08 Isuzu 4le2 GB

INDUSTRIAL
DIESEL ENGINE
4LE2
MODEL
WORKSHOP MANUAL
2003 ISUZU MOTORS LIMITED
FOREWORD
This Workshop Manual is designed to help you perform necessary
maintenance, service, and repair procedures on applicable Isuzu
industrial engines.
Information contained in this Workshop Manual is the latest
available at the time of publication.
Isuzu reserves the right to make changes at any time without prior
notice.
TABLE OF CONTENTS
SECTION 1.
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2.
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
SECTION 3.
LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
SECTION 4.
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
SECTION 5.
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
SECTION 6.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SECTION 7.
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SECTION 8.
CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
GENERAL INFORMATION 1
SECTION 1
GENERAL INFORMATION
TABLE OF CONTENTS
CONTENTS
PAGE
GENERAL REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES ON THE FORMAT OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN DATA AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANGULAR NUT AND BOLT TIGHTENING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE ON MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GASKET LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RECOMMENDED LUBRICATING OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS

1. Before performing any service operation with the engine mounted, disconnect the grounding cable
from the battery.
This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools for the job at hand.
Where specified, use the specially designed tool or tools.
3. Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you
remove them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.
It is especially important to keep fastening parts separate. These parts vary in hardness and design,
depending on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly.
Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine
or disconnecting pipes and hoses.
11. Always check and recheck your work. No service operation is complete until you have done this.
12. Information contained in the Main Data and Specifications of the Workshop Manual and the Instruction Book may differ. In this case, the information contained in the Instruction Book should be
considered applicable.
NOTES ON THE FORMAT OF THIS MANUAL

This Workshop Manual is applicable to the 4LE2 family of industrial diesel engines. Unless otherwise
specified, these engines have common parts and components as well as data and specifications.
Illustrations used in this Workshop Manual are based on the 4LE2 engines.
1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.
2. Common technical data such as general maintenance items, service specifications, and tightening
torques are included in the General Information section.
3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and
reassembly.
4. When the same servicing operation is applicable to several different units, the manual will direct you
to the appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail.
6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area.
(Example)
Major components
Figures in parentheses (
) show the order of disassembling or reassembling.
Water Outlet Pipe (5)

Packing (6)
Thermostat (7)
Water pump ASM (8)
Pulley; Fan (4)

Spacer (2)
Fan; Cooling (1)
Belt; Fan (3)
Fig. 1
7. Measurement criteria are defined by the terms standard and limit.

A measurement falling within the standard range indicates that the applicable part or parts are serviceable.
Limit should be thought of as an absolute value.
A measurement which is outside the limit indicates that the applicable part or parts must be either
repaired or replaced.
8. Components and parts are listed in the singular form throughout the Manual.
9. The following symbols appear throughout this Worshop Manual. They tell you the type of service
operation or step to perform.
...
Remove
...
Adjustment
...
Installation
...
Cleaning
...
Disassembly
...
Important Operation Requiring Extra Care
...
Reassembly
...
Specified Torque (Tighten)
...
Alignment (Marks)
...
Special Tool Use Required for Recommended

(Isuzu Tool or Tools)
...
Directional Indication
...
Commercially Available Tool Use Required or

Recommended
...
Inspection
...
Lubrication (Oil)
...
Measurement
...
Lubrication (Grease)
...
Sealant
10. Direction used in this Manual are as follows:

Front
The cooling fan side of the engine viewed from the flywheel.
Right
The injection pump side of the engine.
Left
The exhaust manifold side of the engine.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is No.
The engines direction of rotation is counterclockwise viewed from the flywheel.
APPEARANCE
1. MODEL 4LE2
(1) Left side view
Fig. 2
(2) Right side view
Fig. 3
MAIN DATA AND SPECIFICATIONS

1. MODEL 4LE2
Engine model(s)
4LE2
Item
Type
4-cycle, verlical in-line, water cooled, OHV
Timing drive system
Gear drive
No. of cylinders - bore stroke

Displacement
mm
4 85 92
L (cid)
2.179 (133)
Compression ratio
18.8 : 1
Type of combustion
Direct injection
Overall length width height
mm
691 449 616
kg (lb)
155 (342)
(when at stop)
14
Dry weight
Fuel injection timing (BTDC)
Firing order
1342
Fuel
Highspeed diesel fuel (SAE No.2)

min-1
Idling speed
Compression pressure
Valve clearance (cold)
mm (in)
Valve
operating
timing
MPa(kg/cm2/psi)
850
3 (31/440) or more/250 min-1
Intake
0.4 (0.0157)
Exhaust
0.4 (0.0157)
Open (BTDC)
15
Close (ABDC)
29
Open (BBDC)
40
Close (ATDC)
16
Intake valve
Exhaust valve
Injection pump
Bosch type
Governor
Mechanical type
Nozzle
Multi-hole type
Injection pressure
MPa(kg/cm2/psi)
17.7 (180/2560)
Oil pump
Trochoid type
Oil filter
Cartridge type
Lubricant capacity: In total
L (qts)
About 8.7 (9.2)
Generator output
(V A)
12 35
(V KW)
12 2.0
Starter output
(Note) These specifications may be subject to change without notice.

Figures in the column with an asterisk (*) are different for each machine. Refer to the specifications provided by machine manufacturers.
TIGHTENING TORQUE SPECIFICATIONS

The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.
STANDARD BOLT
Nm (kgfm)
Bolt
Identification
Bolt
Diameter
pitch (mm)
M 6 1.0
003.9007.8 {00.400.8}
004.9009.8 {00.501.0}
M 8 1.25
007.8017.7 {00.801.8}
011.8022.6 {01.202.3}
016.7030.4 {01.703.1}
M10 1.25
020.6034.3 {02.103.5}
027.5046.1 {02.804.7}
037.3062.8 {03.806.4}
019.6033.4 {02.003.4}
027.5045.1 {02.804.6}
036.3059.8 {03.706.1}
M12 1.25
049.1073.6 {05.007.5}
060.8091.2 {06.209.3}
075.5114.0 {07.711.6}
* M12 1.75
045.1068.7 {04.607.0}
056.9084.4 {05.808.6}
071.6107.0 {07.310.9}
M14 1.5
076.5115.0 {07.811.7}
093.2139.0 {09.514.2}
114.0171.0 {11.617.4}
* M14 2.0
071.6107.0 {07.310.9}
088.3131.0 {09.013.4}
107.0160.0 {10.916.3}
M16 1.5
104.0157.0 {10.616.0}
135.0204.0 {13.820.8}
160.0240.0 {16.324.5}
* M16 2.0
100.0149.0 {10.215.2}
129.0194.0 {13.219.8}
153.0230.0 {15.623.4}
M18 1.5
151.0226.0 {15.423.0}
195.0293.0 {19.929.9}
230.0345.0 {23.435.2}
* M18 2.5
151.0226.0 {15.423.0}
196.0294.0 {20.030.0}
231.0346.0 {23.635.3}
M20 1.5
206.0310.0 {21.031.6}
270.0405.0 {27.541.3}
317.0476.0 {32.348.5}
* M20 2.5
190.0286.0 {19.429.2}
249.0375.0 {25.438.2}
293.0440.0 {29.944.9}
M22 1.5
251.0414.0 {25.642.2}
363.0544.0 {37.055.5}
425.0637.0 {43.364.9}
* M22 2.5
218.0328.0 {22.233.4}
338.0507.0 {34.551.7}
394.0592.0 {40.260.4}
M24 2.0
359.0540.0 {36.655.0}
431.0711.0 {43.972.5}
554.0831.0 {56.584.7}
* M24 3.0
338.0507.0 {34.551.7}
406.0608.0 {41.462.0}
521.0782.0 {53.179.7}
* M10 1.5
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting.
TIGHTENING TORQUE SPECIFICATIONS

The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.
FLANGED HEAD BOLT
Nm (kgfm)
Bolt
Identification
Bolt
Diameter
pitch (mm)
M 6 1.0
004.6008.5 {00.500.9}
006.6012.2 {00.601.2}
M 8 1.25
010.50196 {01.102.0}
015.3028.4 {01.602.9}
018.1033.6 {02.103.4}
M10 1.25
023.1038.5 {02.403.9}
035.4058.9 {03.606.1}
042.3070.5 {04.307.2}
022.3037.2 {02.303.8}
034.5057.5 {03.505.8}
040.1066.9 {04.106.8}
M12 1.25
054.9082.3 {05.608.4}
077.7117.0 {07.911.9}
085.0128.0 {08.713.0}
* M12 1.75
051.0076.5 {05.207.8}
071.4107.0 {07.310.9}
079.5119.0 {08.112.2}
M14 1.5
083.0125.0 {08.512.7}
115.0172.0 {11.717.6}
123.0185.0 {12.618.9}
* M14 2.0
077.2116.0 {07.911.8}
108.0162.0 {11.116.6}
116.0173.0 {11.817.7}
M16 1.5
116.0173.0 {11.817.7}
171.0257.0 {17.426.2}
177.0265.0 {18.027.1}
* M16 2.0
109.0164.0 {11.216.7}
163.0244.0 {16.624.9}
169.0253.0 {17.225.8}
* M10 1.5
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
ANGULAR NUT AND BOLT TIGHTENING METHOD
1. Carefully wash the nuts and bolts to remove all oil

and grease.
2. Apply a coat of molybdenum disulfide grease to the

threads and setting faces of the nuts and bolts.
Fig. 4
3. Tighten the nuts and bolts to the specified torque

(snug torque) with a torque wrench.
Snug torque
Fig. 5
Center line
Fig. 6
4. Draw a line [A-B] across the center of each bolt.
5. Draw another line [C-D] on the face of each of the
parts to be clamped. This line should be an extension of the line [A-B].
Line
Fig. 7
6. Draw another line [F-G] on the face of each of the

parts to be clamped. This line will be in the direction of the specified angle [Q] across the center [E]
of the nut or bolt.
E
Specified angle (Q)
F
Coinciding line
Fig. 8
7. Use a socket wrench to tighten each nut or bolt to

the point where the line [A-B] is aligned with the line
[F-G].
Tighten
A
C
B
G
Fig. 9
Example: Specified Angle and Tightening Rotation
Fig. 10
B C D E
30
1/12 of a turn
60
1/6 of a turn
90
1/4 of a turn
180
1/2 of a turn
360
One full turn
TIGHTENING TORQUE ON MAJOR COMPONENTS

1. COOLING FAN AND WATER PUMP
Nm (kgfm/ft. lb)
19 28
(1.9 2.9 / 14 21)
12 18
(1.2 1.8 / 9 13)
12 18
(1.2 1.8 / 9 13)
19 28
(1.9 2.9 / 14 21)
To cylinder head
19 28
(1.9 2.9 / 14 21)
To cylinder head
19 28
(1.9 2.9 / 14 21)
19 28
(1.9 2.9 / 14 21)
34 46
(3.5 4.7 / 25 34)
Fig. 11
2. CYLINDER HEAD AND CYLINDER HEAD COVER

Nm (kgfm/ft. lb)
8 12
(0.8 1.2 / 6 9)
8 12
(0.8 1.2 / 6 8)
24
(0.2 0.4 / 1.4 2.9)
8 12
(0.8 1.2 / 6 9)
(Apply sealant.)
83 93
(8.5 9.5 / 61 69)
60 90
15 20
(1.5 2.0 / 11 14)
(Apply engine oil.)
19 28
(1.9 2.9 / 14 21)
0.9 1.1
(0.09 0.11 / 0.6 0.8)
(Apply Locktite No.262 to this part.)
25 34
(2.5 3.5 / 18 25)
19 28
(1.9 2.9 / 14 21)
(Apply engine oil.)

