreassembled.

•Asforpartswherealiquidgasketisused,remove anoldliquidgasketcompletelyandcleanitup thoroughlysothatnooil,waterordustmaybe clungtothem.Then,applythedesignatedliquid gaskettoeachplaceanewbeforeassembly.

•Surfacescoveredwithliquidgasketmustbe assembledwithin7minutesofgasketapplication. Ifmorethan7minuteshaveelapsed,removethe existingliquidgasketandapplynewliquidgasket.

•Whenassemblingorinstallingparts,fastenthem withthespecifiedtighteningtorquesothatthey maybeinstalledproperly.

Mattersthatrequireattentioninspecificallydealing withthisengine.

Holesorclearancesinthefuelsystem,whichserveas apassageoffuel,includingtheinsideoftheinjector, aremadewithextremeprecision.Forthisreason,they arehighlysensitivetoforeignmatterandifitgetsin,it canleadtoanaccidentontheroad,forinstance;thus, makesurethatforeignmatterwillbepreventedfrom gettingin.

Whenservicingthefuelsystem,everyprecautionmust betakentopreventtheentryofforeignmaterialintothe system.

•Beforebeginningtheserviceprocedure,washthe fuellineandthesurroundingarea.

•Performtheserviceprocedureswithcleanhands. Donotwearworkgloves.

•Immediatelyafterremovingthefuelhoseand/or fuelpipe,carefullytapevinylbagsoverthe exposedendsofthehoseorpipe.

•Ifpartsaretobereplaced(fuelhose,fuelpipe, etc.)donotopenthenewpartpackaginguntil installation.

Workprocedure

•Thefuelopeningmustbequicklysealedwhen removingthefuelpipe,injectionpipe,fuelinjector, fuelsupplypump,andcommonrail.

•Theeyeboltsandgasketmustbestoredinaclean partsboxwithalidtopreventadhesionofforeign matter.

•Fuelleakagecouldcausefires.Therefore,after finishingthework,wipeoffthefuelthathasleaked outandmakesurethereisnofuelleakageafter startingtheengine.

1A-4ENGINEMECHANICAL(4HK1,6HK1)

Howtoreadthemodel

4HK1

Name 1.CastTheEngineModel2.StampAnEngineNumber

Name 1.StampAnEngineNumber

Explanationsonfunctionsandoperation

Electronicenginecontrol

Withthecontrolunit,therangefrominjectiontoair intake/exhaust,includingfuelinjectionquantity, injectiontiming,intakeairrestriction,EGR,andidling rpm,iscontrolled.

Cylinderblock

Thecylinderblockiscast-ironwiththecenterdistance ofeachborebeingequalandisofthehighlyrigid, symmetricalstructurewiththecrankshaftcenterbeing thecenter.Thebearingcapisoftheladderframe structureandtightenedupundertheplasticrange rotationanglemethod.

Crankshaft

Tuftridingisgiven,whileontheNo.1balanceweight

Cylinderliner

Thecylinderlinerisselectedtomatchaninternal diameterofaboreofthecylinderblockandbuilt,which isimprintedontheleftsideofthecylinder.

Piston

Thepistonisaluminum-alloyandanautothermatic pistonwithastrutcast,whilethecombustionchamber isaroundreentranttype.

Cylinderhead

Thecylinderheadiscast-ironandthereare4valves percylinder.Theangulartighteningmethodofthe cylinderheadboltfurtherincreasesreliabilityand durability.

imprintedisthegradeofeachjournaldiameter.

1A-6ENGINEMECHANICAL(4HK1,6HK1)

EGRsystem

Basedupondata,includingwatertemperature,engine speedsorengineloads,itiscontrolledviaEngine ControlModule(ECM)topurifyexhaustbyrecycling partofit.

ItsmaincomponentsincludeanEGRvalve,anEGR coolerandvarioussensors.

Connectingrodcapbolt

Theangulartighteningmethodoftheconnectingrod capboltfurtherincreasesreliabilityanddurability.

Commonrail-typeelectroniccontrolinjection system

Thecommonrail-typeelectroniccontrolinjection systemiscomposedofafuelsupplypumpthatsetsthe targetpressureofhigh-pressurefuelandsupplyit,a commonrailthatmeasuressuchhigh-pressurefuel andafuelinjectorthatturnsitintoafinesprayand injectsit.EachiscontrolledviaECMbasedupon varioussignals,whileinjectiontimingorfuelinjection quantityiscontrolledundereverypossibledriving condition.