Fig. 12
4. CYLINDER BLOCK AND OTHER COMPONENTS (2)

Nm (kgfm/ft. lb)
20 25
(2.0 2.5 / 15 18)
10 14
(1.0 1.4 / 7 10)
8 12
(0.8 1.2 / 6 9)
15 25
(1.5 2.5 / 11 18)
31 41
(3.2 4.2 / 23 30)
19 28
(1.9 2.9 / 14 21)
8 12
(0.8 1.2 / 5.8 8.7)
19 28
(1.9 2.9 / 14 21)
21 30
(2.1 3.1 / 15 22)
(Apply engine oil.)
Positioning
pin.
8 12
(0.8 1.2 / 6 9)
69 88
(7.0 9.0 / 51 65)
19 28
(1.9 2.9 / 14 21)
19 28
(1.9 2.9 / 14 21)
Fig. 14
5. CYLINDER BLOCK AND OTHER COMPONENTS (3)

Nm (kgfm/ft. lb)
Apply Locktite
No.262 (2 locations).
8 12
(0.8 1.2 / 6 9)
12 16
(1.2 1.6 / 9 12)
8 12
(0.8 1.2 / 6 9)
Rotate 3/4 turn after

contacted with
sealing surface.
1.5 25
(1.5 2.5 / 11 18)
(With PTO provided)
8 12
(0.8 1.2 / 6 9)
19 28
(1.9 2.9 / 14 21)
8 12
(0.8 1.2 / 6 9)
19 28
(1.9 2.9 / 14 21)
Fig. 15
41 55
(4.2 5.6 / 30 41)
8 12
(0.8 1.2 / 6 9)
6. TURBOCHARGER
Nm (kgfm/ft. lb)
19 28
(1.9 2.9 / 14 21)
Fig. 16
GASKET LOCATION
1. LOCATIONS WHERE GASKETS ARE USED
Packin; nozzle holder

Gasket; nozzle holder
Packin; joint bolt
O-ring
Packin; headcover
() Sealant should not be
applied.
Gasket
Seal; valve
Packin;
water outlet pipe
Gasket;
cylinder head
Packin;
idle spring set screw
O-ring;
fuel cut lever
Packin;
rear cover
(PTO)
Packin;
governor
cover
Gasket;
exhaust
manifold
Oil seal;
crankshaft
rear
O-ring;
control lever
O-ring;
Oil strainer
O-ring;
angleich cover
Oil seal;
crankshaft front
O-ring;
Oil pump
O-ring;
Oil drain plug
Fig. 17
Gasket;
exhaust silencer
2. LOCATIONS WHERE SEALANT IS APPLIED

Location
Name of part
Condition for use

Name of
mating part
Object to be
sealed
Groove to be
applied
Name of
sealant
Oil pan
Cylinder block
Engine oil
(10W-30)
Not provided
TB1207C
Rocker bracket
Cylinder head
Engine oil
(10W-30)
Provided
TB1207B
Air inlet pipe
Cylinder head cover
Air
Provided
TB1207C
Front plate
(with PTO provided)
Cylinder block
Engine oil
(10W-30)
Provided
TB1207B
Timing case (with

PTO provided)
Front plate
Engine oil
(10W-30)
Provided
TB1207B
Timing case (with

no PTO provided)
Cylinder block
Engine oil
(10W-30)
Provided
TB1207B
Water pump ASM
Cylinder block
Cooling water
Not provided
TB1207C
Rear cover;
water pump
Body; water pump
Cooling water
Provided
TB1207B
Housing cover;
injection pump
Cylinder block
Engine oil
(10W-30)
Provided
TB1207B
10
Solenoid; fuel cut
Cylinder block
Engine oil
(10W-30)
Provided
TB1207C
11
Retainer; oil seal
Cylinder block
Engine oil
(10W-30)
Provided
TB1207B
12
Indicator; air cleaner
Air cleaner
Air
Not provided
(Sealing tape)
Fig. 18
Cautions:
1. Always use the above brandnames or an equivalent as the sealant.
2. Since Loctite FMD127 and Three-Bond 1386 are anaerobic, do not use them in case a gap exceeding
0.25 mm is occurring between the metallic mating surfaces since satisfactory effects cannot be
expected.
3. Always use the optimum quantity of sealant. Observe the handling precautions designated for
respective products.
When applying a sealant :
(1) when applying a sealant over a surface where some other liquid gasket was used previously, thoroughly clean the reside sealant using a scraper and wipe the surface by waste cloth to remove oil,
moisture, dust, etc. from the surface.
(2) When using the gasket remover Bundo 391D made by Three-Bond (Isuzus Part No. 1-8840-0542-0)
to facilitate the cleaning work, apply the remover and leave it as is for about 10 minutes before
starting the removal work.
(3) Be careful not to apply too much or too little.
(4) How to use the TB1207C and TB1207B
Apply them with a line diameter of 3 mm or more and for a thickness of 1 ~ 2 mm.
Apply them along the gluing groove without interruptions and assemble the mating structures with 5
minutes.
Also, after finishing the assembly, leave the assembly as is for at least 2 hours and do not run the
engine during this period.
Bolt hole
Determina
tion
Dent
Dent
Apply onto the bore surface

of the bolt hole.
Specified bead width
(Reference)
Anaerobic : 2 ~ 3 mm
Others : 2 ~ 6 mm
Caution: When the application method is being designated in the repair manual, follow the designation.
3. Locktite
Types
Colors
Loctite 242
Blue
Work procedures
1.
2.
Loctite 262
Loctite 271
Red
Red
Wipe the thoroughly remove oil, grease and moisture from

the mating surfaces such as the bolt surface, bolt hole,
thread surface of the nut.
Apply Locktite.
Apply over the tip end
surface, namely 1/3 of
the threaded section.
3. Tighten the bolt at the specified torque.

Caution: After tightening the bolt, do not apply excessive
torque or vibrations for about an hour until the
applied Loctite sets.
MAINTENANCE
1. VALVE CLEARANCE AND ADJUSTMENT
Note:
The cylinder head bolts were previously tightened with
the Angular Tightening Method. Therefore, it is not
necessary to retighten the cylinder head bolts before
adjusting the valve clearance.
Fig. 19
1. Bring the piston in either the No. 1 cylinder or the

No. 3 cylinder to Top Dead Center on the compression stroke by turning the crankshaft until the TDC
mark on the front cover aligns with the groove mark
on the crankshaft pulley.
Groove mark
TDC mark
2. Check to see if there is play in the No. 1 intake and

exhaust valve rocker arms.
gear
(Timing
case cover )
If the No. 1 cylinder intake and exhaust valve rocker

arms have play, the No. 1 piston is at TDC on the
compression stroke.
Crank
pulley
Fig. 20
If the No. 1 cylinder intake and exhaust valve rocker

arms are depressed, the No. 4 piston is at TDC on
the compression stroke.
Adjust the circle or double circle marked valves as
shown in Fig. 22, while the No. 1 or the No.4 cylinder is at TDC on compression stroke.
mm (in)
No.1 cylinder
exhaust
No.1 cylinder
intake
I ; Intake
1
I
2
E
0.40 0.05 (0.015 0.002)
3. Loosen each valve clearance adjusting screw as

shown in the illustration.
Fig. 21
Cylinder No.
Valve
arrangement
No. 1 cylinder
TDC for compression
No. 4 cylinder
TDC for compression
Intake and Exhaust

Valve Clearance (cold)
3
E
4
E
4. Insert a 0.40 mm (0.015 in) feeler gauge between the

rocker arm and the valve stem end.
5. Turn the valve clearance adjusting screw until a
slight drag can be belt on the feeler gauge.
6. Tighten the lock nut securely.

E ; Exhaust
Fig. 22
7. Rotate the crankshaft 360.

Realign the crankshaft pulley.
8. Adjust the clearances for the remaining valves as
shown in the illustration.
2. LUBRICATIN SYSTEM
Cartridge (Spin-On) Type
Cartridge
Removal
Remover and Installer: Filter Wrench
1. Loosen the used oil filter by turning it counterclockwise with the filter wrench.
2. Discard the used oil filter.
Installation
1. Wipe the oil filter mounting face with a clean rag.
Fig. 23
This will allow the new oil filter to seat properly.

2. Lightly oil the O-ring.
3. Turn in the new oil filter until the sealing face is fitted against the O-ring.
4. Use the filter wrench to turn in the oil filter an additional 3/4 of a turn or one turn.
5. Check the engine oil level and replenish to the specified level if required.
6. Start the engine and check for oil leakage from the
oil filter.
3. COOLING SYSTEM
Cooling Fan Drive Belt
Adjustment
Fan pulley 1
About 10 mm
1. Check the cooling fan drive belt for cracking and

other damage.
Generator pulley
2
2. Check the drive belt tension by exerting a force of 98

N (10 kg) midway between the Fan pulley 1 and the
Generator pulley 2.
Depress here
Cooling
fan drive
belt
Crank pulley
Fig. 24
3. Adjust the belt tension by loosening the Generator

mounting bolt and the Generator adjusting bolt and
pivoting the Generator.
Be sure to retighten the bolts after adjusting the belt
tension.
mm (in)
Cooling Fan Drive
Belt Deflection
7.5 8.5
(0.3 0.33)
4. INJECTION TIMING
Note:
Take care to avoid entry of dust or foreign particles into
the pump interior when the timing adjustment is made.
Delivery valve
holder
Injection pump
Delivery
spring
1.
Remove the injection pipe of the No. 1 cylinder.
2.
Remove the delivery valve holder of the injection

pump of the No. 1 cylinder, and then pull out the
delivery spring.
3.
With the spring left removed, install the delivery

valve holder.
4.
Slowly turn the crankshaft pulley clockwise, at the

same time, continue to feed the fuel.
When the fuel stop flowing out from the No. 1 delivery valve holder, stop turning the crankshaft.
Fig. 25
This crank angle position is the starting point of

injection.
5.
Groove mark
TDC mark
In the condition at Step (4) above, confirm what

degree the groove mark of the crank pulley is at,
when seen by the timing mark, provided in the
timing gear case.
When the value is out of the range of the normal
injection timing, adjust it accordingly.
Timing gear
case cover
* Injection timing
Crank
pulley
Injection pump
Cylinder block
Identification
mark
Note:
The injection timing varies according to the specifications of the machine.
Fig. 26
Shim
BTDC 14
6.
Adjust the injection timing with a shim between the

injection pump and the cylinder block.
Shim is available in the following 9 types, and identification mark is stamped (or imprinted) on the top
face.
Identification mark of shim and its thickness

Knock hole
Fig. 27
(mm)
Mark
Thickness
Mark
Thickness
Mark
Thickness
0.2
0.5
0.8
0.3
0.6
10
1.0
0.4
0.7
12
1.2
Note:
For each of the injection pumps of three cylinders, the
shim adjustment is made at the same time.
When a shim is missing while overhauling the engine
and the shim thickness is unknown, assemble the
engine with provisional shim inserted. After assembling
the engine, check the injection timing and adjust the
shim until the normal injection timing is obtained.
Reference:
To add the 0.1 mm shim thickness corresponds to the 1
degree of crankshaft angle advance.
Air bleeding from fuel (automatic air-bleeding system)
1.
For the automatic air-bleeding system

When the starter switch is set to OPERATION, the
electromagnetic pump is activated to force-feed fuel
to the fuel pipe and the leak-off pipe, and air in the
fuel system is automatically bled.
2.
Injection Pump
Fig. 28
For non-automatic air-bleeding system

While sending fuel by means of the force of the electromagnetic pump, the fall from the fuel tank or the
feed pump lever, bleed air out of the fuel pipe eye
bolt of the No. 1 cylinder injection pump, the leak-off
pipe eye bolt of the injection nozzle and the airbleeder plug of the fuel filter, starting with the one
installed the lower most and upward.
5. COMPRESSION PRESSURE MEASUREMENT

Compression gauge
1. Operate the engine to warm-up until the coolant

temperature reachs to 75C (167F).
2. Remove all of the glow plugs and the injection
pipes.
Adapter; gauge
3. Attach a compression gauge to the No. 1 cylinder

glow plug installation threads.
Note:
Compression pressure may be measured starting at any
cylinder and in no particular cylinder order. However, it
is very important that the compression pressure be
measured in each cylinder.
Therefore, start at the No. 1 cylinder and work back. In
this way, you will be sure to measure the compression
pressure in each cylinder.
Fig. 29
Compression Gauge
5-8840-2675-0
Compression Gauge Adapter 5-8840-9029-0
4. Crank the engine with the starter motor and take the
compression gauge reading.
MPa (kgf/cm2 /psi) at 250 min-1
Standard
Limit
3 (31/440)
2.5 (26/370)
5. Repeat the procedure (.Steps 3 and 4.) for the

remaining cylinders.
Fig. 30
Compression pressure should be approximately the

same for each cylinder. A variation exceeding 200
kPa (2.0 kg/cm2 /.28 psi.) is unacceptable.
If the measured value exceeds the specified limit,
the related parts must be checked.
6. FUEL SYSTEM
Fuel Filter Replacement
Cartridge (Spin-On) Type
Removal
1.
Loosen the fuel filter by turning it counterclockwise

with the filter wrench or your hand. Discard the
used filter.
Filter Wrench
2.
Wipe the fuel filter fitting face clean with a rag.

This will allow the new fuel filter to seat properly.
Fig. 31
Installation
1.
Apply a light coat of engine oil to the O-ring.
2.
Supply fuel to the new filter.

This will facilitate air bleeding.
3.
Turn in the new fuel filter until the filter O-ring is fitted against the sealing face.
4.
Use the filter wrench to turn in the fuel filter an additional 2/3 of a turn.
Injection nozzle
Check to see if the spray condition and the injection

pressure are normal. Adjust them to the specified value
respectively when they dont meet the standard valve.
Spray Condition
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dipping)
Fig. 32
MPa (kgf/cm2 /psi)

Injection pressure
17.7 (180/2560)
Using a nozzle tester, adjust the injection pressure with a

shim.
Special tool: Nozzle tester
Fig. 33
RECOMMENDED LUBRICATING OIL

TYPE OF LUBRICANTS (API)
DIESEL ENGINE OIL; CC OR CD GRADE
ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 5W20
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
[Single grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 20, 20W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 40
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
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;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W
SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
Ambient
temperature
[Multi grade]
25C 20C 15C

(13F) (4F) (5F)
0C
(32F)
15C
(59F)
25C 30C
(77F) (86F)
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 15W40, 20W40
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
Fig. 34
MEMO
ENGINE 27
SECTION 2
ENGINE
TABLE OF CONTENTS
CONTENTS
PAGE
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
28 ENGINE
DISASSEMBLY
1. EXTERNAL PARTS (Left-hand side)
(9)
(10)
(2)
(1)
(8)
(3)
(5)
(11)
(7)
(4)
(6)
Fig. 35
(1) Exhaust silencer

(2) Exhaust pipe
(3) Cooling fan and spacer
(4) Fan belt
(5) Fan pulley
(6) Generator
(7) Starter
(8) Exhaust manifold and gasket
(9) Cylinder head cover and air intake pipe
(10) Water outlet pipe and thermostat
(11) Water pump assembly
ENGINE 29
2. EXTERNAL PARTS (Right-hand side)
(15)
(14)
(13)
(12)
(18)
(16)
(19)
(17)
(20)
Fig. 36
(12) Injection pipe . . . . . . . . . 4 pcs.

(13) Fuel hose
(14) Fuel leak off pipe
(15) Fuel pipe
(16) Engine stop solenoid
(17) Injection pump housing cover
(18) Injection pump and shim . . . . . . . . . 4 set
(19) Oil filter
(20) Oil level gauge
30 ENGINE
Leak off pipe
Fuel pipe
Injection pipe
Leak off pipe
Fuel pipe
Eye bolt
Injection pipe
1.
Loosen the sleeve nuts on the nozzle holder side and

on the injection pump side, and then disconnect the
injection pipes.
2.
Disconnect the leak off pipe together with gaskets.
3.
Remove the eye bolt, and then disconnect the fuel

pipe.
Nozzle holder
Injection pump
Fig. 37
Solenoid ASM
Remove the solenoid ASM.
Solenoid ASM
Fig. 38
Injection pump housing cover

Stud bolt
1.
Remove the bolts and nut.
2.
Install the bolts (M8 x 1.25) to the replacer hole.
3.
Tighten the bolts, and then remove housing cover.
Housing cover
Fig. 39
Housing cover
Mark : M81.25 for replacer

Fig. 40
Fuel cut cover
Pin(6 )
Governor cover
Fig. 41
Injection pump
1.
Align the hole of the fuel cut lever with the hole of
the governor cover, and then insert a pin (6) into
this hole to hold the fuel cut lever.
2.
Check to see if the pin groove of the control link is at

the center of the injection pump.
3.
Remove the injection pump, and then take out the

shim.
ENGINE 31
NOTE:
Injection pump
center position
Control link
1.
Mark each injection pump as to which cylinder it

was removed from.
2.
Do not reuse the shim, replace it with the same

thickness that was removed.
Injection pump
rack pin
Fig. 42
Injection pump ASM
Shim
* Stud
Cylinder block
Fig. 43
Backlash of timing gear
mm (in)
STANDARD
LIMIT
CRANK GEAR/
IDLER GEAR
0.04
(0.0017)
0.2
(0.0079)
CAM GEAR/
IDLER GEAR
0.03
(0.0012)
0.2
(0.0079)
IDLER GEAR END PLAY
mm (in)
STANDARD
LIMIT
0.058 0.115 (0.0023 0.0045)
0.2 (0.0079)
CRANKSHAFT END PLAY
mm (in)
STANDARD
LIMIT
0.058 0.208 (0.0023 0.0082)
0.3 (0.0118)
32 ENGINE
3. INTERNAL PARTS
Disassembly Steps
(1) Rocker Bracket Assembly
(2) Push Rods
(3) Rear Hanger
(4) Front Hanger
(5) Cylinder Head Assembly
(6) Cylinder Head Gasket
(7) Tappets
(8) Oil Pan
(9) Oil Strainer
(10) Oil Pipe
(11) Crank Pulley
(12) Flywheel
(13) Flywheel Housing
(14) Timing Gear Case (without PTO)
(15) Oil Pump Assembly
(16) Idler Gear and Shaft
(17) Cam Gear
(18) Camshaft
(19) Rear Seal Retainer
(20) Piston Assemblies
(21) Crankshaft
ENGINE 33
Internal Parts (1/3)
(14)
(1)
(3)
(2)
(5)
(18)
(17)
(7)
(4)
(16)
(15)
(6)
Fig. 44
34 ENGINE
(20)
(13)
Do not pull out

this bolt.
(9)
(12)
(21)
(10)
Rear
(19)
(11)
(8)
Fig. 45
ENGINE 35

When provided with PTO
(14-2)
(14-1)
(15)
Fig. 46
36 ENGINE
Rocker bracket
Install of
nuts (6)
Push rod
Install of
bolts (5)
1.
Remove the rocker bracket assembly.

(M6 1 . . . . . 5 bolts and 6 nuts)
2.
Pull out the push rods (8 pcs.).
Marks : Thread hole (M8 x 1.25) for replacer of rocker

bracket assembly
Rocker Bracket
Fig. 47
Cylinder head assembly
Rear
hanger
Head bolt
(M12)
Cylinder head
ASM
(M8)
Fig. 48
Remove the rear and front hangers.
2.
When removing the cylinder head bolts, loosen

them slowly, a little at a time, starting with the
outside, working in a circular pattern inward.
3.
Remove the cylinder head assembly and the head

gasket.
4.
Pull out the tappet from the cylinder body.
Head gasket
Front hanger
1.
12
15
11
13
14
Fig. 49
10
7
6
ENGINE 37
Cylinder Head Assembly
Glow plug (2)

Connector (1)
Seal; valve
Split collar (4)
Guide; valve
Spring seat (5)
Studs are applied with
sealing agent.
Do not pull them out.
(5 locations)
Valve spring (6)
Nozzle holder (3)
Valve (7)
Hot plug
Seat; valve insert
Fig. 50
Valve mechanism
1.
Before disassembling the valve mechanism, remove

the connector, glow plug and nozzle holder assembly.
2.
Compressing the valve spring, remove the split collar, spring seat, valve spring and valve.
38 ENGINE
Timing Gear
Bearing
Wear ring
Cam shaft (8)

Pin
Bearing
Snap ring (7)
Cam gear (6)
Fly weight ASM (5)
Shaft; idle gear (3)

Lock nut
Idle gear (2)
Sleeve (4)
Thrust collar
Crankshaft
Key
Crank gear
Crank pulley (1)
Washer
Fig. 51
ENGINE 39
Timing gear
1.
Remove the idle gear and the idle gear shaft.
2.
Pull out the sleeve from the tip end of the cam shaft.
3.
Remove the lock nut of the cam shaft gear, and then
remove the flyweight assembly and the cam gear.
Camshaft
Crankshaft
Snap ring
Fig. 52
1.
Remove the snap ring which holds down the front

bearing of the cam shaft from the ring groove of the
cylinder block.
2.
Pull out the cam shaft from the cylinder block,

together with the bearing.
40 ENGINE
Piston and Connecting Rod
Piston ring (4)

Snap Pipe (5)
Piston
Piston pin (6)
Bush
(The drawing-out of the bush must
be limited to only when replaced.
Conrod bolt
(The drawing-out ot the conrod bolt
must be limited to only when replaced.)
Connecting rod (7)

Cap (6)
Cap nut (1)
Fig. 53
Piston and connecting rod

Piston
Connecting rod
cap
1.
Turning the crankshaft, position the piston to be

removed at the bottom dead center.
2.
Loosen the cap nut of the connecting rod, and then

remove it.
3.
Give another rotation to the crankshaft to position

the piston at the top dead center.
4.
With the handle of a hammer placed at the bottom

of the connecting rod, push the piston assembly
upward out of the cylinder block.
Fig. 54
Notes:
1.
Before removing the piston, scrape the carbon

deposit off the cylinder wall.
2.
When pushing out the piston assembly, care should

be taken not to damage the cylinder wall.
3.
Attach a tag with a cylinder number to the removed

caps and bearings to keep them in order.
ENGINE 41
Piston ring
Remove the piston ring with a ring pliers.
Pliers: piston ring 1-85221-029-0
Fig. 55
Brass bar
Piston pin
1.
Remove the snap rings with a commercially available tool.
2.
With a brass bar attached to the piston pin, push it

out by hammering it lightly.
Note:
Keep the pistons, piston pins and connecting rods in
order for each cylinder.
Piston pin
Fig. 56
42 ENGINE
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
1. CYLINDER BLOCK
Cylinder block
Check the cylinder block for wear, damage or any other
defects.
Use the hydraulic gauge to check the water jacket water
pressure.
Apply water pressure to the water jacket at 5 kg/cm2
(71.1 psi) for three minutes.
Fig. 57
Cylinder bore
Y
X
Measurement position: 13mm below the top

(Measure in X-X and
Y-Y directions.)
(Near the No. 1
compression ring)
mm (in)
Fig. 58
Standard
Limit
85
85.2
Repair method
Perform boring and
honing of the inner
diameter.
Cylinder bore diameter and grade mark

Bore grade mark
(Stamp position)
Fig. 59
The grade mark is stamped on the top surface of the

cylinder block (on the mating face with the cylinder
head).
ENGINE 43
mm (in)
Engine
4LE2
Bore Diameter
Grade
85.000 85.010
(3.3464 3.3468)
85.011 85.020
(3.3468 3.3472)
85.021 85.030
(3.3472 3.3476)
Cylinder Body Upper Face Warpage

1
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.
Regrind the cylinder body upper face if the measured
values are greater than the specified limit but less than
the maximum grinding allowance.
2
Fig. 60
If the measured values exceed the maximum grinding

allowance, the cylinder body must be replaced.
Cylinder Body Upper Face Warpage
A
Standard
Limit
Maximum Grinding
Allowance
0.075 (0.0029)
0.15 (0.0059)
0.3 (0.0118)
E
C
mm (in)
If the measured value is less than the limit, the cylinder

body may be reground.
Fig. 61
Cylinder Body Height H (Reference)
Fig. 62
Engine
Standard
4LE2
307.94 308.06
(12.123 12.128)
mm (in)
44 ENGINE
2. CYLINDER HEAD
Cylinder head inspection
Remove carbon deposit on the bottom surface of the
head with care not to damage the valve seat.
Leakage: Water pressure test 5kg/cm2 (for 3 minutes)
Fig. 63
Cylinder Head Lower Face Warpage

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

the four sides and the two diagonals of the cylinder
head lower face.
2.
Regrind the cylinder head lower face if the measured values are greater than the specified limit but
less than the maximum grinding allowance.
Fig. 64
If the measured values exceed the maximum grinding

allowance, the cylinder head must be replaced.
Cylinder Head Lower Face Warpage
A
F
E
C
mm (in)
Standard
Limit
Maximum Grinding
Allwance
0.075 (0.0029)
0.15 (0.0059)
0.3 (0.0118)
Fig. 65
Cylinder Head Height H (Reference)

Engine
Standard
4LE2
63.90 64.10
(2.515 2.523)
mm (in)
Note:
If the cylinder head lower face is reground, valve
depression must be checked.
Fig. 66
ENGINE 45
3. VALVE, VALVE SEAT INSERT AND VALVE SEAL

Inspection of valve seat
Cylinder head
Valve
1.
A Contact width
2.
B Valve depression
mm (in)
Standard
Limit
2.0 (0.0787)
2.5 (0.0984)
IN
0.7 (0.0276)
1.2 (0.0427)
EX
0.9 (0.0354)
1.5 (0.0591)
Contact width
B
Valve depression
45
Fig. 67
Valve thickness
Nominal
Limit
IN
1.0
(0.03937)
0.7
(0.0276)
EX
0.8
(0.0315)
0.5
(0.0197)
Repair method
Replace
Fig. 68
Valve Stem Outside Diameter

Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
valve must be replaced.
Valve Stem Outside Diameter
Fig. 69
mm (in)
Standard
Limit
Intake Valve
7.0
(0.2756)
6.85
(0.2697)
Exhaust Valve
7.0
(0.2756)
6.80
(0.2677)
46 ENGINE
Valve Seat Insert Replacement
2
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.
Fig. 70
Use a screwdriver 3 to pry the valve seat insert

free.
Take care not to damage the cylinder head 4.
4.
Carefully remove carbon and other foreign material

from the cylinder head insert bore.
Valve Seat Insert Installation

3
1.
Carefully place the attachment 1 (having a smaller

outside diameter than the valve seat insert) on the
valve seat insert 2.
Note:
2
The smooth side of the attachment must contact the

valve seat insert.
2.
Fig. 71
Use a bench press 3 to gradually apply pressure to

the attachment and press the valve seat insert into
place. 4,000 kg (8,819 lbs.)
Note:
Do not apply an excessive amount of pressure with the
bench press. Damage to the valve seat insert will
result.
Valve Seat Insert Correction
2
(0 .0 m
.0 m
8
in
.)
150
90
30
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.
Fig. 72
Valve Seat Angle
degree
45
Note:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
Fig. 73
ENGINE 47
Fig. 74
3.
Apply abrasive compound to the valve seat insert

surface.
4.
Insert the valve into the valve guide.
5.
Apply light pressure to the valve while turning 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.
8.
Clean the head and valves to remove the abrasive

compound and metal particles.
4. VALVE SPRING
Valve Spring Inclination
Use a surface plate and a square to measure the valve
spring inclination.
If the measured value exceeds the specified limit, the
valve spring must be replaced.
mm (in)
Valve Spring
Inclination
Standard
Limit
1.8
(0.0709)
2.5
(0.0984)
Fig. 75
Valve Spring Tension

Use a spring tester to measure the valve spring tension.
mm (in)
Valve Spring
Tension at 29.9 mm
Set Length
Standard
Limit
17.0
(37.479)
15.0
(33.069)
Fig. 76
Valve Spring Free Length

Use a vernier caliper to measure the valve spring free
length.
mm (in)
Fig. 77
Exhaust and Intake