Fuelinjector

Thefuelinjectorisa7-holenozzlethatadjustsfuel injectionquantityorinjectiontimingbyopeningor closinganelectromagneticvalveontheheadofthe fuelinjector.

ECMcorrectsthedispersionoffuelinjectionquantity betweenfuelinjectorsaccordingtoIDcodedatain memory.Atthereplacementoffuelinjectors,IDcode datashouldbestoredinECM.

Fuelfilterwithsedimenter

Itisafuelfilterwithsedimenterthatgetsridofwaterby makinguseofthedifferenceinspecificgravitybetween lightoilandwater,whichcomeswithanindicatorthat notifiesyouthatitisfilledwithwater.

Preheatingsystem

ThepreheatingsystemconsiststheECM,theglow relay,glowplugsandtheglowindicatorlamp.The preheatingsystemisoperatedwhentheenginecoolant temperatureislow,andmaketheengineeasytostart.

Lubricationsystem

Itisanoilfilterwithfull-flowbypass,whichusesa water-cooloilcoolerandoiljettocoolthepiston.

Functioncheck

Inspection/adjustmentofvalveclearance

1.Inspectionofvalveclearance

•Removethecylinderheadcover.

•RemovethefuelinjectorharnessASM.

•Loosentheterminalnutsalternatelytoremove.

•Removetheleakoffpipe.

•RotatethecrankshafttomaketheNo.1cylinder meetthecompressiontopdeadcenter(TDC).

•Inserta0.4mm(0.016in)thicknessgaugeintoa clearancebetweentherockerarmandthebridge tocheckitandadjustitifneeded.

Valveclearancemm(in)

Intakevalve0.4(0.016) Exhaustvalve0.4(0.016)

Caution: Adjustwhilebeingcold.

2.Adjustmentofvalveclearance

Caution:

Adjustvalveclearancecarefullysothatthebridgemay becomelevel(hittheendofthe2valveaxes).

a.Completelyloosenallofthebridgeandrocker armadjustingnutsandadjustingscrews (4HK1:8nutsand8screws,6HK1:12nutsand 12screws).

b.Placea0.4mm(0.016in)thicknessgauge betweentheNo.1cylinderrockerarmendand thebridgecap.

c.Tightentherockerarmadjustingscrewuntilthe thicknessgaugeissnug(nottight)betweenthe rockerarmendandthebridgecap.

d.Tightentherockerarmlocknut.

e.Tightenthebridgeadjustingscrewuntilthe bridgecontactsthevalvehead.

f.Tightenthebridgelocknut.

g.Checkthatthethicknessgaugeisstillheld snuglybetweentherockerarmendandthe bridgecap.Ifitistootight,slightlyloosenthe bridgeadjustingscrewandlocknuttorestore snugness.

h.Removethethicknessgauge.

i.RepeatSteps2through5fortheremaining cylinders.

Tighteningtorque:22Nm(2.2kgm/16lbft)

Name

1.RockerArm

2.BridgeCap

3.Bridge

•Withathicknessgaugekeptinserted,tighten anadjustingscrewofthebridgelightlyand makesurethatthetipoftheadjustingscrew touchestheendofvalveaxisandthe movementofthethicknessgaugehasbecome tight.

•Then,checkiftheendofthevalveaxisonthe oppositesideisunstableorhitsdiagonally.If so,loosenthebridgeadjustingscrewalittleso thattheendofthevalvesonbothsidesmay touchproperly.

Valvebridgeclearance:0.1mm(0.0039in)or less

•Aftermakinganadjustmentsothattheendof thevalvesonbothsidesmaytouchproperly, tightenupanadjustingscrewnutofthebridge withaflatheadscrewdriversothatthebridge adjustingscrewmaynotrotate.

Tighteningtorque:22Nm(2.2kgm/16lbft)

Caution: Iftheadjustingscrewofthebridgeispoorlyadjusted, thebridgewouldtiltandbepusheddownandseized, whichmaydamagethebridgeguide,forexample. Thus,adjustitaccurately.

Tighteningtorque:

Rockerarmadjustment screwnut 22Nm(2.2kgm/16lbft)

Bridgeadjustmentscrew nut 22Nm(2.2kgm/16lbft)