Valve Spring Free
Length
Standard
Limit
42.1
(1.6575)
40.0
(1.5748)
48 ENGINE
5. TAPPET (Cam Follower or Valve Lifter) AND PUSH ROD

TAPPET
Inspect the tappets for excessive wear, damage and any
abnormalities.
Use a micrometer to measure the tappet diameter.
mm (in)
Standard
Tappet Diameter
20.967 20.980
(0.82547 0.82598)
Fig. 78
Use a dial indicator to measure the clearance between

the tappet and cylinder body tappet travelling bore.
mm (in)
Tappet and Tappet
Travelling Bore
Clearance
Standard
Limit
0.020 0.054
(0.00079 0.00213)
0.08
(0.00315)
Fig. 79
PUSH ROD
Use a filler gauge to measure the valve push rod runout.
Roll the push rod along a smooth flat surface (illustration).
mm (in)
Limit
Push Rod Run-Out
Fig. 80
0.3 (0.0118)
ENGINE 49
6. CAM SHAFT
Inspection of cam shaft
Check the journal and the cam for evidence of wear,
damage or any other defect.
Camshaft
Note:
With the front and rear parts of camshaft pressed in
with ball bearings, and with the cylinder block pressed
in with roller bearings as the center bearing, check to
see if the camshaft rotates smoothly with no play at
each bearing.
Fig. 81
Measurement of journal and cam

1.
Cam height (A B)
mm (in)
Standard
Limit
Repair method
Intake
6.13
5.83
(0.2413) (0.2295)
Replace
Exhaust
6.43
6.13
(0.2531) (0.2413)
Replace
Fig. 82
2.
I II
I II
A'
A
B'
B
B'
3.
Center journal diameter
mm (in)
Nominal
Limit
Repair method
52
(2.0472)
51.92
(2.0441)
Replace
Uneven wear of journal
mm (in)
A'
Fig. 83
4.
Fig. 84
Nominal
Limit
Repair method
52
(2.0472)
0.05 (0.002)
Replace
Runout of cam shaft
mm (in)
Nominal
Limit
Repair method
0.02
(0.008)
0.1 (0.004)
Replace
50 ENGINE
7. ROCKER ARM SHAFT AND ROCKER ARM

Inspect all disassembled parts for wear, damage and any
abnormalities.
Fig. 85
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm outside
diameter.
shaft must be replaced.
mm (in)
Standard
Limit
Rocker Arm Shaft 11.935 11.955

Diameter
(0.4699 0.4707)
Fig. 86
11.85
(0.4665)
Rocker Arm Shaft and Rocker Arm Clearance

1.
Use a vernier caliper to measure the rocker arm

bushing inside diameter.
mm (in)
Standard
Rocker Arm Bushing
Inside Diameter
Fig. 87
2.
11.960 11.980
(0.4709 0.4717)
Measure the rocker arm shaft outside diameter.

Replace either the rocker arm or the rocker arm shaft
if the clearance exceeds the specified limit.
mm (in)
Rocker Arm Bushing
and Rocker Arm
Shaft Clearance
3.
Fig. 88
Standard
Limit
0.005 0.045
(0.0002 0.0018)
0.2
(0.0079)
Check that the rocker arm oil port is free of obstructions.

If necessary, use compressed air to clean the rocker
arm oil port.
ENGINE 51
8. PISTON, PISTON PIN AND PISTON RING

Clearance between piston and cylinder bore
About 64
1.
Measure the outside diameter of the piston at about

64 mm from the top in a right angle to the piston pin
(in the unit of 1/1,000 mm).
2.
Calculate the clearance based on the measurements

of the cylinder bore and the outside diameter of the
piston.
mm (in)
Clearance
0.040 0.085 (0.0015 0.0033)
Fig. 89
Outside diameter of piston and grade mark

The grade mark is stamped on the top surface of the
piston installed at the factory.
The piston for service part doesnt have the grade.
mm (in)
Model
Outside diameter of piston
Grade
4LE2
84.945 84.960
(3.3443 3.3449)
NON
Fig. 90
Wear of piston pin (outside diameter)

mm (in)
Fig. 91
Nominal
Limit
25.0
(0.9843)
24.97
(0.9831)
Remarks
Replace if worn
beyond limit
52 ENGINE
Clearance between piston pin and piston pin hole
mm (in)
Standard
4LE2
0.007 0.017
(0.00027 0.00067)
Piston ring gap

With the ring inserted into the cylinder bore, push it in
with the piston head so that it becomes a right angle to
the cylinder, and then measure the gap of the piston
ring.
If worn beyond the limit, replace the rings.
mm (in)
Standard
Fig. 92
1st
compression ring
0.2 0.35
(0.0079 0.0138)
2nd compression
ring
0.35 0.5
(0.0138 0.0197)
Oil ring
0.2 0.4
(0.0079 0.0157)
Limit
1.5
(0.0590)
1.0
(0.03937)
Clearance between piston ring groove and ring

Measure clearance at several places on the circumference.
If worn beyond the limit, replace the rings or piston.
4LE2
Fig. 93
mm (in)
Standard
Limit
1st
compression ring
0.085 0.105
(0.0033 0.0041)
0.2
(0.0078)
2nd
compression ring
0.050 0.085
(0.0020 0.0033)
0.15
Oil ring
0.030 0.070
(0.0011 0.0027)
(0.0059)
ENGINE 53
9. CONNECTING ROD AND CONNECTING ROD BEARING

Torsion and parallelism of connecting rod
If worn beyond the limit-repair or replace.
mm (in)
Per 100 mm (3.94)
Standard
Limit
Torsion
0.05
(0.002)
0.2
(0.0079)
Parallelism
0.05
(0.002)
0.15
(0.0059)
Fig. 94
Clearance between small end pin hole of connecting rod

and piston pin, inside diameter of bushing
mm (in)
Clearance
Inside diameter
Standard
Limit
0.008 0.020
(0.0003 0.0008)
0.05
(0.0020)
25 (0.9843)
Fig. 95
Connecting Rod Bearing Inspection

1.
Fit the connecting rod bearing lower half into the

connecting rod bearing cap.
2.
Check the connecting rod bearing lower half tension.

If the tension is insufficient, the bearing must be
replaced.
3.
Tighten the connecting rod and the bearing cap to

the specified torque.
Nm (kgfm/ft. lb)
Fig. 96
Tightening torque
74 - 83 (7.5 - 8.5 / 54 - 61)
Clearance between bearing and crank pin, inside diameter with bearing installed and without.
mm (in)
Clearance
Fig. 97
Standard
Limit
0.035 0.073
(0.0014 0.0029)
0.10
(0.0039)
54 ENGINE
10.CRANKSHAFT AND CRANKSHAFT BEARING

Outside diameters of journal and pin
If worn beyond the limits-replace
Crank journal
4LE2
mm (in)
Standard
Limit
60.0 (2.3622)
59.86 (2.3567)
Crank pin
Fig. 98
mm (in)
4LE2
Standard
Limit
49.0 (1.9291)
48.87 (1.9240)
Note:
When there occurs an uneven wear to the crankshaft,
replace it with a new one without grinding it for reuse.
Clearance between journal and bearing inside diameter
with bearing installed and without
mm (in)
Clearance
Standard
Limit
0.029 0.072
(0.0011 0.0028)
0.11
(0.0043)
Fig. 99
Runout of crankshaft
Replace if beyond limit
mm (in)
Standard
Limit
0.025 (0.001)
0.05 (0.002)
Fig. 100
Crankshaft gear
Check the crankshaft gear visually for damage and any
other defects.
Fig. 101
ENGINE 55
Oil seal
Timing gear case
When the lip of an oil seal is found defective, replace it

with a new one.
Installation
Use the crankshaft front oil seal installer to install the
crankshaft front oil seal.
Front oil seal
Fig. 102
11.FLYWHEEL AND RING GEAR

Ring Gear Replacement
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.
Ring Gear Removal
Strike around the edges of the ring gear with a hammer
and chisel to remove it.
Fig. 103
Ring Gear Installation

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

thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200C (390F).
2.
Use a hammer to install the ring gear when it is sufficiently heated.
Fig. 104
12.TIMING GEAR
Uneven wear of idle gear shaft
mm (in)
Nominal
Limit
45.0 (1.7717)
0.1 (0.0039)
Fig. 105
Clearance between idle gear bushing and shaft

mm (in)
Fig. 106
Standard
Limit
0.025 0.085 (0.001 0.0033)
0.2 (0.0079)
56 ENGINE
REASSEMBLY
1. CYLINDER HEAD ASSEMBLY
Glow plug (7)
Connector (8)
Seal; valve (1)
Split collar (5)
Guide; valve
Spring seat (4)
Apply Locktite No.262
to this portion.
(5 locations)
Valve spring (3)
Nozzle holder (6)
Valve (2)
Hot plug
Seat; valve insert

Fig. 107
Important Operations
Valve Stem Oil Seal
1.
Lubricate the oil seals and valve stem sealing area

with engine oil.
2.
Use a valve stem oil seal installer to install the oil

seal.
Valve Stem Oil Seal Installer: 5-8840-9033-0
Fig. 108
Intake and Exhaust Valves

1.
Place the cylinder head on a flat wooden surface.
2.
Lubricate valve stems with engine oil.
3.
Install the valves to the intake or exhaust guides.

Install the valves to their original lapped valve seats.
Fig. 109
ENGINE 57
Intake and Exhaust Valve Springs
Install the valve springs with their painted end (the close
pitched end) facing down.
Painted potion
Fig. 110
Spring compressor
Split collar
Spring Seat Split Collar

1.
Use a spring compressor to push the valve spring

into position.
2.
Install the spring seat split collar.
3.
Set the spring seat split collar by tapping lightly

around the head of the collar with a rubber hammer.
Spring Compressor: 5-8840-9030-0
Fig. 111
Nozzle holder assembly

Bolt
Eye bolt
Before assembling the nozzle holder assembly, check to

see if the spray condition and the spray pressure of the
injection nozzle are appropriate, (Refer to INSPECTION
AND SERVICE.)
Bracket
Assemble to the cylinder head the gasket.
Nozzle holder ASM
Install the nozzle holder assembly, and then tighten it to

Gasket
Fig. 112
Nm (kgfm/ft. lb)
Tightening torque
31 - 41 (3.2 4.2 / 23 - 30)
Glow plug and connector

Glow plug
Assemble the glow plug to the cylinder head, and then

tighten it to the specified torque.
Install the connector to the glow plug, and then tighten
until snug.
Nm (kgfm/ft. lb)
Connector
Fig. 113
Parts
Tightening torque
Glow plug
15 - 20 (1.5 2.0 / 11 - 14)
58 ENGINE
2. PISTON AND CONNECTING ROD
Piston ring (5)

Snap Pipe (4)
Piston (1)
Piston pin (3)
Bush (2)
bolt removed
* Rod
for clarity.
*
Connecting rod (2)
Cap (7)
Cap nut (8)
Bearing (6)
Fig. 114
Important Operations
Conventional
piston heater
Piston
Use a piston heater to heat the pistons to approximately
100C (212F).
Connecting Rod
Fig. 115
(Hot plug side)
Front mark
Engine
front
direction
Isuzu mark
Cylinder number
stamped side
Fig. 116
1.
Install the connecting rod to the piston with setting

the marks as illustrated.
2.
Install the piston pin into the piston and the connecting rod bushing.
ENGINE 59
Piston Pin Snap Ring
1.
Use a pair of snap ring pliers to install the piston pin

snap ring.
2.
Check that the piston moves smoothly on the piston

pin.
Fig. 117
Piston Ring
1st
1.
Use a piston ring installer to install the three piston

rings.
Piston Ring Installer
2nd
Install the piston rings in the following order.

(1) Oil ring
(2) 2nd compression ring
Oil
(3) 1st compression ring

The marked side of the two compression rings must
be facing up.
Fig. 118
The undercut side of the second compression ring

will be facing down.
As the oil ring has no any facing mark, it may face in
either direction.
2.
Lubricate the piston ring surfaces with engine oil.
3.
Check that the piston rings rotate smoothly in the

piston ring grooves.
60 ENGINE
3. INTERNAL PARTS
Reassembly Steps
(1) Crankshaft
(2) Piston Assembly
(3) Rear Seal Retainer
(4) Camshaft
(5) Cam Gear
(6) Idler gear and Shaft
(7) Oil Pump Assembly
(8) Timing Gear Case (Without PTO)
(9) Flywheel Housing
(10) Flywheel
(11) Crank Pulley
(12) Oil Pipe
(13) Oil Strainer
(14) Oil Pan
(15) Tappets
(16) Cylinder Head Gasket
(17) Cylinder Head Assembly
(18) Push Rods
(19) Rocker Bracket Assembly
(20) Engine Hangers
ENGINE 61
(2)
(9)
(13)
(10)
(1)
(12)
Rear
(3)
(11)
(14)
Fig. 119
62 ENGINE
(8)
(19)
(20)
(18)
(17)
(4)
(5)
(15)
(20)
(6)
(7)
(16)
Fig. 120
ENGINE 63
(8-1)
(8-2)
(7)
Fig. 121
64 ENGINE
Crankshaft bearing
With oil hole

and groove
(Upper)
Fit correctry
Note that there is an oil hole and an oil groove in the

upper bearing (on the block side), but not in the lower
bearing (on the bearing cap side).
Fit the bearing tang firmly into the slot machined on the
cylinder body bearing arches.
No oil groove and hole
(Lower)
Fig. 122
Crankshaft and bearing

Lubricate the bearings with engine oil, install the crankshaft, install the thrust bearings with the groove facing
the crankshaft.
Thrust Bearing
Crankshaft
Bearing
Fig. 123
Arrow mark
10
2 3
Crankshaft Bearing Cap
1.
Lubricate the bearing cap bolts with engine oil.
2.
Install the bearing caps to the crankshaft.

The arrow mark must be pointing to the front of the
engine.
8
Front
3.
Tighten the bearing cap bolts to the specified torque

a little at a time in the numerical order shown in the
illustration.
Nm (kgfm/ft. lb)
Fig. 124
Crankshaft Bearing Cap

Bolt Torque
4.
83 - 93 (8.5 - 9.5 / 61 69)
Check that the crankshaft turns smoothly by manually rotating it.
ENGINE 65
Position the rings as shown making sure the ring gaps
are away from the thrust side.
1st
2nd
Oil
Fig. 125
Piston and Connecting Rod

Special tool
Lubricate the piston, the piston rings, and the connecting rod bearings with engine oil.
Front mark
Position the piston front mark towards the front of the

engine.
Use the piston ring compressor to compress the piston
rings.
Use a hammer grip to push the piston in until it makes
contact with the crank pin.
At the same time, rotate the crankshaft until the crankpin
reaches its highest point.
Fig. 126
Set the bearing cap cylinder number marks and the connecting rod cylinder number marks.
The marks must be facing the injection pump side.
Nm (kgfm/ft. lb)
Cylinder
No.
Tightening torque
74 - 83 (7.5 8.5 / 54 - 61)
Note:
After installation, confirm that the crankshaft rotates
smoothly.
Fig. 127
6
Installation of retainer
After applying engine oil to the lip of the oil seal, install
the retainer. Apply sealant TB1207B to the retainer.
Tighten bolts on the retainer to the specified torque in

the order as shown in the figure left.
Nm (kgfm/ft. lb)
Tightening torque
5
Fig. 128
8 - 12 (0.8 - 1.2 / 6 - 9)
66 ENGINE
Camshaft assembly
1.
Apply engine oil to the inside of the bearing of

the cylinder block, and then install the camshaft
assembly.
Note:
When installing the assembly, care should be taken not
to damage the bearing.
2.
Fig. 129
After installation of the snap ring to the outside of

the front bearing, check to see if the camshaft
rotates smoothly.
Cam gear and sleeve

Cam gear
1.
Install the cam gear to the camshaft so that the timing point (a dot mark ) comes to the front side.
2.
With the flyweight installed, tighten the cam gear

with a lock nut.
Nm (kgfm/ft. lb)
Timing point
Sleeve
Tightening torque
Lock nut
Fly weight
69 - 88 (7.0 - 9.0 / 51 - 65)
3.
Apply engine oil to the shaft of the sleeve and the

slide of the flyweight.
4.
With the lip of the sleeve placed in the cavity of the

flyweight, insert the shaft of the sleeve into the tip
end of the camshaft.
Fig. 130
Note:
Check to see if the sleeve moves smoothly.
Idle Gear
Idle gear
Install the idler gear shaft with the oil hole facing upward.
Timing point
Lubricate the shaft with oil.
Thrust collar
Install the idler gear.

Idle gear shaft
Timing point
Align the timing marks as shown in the illustration.

Install the thrust collar and tighten the bolts to the
specified torque.
Nm (kgfm/ft. lb)
Fig. 131
Tightening torque
Cam gear
Timing point
Idle gear
Crank gear
Fig. 132
21 - 30 (2.1 3.1 / 15 22)
ENGINE 67
Oil pump assembly
1.
Cylinder block
When PTO is not provided, install the oil pump

assembly to the cylinder block.
PTO not provided

Tightening torque
Nm (kgfm/ft. lb)
19 - 28 (1.9 2.9 / 14 21)
Fig. 133
2.
When PTO is provided, install the oil pump to the

front plate.
PTO provided
Front plate
Tightening torque
Nm (kgfm/ft. lb)
8 - 12 (0.8 1.2 / 6 9)
Fig. 134
Front plate (only for those provided with PTO)

Front plate
Apply sealant to the front plate incorporated with the oil

pump before installing it to the cylinder block.
Nm (kgfm/ft. lb)
Tightening torque
19 - 28 (1.9 2.9 / 14 21)
(with PTO)
Fig. 135
Front oil seal

Timing gear case
Front oil seal
Install the front oil seal to the timing gear case.

Installation is made according to the L dimension
shown in the figure.
mm (in)
L dimension
Fig. 136
PTO not provided
60.2 60.8 (2.370 2.384)
PTO provided
40.2 40.8 (1.582 1.606)
68 ENGINE
Timing gear case (with governor)
Governor cover
Timing gear case
When not provided with PTO, install the timing gear

case to the cylinder block. When provided with PTO,
install it to the front plate.
1.
Put the link plate of the governor incorporated in

the gear case through the connecting hole of the
injection pump in advance.
2.
Apply engine oil to the bushes provided on both

ends of the main spring lever of the governor.
3.
Apply sealant to the gear case, and then install it to

the cylinder block or the front plate.
Front oil seal
Nm (kgfm/ft. lb)
Case tightening torque
4.
Fig. 137
19 - 28 (1.9 2.9 / 14 21)
Assemble the gasket and the governor cover to the

top of the gear case, and then tighten them to the
specified torque.
Nm (kgfm/ft. lb)
Cover tightening torque
8 - 12 (0.8 1.2 / 6 9)
Flywheel housing
Install the flywheel housing to the cylinder body.
Nm (kgfm/ft. lb)
Tightening torque
41 - 55 (4.2 5.6 / 30 40)
Fig. 138
Flywheel
Lubricate bolts with engine oil.
Tighten a little at a time in the sequence shown in the
illustration.
Nm (kgfm/ft. lb)
Tightening torque
Apply
engine oil
Fig. 139
88 - 108 (9 11 / 65 80)
ENGINE 69
Crank pulley
Lubricate the lip of the front, seal with oil
Crankshaft
Install the crank pulley, lock the crankshaft and tighten

the front bolt.
Nm (kgfm/ft. lb)
Crank pulley
Tightening torque
167 - 186 (17 19 /123 137)
Washer
Front oil seal

Fig. 140
Oil pipe and oil strainer

To 2nd bearing cap
Oil strainer
1.
Install the oil pipe from the oil pump assembly to

the cylinder block and tighten the sleeve nuts.
2.
Install the oil strainer to the oil pump, and then

tighten the bracket of the strainer to the No. 2 bearing cap.
Nm (kgfm/ft. lb)
Tightening torque
Oil pipe
19 - 28 (1.9 2.9 / 14 21)
Fig. 141
Oil pan
1.
Apply sealant to the oil pan.
2.
Install the oil pan to the cylinder block and tighten

fixing bolts evenly.
Nm (kgfm/ft. lb)
Tightening torque
8 - 12 (0.8 1.2 / 6 9)
Fig. 142
Tappet and head gasket

1.
Install the tappet to the cylinder block.
2.
When installing the head gasket, face up the UP

mark.
Install the head gasket over the cylinder head locating dowels.
Fig. 143
70 ENGINE
Cylinder head assembly
11
12
14
13
8
4
15
Lubricate the bolts with oil.

9
Tighten the bolts in the sequence shown in the illustration to the specified torque.
Nm (kgfm/ft. lb)
10
Bolt size
M12 1.5
(8 each)
Tightening torque
83 93
(8.5 - 9.5 / 61 69)
M8 1.25
(4 each)
Fig. 144
6090
24 34
(2.5 - 3.5 / 8 25)
Push rod
Install the push rods.
Rocker arm bracket assembly
Rocker arm
Apply liquid gasket to the the bottom of the rocker arm

bracket assembly, being careful not to get any in the
groove around the oil galley as shown in the illustration.
Rocker spring
Install the rocker arm bracket assembly making sure the

push rods align with the rocker arms and tighten to the
specified torque.
Nm (kgfm/ft. lb)
Tightening torque
Rocker arm
bracket
Fig. 145
(Rocker bracket bottom surface)
Apply stem of sealant
the application
Avoid
of sealant to this groove.
Oil gallery
Fig. 146
8 - 12 (0.8 1.2 / 6 9)
ENGINE 71
Adjustment of valve clearance
Refer to Section General

Information Maintenance
(on page 20).
Front hanger and rear hanger

Rear hanger
Tighten them to the specified torque shown below.

Nm (kgfm/ft. lb)
Tightening torque
Front hanger
Fig. 147
19 - 28 (1.9 2.9 / 14 21)
72 ENGINE
4. EXTERNAL PARTS (Right-hand Side)
(6)
(5)
(7)
(8)
(3)
(2)
(4)
(1)
Fig. 148
(1) Dipstick
(2) Oil Filter
(3) Injection Pump
(4) Injection Pump Housing Cover
(5) Fuel Pipe
(6) Leak Off Pipe
(7) Fuel Hose
(8) Injection Pipe
ENGINE 73
5. EXTERNAL PARTS (Left-hand Side)
(18)
(10)
(11)
(19)
(12)
(17)
(15)
(9)
(13)
(16)
(14)
Fig. 149
(9) Water Pump

(10) Thermostat and Water Outlet Pipe
(11) Cylinder Head Cover
(12) Exhaust Manifold
(13) Starter
(14) Generator
(15) Fan Pulley
(16) Fan Belt
(17) Cooling Fan
(18) Exhaust Pipe
(19) Exhaust Silencer
74 ENGINE
Dipstick
Dipstick
Cartridge
Oil filter (cartridge)

1.
Insert the dipstick.
2.
Install the cartridge with a filter wrench (commercially available).
(1) Apply engine oil thinly to the gasket of the cartridge.

(2) Screw in the cartridge until the gasket comes into
contact with the seal, and then tighten it by giving it
about 3/4 turns.
Fig. 150
Injection pump
center position
Control link
(Reference: Tightening torque
12 to 16 Nm
(1.2 1.6 kgfm))
Injection pump
Fuel cut lever
Pin
(6)
Align the two (2) holes in the fuel cut lever and the governor and lock into place with a pin.
This will center and hold the control link for the installation of the injection pumps.
Fig. 151
Injection pump ASM
Install a new shim with the same thickness as the one

that was removed. (Refer to the maintenance section on
shim selection).
Shim
Cylinder block
Fig. 152
Injection pump
center position
Install the injection pump making sure the rack pin is in

the groove of the control rack before tightening the
injection pump to the specified torque.
Nm (kgfm/ft. lb)
Control link
Rack pin
Tightening torque
19 - 28 (1.9 2.9 / 14 21)
Remove the rack pin (6) which is inserted into the fuel
cut lever, and then confirm that the fuel cut lever moves
smoothly.
Fig. 153
ENGINE 75
Injection pump housing cover
Housing cover
After applying sealant (TB1207B) to the housing cover,

install it to the cylinder block by the side of the injection
pump.
Nm (kgfm/ft. lb)
Tightening torque
8 - 12 (0.8 1.2 / 6 9)
Note:
The areas of the housing cover to which liquid gasket is
applied are about 4 mm in width from the cover edge
and about 2 mm around the bolts.
Fig. 154
Housing cover
Apply potion of sealant
About 4mm in width

from the cover edge
About 2mm
around the bolt hole
Fig. 155
Solenoid assembly
1.
Solenoid ASM
Apply sealant (TB1207C) to the surface (bite groove)

in which the solenoid is installed.
Note:
Avoid the application of sealant to the screw thread.
2.
Fig. 156
Tightening torque
Solenoid ASM
Installed surface
Apply surface
of sealant
Screw thread
Avoid the application
of sealant
Fig. 157
Screw in the solenoid from the rear of the cylinder

block (the rear of the No. 3 injection pump rack), and
then tighten it to the specified torque.
Nm (kgfm/ft. lb)
15 - 25 (1.5 2.5 / 11 18)
76 ENGINE
Fuel pipe
Leak off pipe
Fuel pipe
Leak off pipe
Fuel hose
Nozzle holder
1.
Install the fuel pipe to the injection pump and then

2.
Install the leak off pipe to the nozzle holder and then
Nm (kgfm/ft. lb)
Injection pump
Tightening torque
Fig. 158
Fuel pipe
20 - 25 (2.0 2.5 / 14 18)
Leak off pipe
10 - 14 (1.0 1.4 / 7 10)
Note:
When tightening it, hold the pipe securely by hand so
that it will not rotate.
3.
Connect the fuel pipe and the leak off pipe with the
fuel hose and fix them with clips.
Injection pipe
Injection pipe
Nozzle holder
Install the injection pipe to the injection pump and the

nozzle holder and tighten them up with sleeve nuts.
Nm (kgfm/ft. lb)
Tightening torque
Injection pump
15 - 25 (1.5 2.5 / 11 18)
Note:
Set the thread of the sleeve nut securely before tightening it up.
Fig. 159
Water pump assembly

1.
Put sealant on the water pump where it contacts the

block and head.
2.
Tighten to the specified torque.
(L=60)
Nm (kgfm/ft. lb)
Tightening torque
(L=40)
19 - 28 (1.9 2.9 / 14 21)
Tighten together with

adjusting plate
Fig. 160
Thermostat
Water outlet pipe
Thermostat
Gasket
Water outlet pipe

Assemble the thermostat, install the gasket and the
water outlet pipe, and then tighten it to the specified
torque.
Nm (kgfm/ft. lb)
Water pump
Fig. 161
Tightening torque
19 - 28 (1.9 2.9 / 14 21)
ENGINE 77
Adjustment of valve clearance
(Refer to Section GENERAL INFORMATION MAINTENANCE.)
Cylinder head cover
Cylinder cover
1.
Gasket
Install the gasket to the cylinder head cover.
Notes:
1.
Much care should be taken for the gasket not to get

dislocated or twisted when installing the head
cover.
2.
Avoid the application of sealant to the rubber gasket.
2.
Install the cylinder head cover to the rocker arm

bracket, and tighten it to the specified torque.
Rocker arm
bracket
Fig. 162
Nm (kgfm/ft. lb)
Tightening torque
2 - 4 (0.2 0.4 / 1.4 2.9)
Air inlet pipe

Cylinder head
cover
Air inlet pipe
1.
Apply sealant (TB1207C) to the surface in which the

air inlet pipe is installed.
2.
Install the air inlet pipe to the cylinder head cover,

and tighten it to the specified torque.
Nm (kgfm/ft. lb)
Tightening torque
8 - 12 (0.8 1.2 / 6 9)
Fig. 163
Exhaust manifold
Gasket
Exhaust
manifold
Assemble the gasket to the cylinder head, install the

exhaust manifold along the stud bolts and tighten it to
Nm (kgfm/ft. lb)
Tightening torque
19 - 28 (1.9 2.9 / 14 21)
Cylinder head
Fig. 164
Starter
Install the starter to the flywheel housing, and tighten it
to the specified torque.
Nm (kgfm/ft. lb)
Tightening torque
Starter
Fig. 165
93 - 113 (9.5 11.5 / 69 83)
78 ENGINE
Generator
Water pump
1.
Tighten the adjust plate together with the water

pump, and then install them temporarily.
2.
Install the bottom of the alternator to the timing gear

case, and then tighten it temporarily with bolts and
nuts.
3.
Install the fixing bolts onto the top of the alternator

through the adjusting plate. (Temporary tightening)
Adjusting plate
Alternator
Fig. 166
Fan pulley and fan belt

Fan pulley
1.
Install the fan pulley to the water pump and then

tighten it up. (2 locations)
2.
Set the fan belt to each pulley.
Water pump
Fan belt
Fig. 167
Fan belt tension

Adjust the alternator as specified and tighten to the
specified torque.
mm (in)
Deflection amount (Press the belt
at its center between the pulleys
with 98 N (10kg / 22 lbs.) force.)
7.5 to 8.5
(0.29 0.33)
mm (in)
Fig. 168
Generator upper
1.9 2.9 (14.0 21.0)
Generator lower
3.5 4.7 (25.0 34.0)
Adjust plate
1.9 2.9 (14.0 21.0)
Cooling fan
Cooling fan
Spacer
Fig. 169
1.
Assemble the spacer before tightening the cooling

fan.
2.
Tighten it to the specified torque. (4 locations)
LUBRICATING SYSTEM 79
SECTION 3
LUBRICATING SYSTEM
TABLE OF CONTENTS
CONTENTS
PAGE
LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
80 LUBRICATING SYSTEM
LUBRICATING OIL CIRCULATION DIAGRAM

Valve opening pressure 98 kPa (1kgf/cm2)
Oil filter
Valve
opening
pressure
440 kPa
(4.5kgf/cm2)
Oil gallery
Main bearing
Idle gear bush
Cylinder head
Crankshaft
Timing gear
Rocker arm
bracket
Connecting rod
Governor
Rocker shaft
Rocker arm
Oil pump
Injection pump
Strainer
Piston
Tappet
Valve stem end
Piston
pin boss
Oil pan
Pressure feeding
Non pressure feeding
Fig. 170
LUBRICATING SYSTEM 81
OIL PUMP
With PTO
Body; Oil pump

Pin (common)
Without PTO
Front plate
(Body; integral structure)
Rotor; outer
Roter; inner
O-ring (common)
Relief valve
Pump gear
Spring
Plug
Oil pump
(common)
Common
Fig. 171
Inspection and replacement

When there is wear, damages or any other defects
found, repair or replace the rotor.
Clearance between the outer rotor or inner rotor and
the pump cover
mm (in)
Standard
Limit
0.040 0.085 (0.0016 0.0033)
0.15 (0.0059)
Clearance between the periphery of the outer rotor and

the pump body
mm (in)
Standard
Limit
0.10 0.185 (0.0039 0.0073)
0.4 (0.0157)
Clearance between the inner rotor and the outer rotor

mm (in)
Standard
Limit
0.17 (0.0067)
0.2 (0.0079)
MEMO
COOLING SYSTEM 83
SECTION 4
COOLING SYSTEM
TABLE OF CONTENTS
CONTENTS
PAGE
COOLING WATER CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
84 COOLING SYSTEM
COOLING WATER CIRCULATION SYSTEM DIAGRAM

Bottom bypass type
thermostat
Cyliner head
Cylinder block
Radiator
Water pump
Fig. 172
bypass circuit)
COOLING SYSTEM 85
WATER PUMP
DISASSEMBLY
Seal unit
Impeller
Bearing unit
Fan center
Cover
Body
Setscrew
Fig. 173
Fan center
Cover
Setscrew
Fan center
Cover
1.
Loosen the set screw.
2.
Remove the cover.
Note:
The cover is applied with sealant (TB1207B). When removing the cover, much care should be taken not to
deform it by applying an excessive force to it.
Fig. 174
Impeller
Seal unit
Bearing unit
Bearing unit
Impeller
Seal unit
Fig. 175
86 COOLING SYSTEM
REASSEMBLY
Bearing unit
Align holes
Body
Bearing unit
With a hole in the bearing unit set in line with one in the
body, lock the bearing unit with a setscrew.
Nm (kgfm/ft. lb)
Set screw tightening torque
Fan center
8 - 12 (0.8 1.2 / 6 9)
Setscrew
Fig. 176
Impeller
Seal unit
Impeller
1.
Apply BELCO bond No. 4 to the surface where the

seal unit comes into contact with the body, and then
assemble the seal unit.
2.
Press in the impeller with a press until the clearance

between the pump impeller and the body gets to the
specified value.
Seal unit
Fig. 177
Cover
Cover
1.
Apply sealant to the surface to which the cover is

installed, and then install the cover.
2.
Apply Screw-lock to the cover installation screws,

and then tighten them.
Fig. 178
Clearance, play and tightening allowance between parts

1.
Clearance between the pump impeller and the body

mm (in)
Standard
2.
0.53 2.17 (0.0209 0.0854)
Play in the water pump ball bearing

mm (in)
Standard
Limit
0.008 0.010 (0.0003 0.0004)
0.2 (0.0079)
3.
Tightening allowance between the fan center and

the bearing shaft
mm (in)
Standard
0.026 0.061 (0.001 0.0024)
COOLING SYSTEM 87
THERMOSTAT
Replace the thermostat when there is wear, damages or
any other defects found.
Opening temp.
80.5 83.5C (177 182F)
Valve lift mm (in.)
8mm or more at 95C

(0.31 inch or more at 203F)
Thermometer
Agitating rod
Thermostat
Wooden piece
Fig. 179
MEMO
FUEL SYSTEM 89
SECTION 5
FUEL SYSTEM
TABLE OF CONTENTS
CONTENTS
PAGE
FUEL CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
NOZZLE HOLDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
90 FUEL SYSTEM
FUEL CIRCULATION SYSTEM DIAGRAM
Fuel tank
Nozzle holder
Injection pump
Nozzle
Fuel filter
Fig. 180
FUEL SYSTEM 91
GOVERNOR
1.
The adjustments of the governor-related parts require the engine performance test.
2.
Before disassembling the governor, measure the dimensions A and B given in the structural
drawing to ensure the same dimensions in reassembly.
3.
Do not disassemble the governor when the performance test cannot be conducted after reassembly.
1. STRUCTURAL DRAWING OF GOVERNOR (1)
Idle speed screw

Idle (sub) spring
Start spring
Fuel cut cover
A
Link plate
Governor shaft
Set spring
Control link
Governor cover
Injection pump
Guide lever
Main spring lever

Main spring
Timing gear case
Floating lever
B
Camshaft
Tensioner lever
Angleich
Full load stopper
Sleeve
Flyweight
Shifter
Fig. 181
92 FUEL SYSTEM
2. STRUCTURAL DRAWING OF GOVERNOR (2)

Start spring
Set spring
Control link
Snap pin
Guide lever
Floating lever
A
Guide piece
Cap nut
Link plate
Shifter
Setscrew
Shaft (floating)
Fuel cut lever
Return spring
Main
spring
Fuel cut shaft
Shifter shaft
Tensioner
lever
O-ring
Idle spring
Lever;
main spring
Bracket; start spring
Speed control screw

Angleich
Return spring
O-ring
A
Shaft
Lever bush
Sleeve
Lever bush
Full load
setscrew
Control lever
Timing gear case
Fig. 182
Cam gear
Flyweight
FUEL SYSTEM 93
3. REASSEMBLY OF CONTROL LEVER RELATED PARTS

(1) Put the lever (main spring) through the hole of the timing gear case lever.
Note:
Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case
lever respectively.
(2) Put the return spring of the control lever through the shaft of the lever (main spring).
(3) Assemble the bushes.
Assemble the bush of the lever (main spring) first, and then the control lever bush.
Note:
When assembling the bushes, apply Loctite (#601) to the periphery of the bushes.
Bush
Apply Loctite No.601
to the peniphery
Lever; Main spring
Protrusion
Pin
Return spring
Timing gear case
Bush
Apply Loctite No.601
to the peniphery
Fig. 183
(4) Hook both ends of the return spring (control lever) securely to the protrusion and the pin of the lever
(main spring) respectively.
94 FUEL SYSTEM
(6) Assemble the control lever.
Assemble the O-ring to the groove of the bushes (control lever) first, and then assemble the washers
and the control lever before tightening up the control lever with a nut.
Nm (kgfm/ft. lb)
Control lever tightening torque
12 - 18 (1.2 1.8 / 9 13)
Control lever
O-ring
Bush
Spring washer
Washer
Groove
Fig. 184
Notes:
1.
Tighten the control lever after locking the control lever firmly.
(Do not tighten the control lever after locking the main spring lever.)
2.
After assembly, confirm that the control lever moves smoothly.
Nut
FUEL SYSTEM 95
4. Reassembly of shifter
(1) Assemble the shifter to the guide lever, put the shaft through it, and then assemble the snap ring.
(2) After assembly, confirm that the shaft moves smoothly.
(3) Also, confirm that the shifter shakes smoothly.
Guide lever
Shifter
Snap ring
Shaft
Fig. 185
96 FUEL SYSTEM
5. Reassembly of governor cover

Assemble the related parts such as the fuel cut lever and the idle spring to the governor cover.
[Stop]
Governor cover
22
Return spring
(Bent-up part)
Thrust
washer
O-ring
Shaft
[Operate]
22
Governor
Nut
Idle spring
Spring washer
(Notched groove)
Fuel cut lever
Fig. 186
Cap
Cap nut
Packing
Lock nut
()
Gasket
Idle screw
Governor
lever
Tensioner lever
Washer
Idle spring
Washer
Snap ring
(Z view of the drawing above)

Fig. 187
(1) When assembling the shaft, apply engine oil to the

sliding portion with the governor cover.
(2) Set both ends of the return spring securely to the
notched groove at the bottom of the cover and the
bent-up arm of the lever respectively.
(3) After reassembling the governor cover, confirm that
the governor moves smoothly.
(4) When assembling the timing gear case to the governor cover, tighten the A dimension shown in the
illustration to 2 3 mm temporarily.
The parts given in the square indicated by (*) are assembled after performance test.
mm (in)
A dimension
(When assembling temporarily)

2 3 (0.0787 0.0118)
FUEL SYSTEM 97
6. Reassembly of full-load stopper

Install the full-load stopper to the timing gear case, and then tighten it with a nut temporarily.
Timing gear case
Full load stopper
Nut; setscrew
Fig. 188
98 FUEL SYSTEM
7. Reassembly of governor lever related components

Assemble each lever and spring to the timing gear case.
Main spring lever

Lever shaft
Tensioner lever
Link plate
Main spring
Eye; start spring
Set spring
Guide piece
Start spring
Guide lever
Snap pin
Plug
Floating lever
Shaft;
floatong lever
Fig. 189
8. Notes when assembling governor related components

(1) When assembling components, apply engine oil to each slide (such as the end face of the lever, the
hole in the shaft, and the periphery of the shaft).
(2) Install the set spring securely to the groove of the pin connecting the floating lever, with much care to
its assembling direction.
(3) Confirm that each lever moves by its dead weight before installing the start spring.
(4) After assembly, confirm that each lever moves smoothly.
And also confirm that each spring operates properly.
FUEL SYSTEM 99
NOZZLE HOLDER ASSEMBLY

DISASSEMBLY
Push rod
Bolt
Spacer
Gasket
Gasket
Nozzle
Nozzle holder
Retainer nut
Adjusting shim
Spring
Fig. 190
NOZZLE ASSEMBLY
Place the removed nozzle in the clean light oil, disassemble it into the nozzle body and the needle valve and
clean them thoroughly. Then check to see if the valve
moves smoothly in the body.
When it does not move smoothly, repair or replace the
nozzle.
Light oil
Fig. 191
Adjustment
For the adjustment of the injection pressure and the
spray condition of fuel, refer to Section 1 INSPECTION
AND SERVICE.
MEMO
TROUBLESHOOTING 101
SECTION 6
TROUBLESHOOTING
Engine does not start
Starter does not run
Engine starts but

does not run
continuously.
Starter runs but does

not start
Check battery
Engine
Battery in
discharging
(Charge)
Fuel system
Fuel injected
No fuel
injected
Fuel injected
Air mixed in
fuel pump
OK
Check
compression
ratio
( )
Check wiring
Loosened
connector or
broken wire
(Retighten or
replace with
new wiring)
OK
Low
compression
ratio
OK
Check for air

mixing
Defective
valve, spring,
gasket, etc.
(Overhaul)
Air mixed
(Retighten it,
replace
packing, bleed
air)
Check starter switch
Defective
(Replace)
Check
preheating
circuit
Check if fuel
comes
to fuel pump
OK
OK
Check magnetic
switch
Defective
(Replace)
OK
Clogged
(Clean)
OK
Normal
operation
of glow
plug
control
resistance
OK
Abnormal
(Adjust)
OK
Disordered
idling
Adjust
idling
Check
injection
timing
Check fuel
filter
( )
Poor
operation
of glow
plug
control
resistance
(Replace)
OK
Retighten,
replace
packing,
bleed air
OK
OK
Check nozzle
Check engine stop
solenoid return
Defective
(Repair or
replace)
Check starter bush
OK
Check solenoid
Poor contact
(Repair or
replace)
OK
Defective starter
(Bring it to a specialty
shop for repair)
Stuck solenoid or
poor operation
(Repair or replace)
OK
Defective injection
pump (Bring
it to a specialty
shop for repair)
Note: Bring it to a specialty shop means that defective parts of the injection pump
and electricals must be brought to a specialty shop for repair. (This note is
applicable to all the following procedures.)
102 TROUBLESHOOTING
Unstable engine rotation
Unstable engine
idling
Idling speed
too high
Unstable rotation at
medium speed
(Hunting)
Unstable rotation at
high speed
Engine does not

change from high to
low rotation
Defective idling
adjustment
Defective control
lever adjustment
Governor spring
deteriorated
Check fuel for air

mixing
Check accelerator
pedal
Defective
valve return
(Adjust)
OK
Check high pressure

pipe for cracking,
clogging or bending
Cracked,
clogged or
bent
(Replace)
OK
OK
Check cylinder for

uneven compression
pressure
Uneven
compression
pressure
(Adjust)
OK
Defective injection
pump (Bring it to a
specialty shop for
repair)
Air mixed
(Bleed
air)mixing
Check fuel pipe for

crash
Crash
(Replace)
OK
OK
OK
Defective injection
pump (Bring it to a
specialty shop for
repair)
Pedal
sticking or
hitching
(Clean or
replace)
OK
Check fuel filter for

clogging
Clogged
(Clean or
replace)
OK
Check uneven fuel

injection
Check nozzle
Defective
(Repair or
replace)
Defective
(Repair or
replace)
Uneven
(Adjust)
OK
Check valve clearance

adjustment
Poor
adjustment
(Adjust)
OK
Defective injection
pump (Bring it to a
specialty shop for
repair)
Defective injection
pump (Bring it to a
specialty shop for
repair)
TROUBLESHOOTING 103
Insufficient output
Fuel system
Check fuel for air

mixing
Air mixed
(Bleed air)
Overheat
Mechanical
system
Check engine
control
Cooling system
Check cooling
water level
Insufficient
OK
Poor
adjustment
OK
OK
Handling
Check fan belt

for slip
Slipping
(Adjust)
OK
(Adjust)
Check fuel filter
or fuel hose for
clogging
Clogged
(Clean or
Replace)
Check inlet air

temperature
Temperatu
re too high
(Improve
ventilation)
OK
OK
Check injection
timing
Abnormal
(Adjust)
Check thermostat
Malfunction
(Replace)
OK
Leak to Leak to
external internal
Repair
Insufficient inlet
air
Air cleaner
stained
(Clean or
replace)
OK
Check nozzle
Defective
(Repair or
replace)
Check
for
leakage
OK
Check valve
clearance and
cam lift
Abnormal
(Adjust or
replace)
OK
Check compression
pressure
Low
Defective
injection pump
(Bring it to a
specialized shop
for repair)
Low
Excessive
blow-by
gas
(Overhaul)
Gas leak from

valve and gasket
(Repair or replace)
Repair or
replace
Care must
be taken
when
replenishing
(Replace)
OK
OK
Engine
rotation
too high
OK
Check high
pressure pipe for
clogging or
bending
Clogged
or bent
(Replace)
Replenish
Check if oil used

is inferior quality,
or engine oil is
too much
Overloaded
Check cooling
system for stain,
and radiator for
clogging
Temperature
abnormally high
Stained or
clogged
(Clean)
OK
Improve
ventilation
104 TROUBLESHOOTING
Abnormal exhaust gas
Check if fuel used is of

inferior quality
OK
Change fuel
Check if engine oil is too

much
White smoke too much
Black smoke too much
Check fuel for water

mixing
Check nozzle
Water mixed
(Change fuel)
OK
Defective
(Repair or replace)
Air cleaner clogged
OK
Replace air
cleaner element
OK
Check air hose for crash
Check injection timing

Advanced too much
Delayed
(Adjust)
OK
(Adjust)
OK
Check injection pump

Check compression ratio
Low
Excessive
blow-by gas
(Overhaul)
Gas leak from

valve and
gasket (Repair
or replace)
OK
OK
Defective injection pump

shop for repair)
Check up and
down
movement of oil
1. Disordered valve timing

2. Broken piston ring or
misassembly
3. Worn camshaft
4. Worn valve or insert
(Overhaul)
Stuck (Overhaul)
Over-discharge of battery
Battery
Wiring
Regulator and generator
Check electrolyte level
Check terminals for warp,

deformation or corrosion
Check belt for slip or damage
Low
OK
Poor contact
(Repair or replace)
Battery
Natural
case
consumpt
cracked
ion
(Replace) (Replenish)
Over
charge
Note: Improper maintenance
Check for broken wire

(Repair or replace)
OK
Slipping or
damaged (Repair
or replace)
Test charging condition
Abnormal
Bring it to a battery shop

Check specific gravity
Low
Recharge
Recharging
impossible
Bring it to a battery specialty shop
OK
OK
TROUBLESHOOTING 105
Oil pressure too low
Oil consumption too much
Oil consumption too much
Check oil level
Check for oil leakage
Check for oil leakage
Low (Replenish)
OK
OK
Leaking (Retighten,
replace packing seal)
Leaking (Retighten,
replace packing seal)
OK
Check cooling water temperature

Check nozzle
Check oil quality
OK
High
(See Overheat)
OK
Defective
(Repair or replace)
Poor quality
(Change to specified oil)
OK
Check oil in crankcase

Improper
viscosity
Abnormal (Adjust)
Water or fuel mixed. Check fuel

system and cooling system
Low
OK
Defective
(Repair or replace)
Oil pump malfunction

Loosened or cracked pipe
Wear of sliding part
Oil pump clogged
(Overhaul)
OK
Gas leak from

valve and gasket
(Repair or
replace)
1.
2.
3.
4.
5.
Oil pump malfunction

Loosened or cracked pipe
Wear of sliding part
Oil pump clogged
Defective valve stem seal
(Overhaul)
(*) Worn bore,and worn or broken

ring (Measure compression
pressure, and check entrance of
dust)
Engine knocking
Mechanical system
Fuel system
Check up movement of oil
Oil stained (Overhaul)
OK
Check compression pressure
Low
OK
Abnormal (Adjust)
OK
Check nozzle
Defective
(Repair or replace)
OK
To fuel system
Note: Fuel used is of poor quality.
Excessive
blow-by gas
(Overhaul)
Gas leak from

valve and gasket
(Repair or
replace)
OK
Check up and down movement of oil
Defective injection pump

shop for repair)
Excessive
blow-by gas
Clogged (Clean)
OK
Check compression ratio
Check relief valve
1.
2.
3.
4.
Check bleeder for clogging
OK
MEMO
SPECIAL TOOLS 107
SECTION 7
SPECIAL TOOLS
The alphanumeric codes in parentheses (
No.
Illustration
) are part numbers assigned by special tool manufacturers.
Part Number
Part Name
Page
1.
5-8840-2675-0
Compression gauge
23
2.
5-8840-9029-0
Compression gauge adapter
23
3.
5-8840-9016-0
(J-28829)
Nozzle tester
24
4.
5-8840-9015-0
(JKM-9004)
Oil filter wrench
5.
5-8840-9030-0
Valve spring compressor
57
6.
1-85221-029-0
Piston ring pliers
41
7.
5-8840-9018-0
(J-8037)
Piston ring compressor
8.
5-8840-9031-0
Front oil seal installer
9.
5-8840-9032-0
Rear oil seal installer
10.
5-8840-9034-0
Camshaft bearing installer
11.
5-8840-9035-0
Valve guide installer
12.
5-8840-9033-0
Valve stem seal installer
MEMO
CONVERSION TABLE 109
SECTION 8
CONVERSION TABLE
TABLE OF CONTENTS
ITEM
PAGE
LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
LENGTH
MILLIMETERS TO INCHES
INCHES TO MILLIMETERS
mm
in.
mm
in.
mm
in.
mm
in.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0.0394
0.0787
0.1181
0.1575
0.1969
0.2362
0.2756
0.3150
0.3543
0.3937
0.4331
0.4724
0.5118
0.5512
0.5906
0.6299
0.6693
0.7087
0.7480
0.7874
0.8268
0.8661
0.9055
0.9449
0.9843
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
1.0236
1.0630
1.1024
1.1417
1.1811
1.2205
1.2598
1.2992
1.3386
1.3780
1.4173
1.4567
1.4961
1.5354
1.5748
1.6142
1.6535
1.6929
1.7323
1.7717
1.8110
1.8504
1.8898
1.9291
1.9685
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
2.0079
2.0472
2.0866
2.1260
2.1654
2.2047
2.2441
2.2835
2.3228
2.3622
2.4016
2.4409
2.4803
2.5197
2.5591
2.5984
2.6378
2.6772
2.7165
2.7559
2.7953
2.8346
2.8740
2.9134
2.9528
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
2.9921
3.0315
3.0709
3.1102
3.1496
3.1890
3.2283
3.2677
3.3071
3.3465
3.3858
3.4252
3.4646
3.5039
3.5433
3.5827
3.6220
3.6614
3.7008
3.7402
3.7795
3.8189
3.8583
3.8976
3.9370
in.
mm
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
101
102
103
104
105
106
107
108
109
3.9764
4.0157
4.0551
4.0945
4.1339
4.1732
4.2126
4.2520
4.2913
111
112
113
114
115
116
117
118
119
4.3701
4.4094
4.4488
4.4882
4.5276
4.5669
4.6063
4.6457
4.6850
121
122
123
124
125
126
127
128
129
4.7638
4.8031
4.8425
4.8819
4.9213
4.9606
5.0000
5.0394
5.0787
131
132
133
134
135
136
137
138
139
5.1575
5.1969
5.2362
5.2756
5.3150
5.3543
5.3937
5.4331
5.4724
27/64
7/16
29/64
15/32
31/64
1/2
0.3969
0.7938
1.1906
1.5875
1.9844
2.3813
2.7781
3.1750
3.5719
3.9688
4.3656
4.7625
5.1594
5.5563
5.9531
6.3500
6.7469
7.1438
7.5406
7.9375
8.3344
8.7313
9.1281
9.5250
9.9219
10.3188
10.7156
11.1125
11.5094
11.9063
12.3031
12.7000
in.
mm
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
13.0969
13.4938
13.8906
14.2875
14.6844
15.0813
15.4781
15.8750
16.2719
16.6688
17.0656
17.4625
17.8594
18.2563
18.6531
19.0500
19.4469
19.8438
20.2406
20.6375
21.0344
21.4313
21.8281
22.2250
22.6219
23.0188
23.4156
23.8125
24.2094
24.6063
25.0031
25.4000
110 CONVERSION TABLE

LENGTH
FEET TO METERS
ft.
10
20
30
40
50
60
70
80
90
100
0
3.048
6.096
9.144
12.192
15.240
18.288
21.336
24.384
27.432
30.480
0.305
3.353
6.401
9.449
12.497
15.545
18.593
21.641
24.689
27.737
30.785
0.610
3.658
6.706
9.754
12.802
15.850
18.898
21.946
24.994
28.042
31.090
0.914
3.962
7.010
10.058
13.106
16.154
19.202
22.250
25.298
28.346
31.394
1.219
4.267
7.315
10.363
13.411
16.459
19.507
22.555
25.603
28.651
31.699
1.524
4.572
7.620
10.668
13.716
16.764
19.812
22.860
25.908
28.956
32.004
1.829
4.877
7.925
10.973
14.021
17.069
20.117
23.165
26.213
29.261
32.309
2.134
5.182
8.230
11.278
14.326
17.374
20.422
23.470
26.518
29.566
32.614
2.438
5.486
8.534
11.582
14.630
17.678
20.726
23.774
26.822
29.870
32.918
2.743
5.791
8.839
11.887
14.935
17.983
21.031
24.079
27.127
30.175
33.223
ft.
10
20
30
40
50
60
70
80
90
100
METERS TO FEET
m
10
20
30
40
50
60
70
80
90
100
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
00
32.8084
65.6168
98.4252
131.2336
164.0420
196.8504
229.6588
262.4672
295.2756
328.0840
3.2808
36.0892
68.8976
101.7060
134.5144
167.3228
200.1312
232.9396
265.7480
298.5564
331.3648
6.5617
39.3701
72.1785
104.9869
137.7953
170.6037
203.4121
236.2205
269.0289
301.8373
334.6457
9.8425
42.6509
75.4593
108.2677
141.0761
173.8845
206.6929
239.5013
272.3097
305.1181
337.9265
13.1234
45.9318
78.7402
111.5486
144.3570
177.1654
209.9738
242.7822
275.5906
308.3990
341.2074
16.4042
49.2126
82.0210
114.8294
147.6378
180.4462
213.2546
246.0630
278.8714
311.6798
344.4882
19.6850
52.4934
85.3018
118.1102
150.9186
183.7270
216.5354
249.3438
282.1522
314.9606
347.7690
22.9659
55.7743
88.5827
121.3911
154.1995
187.0079
219.8163
252.6247
285.4331
318.2415
351.0499
26.2467
59.0551
91.8635
124.6719
157.4803
190.2887
223.0971
255.9055
288.7139
321.5223
354.3307
29.5276
62.3360
95.1444
127.9528
160.7612
193.5696
226.3780
259.1864
291.9948
324.8032
357.6116
10
20
30
40
50
60
70
80
90
100
MILES TO KILOMETERS
miles
10
20
30
40
50
60
70
80
90
100
km
km
km
km
km
km
km
km
km
km
00
16.093
32.187
48.280
64.374
80.467
96.560
112.654
128.747
144.841
160.934
1.609
17.703
33.796
49.890
65.983
82.076
98.170
114.263
130.357
146.450
162.543
3.219
19.312
35.405
51.499
67.592
83.686
99.779
115.872
131.966
148.059
164.153
4.828
20.921
37.015
53.108
69.202
85.295
101.388
117.482
133.575
149.669
165.762
6.437
22.531
38.624
54.718
70.811
86.904
102.998
119.091
135.185
151.278
167.371
8.047
24.140
40.234
56.327
72.420
88.514
104.607
120.701
136.794
152.887
168.981
9.656
25.749
41.843
57.936
74.030
90.123
106.216
122.310
138.403
154.497
170.590
11.265
27.359
43.452
59.546
75.639
91.732
107.826
123.919
140.013
156.106
172.199
12.875
28.968
45.062
61.155
77.248
93.342
109.435
125.529
141.622
157.715
173.809
14.484
30.577
46.671
62.764
78.858
94.951
111.044
127.138
143.231
159.325
175.418
10
20
30
40
50
60
70
80
90
100
KILOMETERS TO MILES
km
10
20
30
40
50
60
70
80
90
100
miles
miles
miles
miles
miles
miles
miles
miles
miles
miles
0
6.214
12.427
18.641
24.855
31.069
37.282
43.496
49.710
55.923
62.137
0.621
6.835
13.049
19.262
25.476
31.690
37.904
44.117
50.331
56.545
62.758
1.243
7.456
13.670
19.884
26.098
32.311
38.525
44.739
50.952
57.166
63.380
1.864
8.078
14.292
20.505
26.719
32.933
39.146
45.360
51.574
57.787
64.001
2.485
8.699
14.913
21.127
27.340
33.554
39.768
45.981
52.195
58.409
64.622
3.107
9.321
15.534
21.748
27.962
34.175
40.389
46.603
52.816
59.030
65.244
3.728
9.942
16.156
22.369
28.583
34.797
41.010
47.224
53.438
59.652
65.865
4.350
10.563
16.777
22.991
29.204
35.418
41.632
47.845
54.059
60.273
66.487
4.971
11.185
17.398
23.612
29.826
36.039
42.253
48.467
54.681
60.894
67.108
5.592
11.806
18.020
24.233
30.447
36.661
42.875
49.088
55.302
61.516
67.729
10
20
30
40
50
60
70
80
90
100

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

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

cm3(cc)
10
20
30
40
50
60
70
80
90
100
in3
in3
in3
in3
in3
in3
in3
in3
in3
in3
0
0.6102
1.2205
1.8307
2.4409
3.0512
3.6614
4.2716
4.8818
5.4921
6.1023
0.0610
0.6713
1.2815
1.8917
2.5019
3.1122
3.7224
4.3326
4.9429
5.5531
6.1633
0.1220
0.7323
1.3425
1.9527
2.5630
3.1732
3.7834
4.3937
5.0039
5.6141
6.2243
0.1831
0.7933
1.4035
2.0138
2.6240
3.2342
3.8444
4.4547
5.0649
5.6751
6.2854
0.2441
0.8543
1.4646
2.0748
2.6850
3.2952
3.9055
4.5157
5.1259
5.7362
6.3464
0.3051
0.9153
1.5256
2.1358
2.7460
3.3563
3.9665
4.5767
5.1870
5.7972
6.4074
0.3661
0.9764
1.5866
2.1968
2.8071
3.4173
4.0275
4.6377
5.2480
5.8582
6.4684
0.4272
1.0374
1.6476
2.2579
2.8681
3.4783
4.0885
4.6988
5.3090
5.9192
6.5295
0.4882
1.0984
1.7086
2.3189
2.9291
3.5393
4.1496
4.7598
5.3700
5.9803
6.5905
0.5492
1.1594
1.7697
2.3799
2.9901
3.6004
4.2106
4.8208
5.4310
6.0413
6.6515
10
20
30
40
50
60
70
80
90
100

VOLUME
GALLONS (U.S.) TO LITERS
U.S. gal.
10
20
30
40
50
60
70
80
90
100
liters
liters
liters
liters
liters
liters
liters
liters
liters
liters
U.S.gal.
00
37.8543
75.7085
113.5628
151.4171
189.2714
227.1256
264.9799
302.8342
340.6884
378.5427
3.7854
41.6397
79.4940
117.3482
155.2025
193.0568
230.9110
268.7653
306.6196
344.4739
382.3281
7.5709
45.4251
83.2794
121.1337
158.9879
196.8422
234.6965
272.5507
310.4050
348.2593
386.1136
11.3563
49.2106
87.0648
124.9191
162.7734
200.6276
238.4819
276.3362
314.1904
352.0447
389.8990
15.1417
52.9960
90.8502
128.7045
166.5588
204.4131
242.2673
280.1216
317.9759
355.8301
393.6844
18.9271
56.7814
94.6357
132.4899
170.3442
208.1985
246.0528
283.9070
321.7613
359.6156
397.4698
22.7126
60.5668
98.4211
136.2754
174.1296
211.9839
249.8382
287.6925
325.5467
363.4010
401.2553
26.4980
64.3523
102.2065
140.0608
177.9151
215.7693
253.6236
291.4779
329.3321
367.1864
405.0407
30.2834
68.1377
105.9920
143.8462
181.7005
219.5548
257.4090
295.2633
333.1176
370.9718
408.8261
34.0688
71.9231
109.7774
147.6317
185.4859
223.3402
261.1945
299.0487
336.9030
374.7573
412.6115
10
20
30
40
50
60
70
80
90
100
liters
LITERS TO GALLONS (U.S.)

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

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

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

MASS
POUNDS TO KILOGRAMS
lbs.
10
20
30
40
50
60
70
80
90
100
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
lbs.
0
4.536
9.072
13.608
18.144
22.680
27.215
31.751
36.287
40.823
45.359
0.454
4.989
9.525
14.061
18.597
23.133
27.669
32.205
36.741
41.277
45.813
0.907
5.443
9.979
14.515
19.051
23.587
28.123
32.658
37.194
41.730
46.266
1.361
5.897
10.433
14.968
19.504
24.040
28.576
33.112
37.648
42.184
46.720
1.814
6.350
10.886
15.422
19.958
24.494
29.030
33.566
38.102
42.637
47.173
2.268
6.804
11.340
15.876
20.412
24.947
29.483
34.019
38.555
43.091
47.627
2.722
7.257
11.793
16.329
20.865
25.401
29.937
34.473
39.009
43.545
48.081
3.175
7.711
12.247
16.783
21.319
25.855
30.391
34.926
39.462
43.998
48.534
3.629
8.165
12.701
17.236
21.772
26.308
30.844
35.380
39.916
44.452
48.988
4.082
8.618
13.154
17.690
22.226
26.762
31.298
35.834
40.370
44.905
49.441
10
20
30
40
50
60
70
80
90
100
kg
KILOGRAMS TO POUNDS
kg
10
20
30
40
50
60
70
80
90
100
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
00
22.046
44.092
66.139
88.185
110.231
132.277
154.323
176.370
198.416
220.462
2.205
24.251
46.297
68.343
90.389
112.436
134.482
156.528
178.574
200.620
222.667
4.409
26.455
48.502
70.548
92.594
114.640
136.686
158.733
180.779
202.825
224.871
6.614
28.660
50.706
72.752
94.799
116.845
138.891
160.937
182.983
205.030
227.076
8.818
30.865
52.911
74.957
97.003
119.049
141.096
163.142
185.188
207.234
229.280
11.023
33.069
55.116
77.162
99.208
121.254
143.300
165.347
187.393
209.439
231.485
13.228
35.274
57.320
79.366
101.413
123.459
145.505
167.551
189.597
211.644
233.690
15.432
37.479
59.525
81.571
103.617
125.663
147.710
169.756
191.802
213.848
235.894
17.637
39.683
61.729
83.776
105.822
127.868
149.914
171.960
194.007
216.053
238.099
19.842
41.888
63.934
85.980
108.026
130.073
152.119
174.165
196.211
218.257
240.304
10
20
30
40
50
60
70
80
90
100
kg
KILOGRAMS TO NEWTON
kg
10
20
30
40
50
60
70
80
90
100
0
98.07
196.13
294.20
392.27
490.34
588.40
686.47
784.54
882.60
980.67
9.81
107.87
205.94
304.01
402.07
500.14
598.21
696.28
794.34
892.41
990.48
19.61
117.68
215.75
313.81
411.88
509.95
608.02
706.08
804.15
902.22
1000.28
29.42
127.49
225.55
323.62
421.69
519.76
617.82
715.89
813.96
912.02
1010.09
39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.70
823.76
921.83
1019.90
49.03
147.10
245.17
343.23
441.30
539.37
637.44
735.50
833.57
931.64
1029.70
58.84
156.91
254.97
353.04
451.11
549.18
647.24
745.31
843.38
941.44
1039.51
68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.12
853.18
951.25
1049.32
78.45
176.52
274.59
372.65
470.72
568.79
666.86
764.92
862.99
961.06
1059.12
88.26
186.33
284.39
382.46
480.53
578.60
676.66
774.73
872.80
970.86
1068.93
10
20
30
40
50
60
70
80
90
100
NEWTON TO KILOGRAMS
N
100
200
300
400
500
600
700
800
900
1000
10
20
30
40
50
60
70
80
90
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
00
10.197
20.394
30.592
40.789
50.986
61.183
71.380
81.578
91.775
101.972
1.020
11.217
21.414
31.611
41.809
52.006
62.203
72.400
82.597
92.795
102.992
2.039
12.237
22.434
32.631
42.828
53.025
63.223
73.420
83.617
93.814
104.011
3.059
13.256
23.454
33.651
43.848
54.045
64.242
74.440
84.637
94.834
105.031
4.079
14.276
24.473
34.670
44.868
55.065
65.262
75.459
85.656
95.854
106.051
5.099
15.296
25.493
35.690
45.887
56.085
66.282
76.479
86.676
96.873
107.071
6.118
16.316
26.513
36.710
46.907
57.104
67.302
77.499
87.696
97.893
108.090
7.138
17.335
27.532
37.730
47.927
58.124
68.321
78.518
88.716
98.913
109.110
8.158
18.355
28.552
38.749
48.947
59.144
69.341
79.538
89.735
99.933
110.130
9.177
19.375
29.572
39.769
49.966
60.163
70.361
80.558
90.755
100.952
111.149
100
200
300
400
500
600
700
800
900
1000

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

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

kg/cm2
10
20
30
40
50
60
70
80
90
100
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
KPa
00
980.7
1961.3
2942.0
3922.7
4903.4
5884.0
6864.7
7845.4
8826.0
9806.7
98.1
1078.7
2059.4
3040.1
4020.7
5001.4
5982.1
6962.8
7943.4
8924.1
9904.8
196.1
1176.8
2157.5
3138.1
4118.8
5099.5
6080.2
7060.8
8041.5
9022.2
10002.8
294.2
1274.9
2255.5
3236.2
4216.9
5197.6
6178.2
7158.9
8139.6
9120.2
10100.9
392.3
1372.9
2353.6
3334.3
4314.9
5295.6
6276.3
7257.0
8237.6
9218.3
10199.0
490.3
1471.0
2451.7
3432.3
4413.0
5393.7
6374.4
7355.0
8335.7
9316.4
10297.0
588.4
1569.1
2549.7
3530.4
4511.1
5491.8
6472.4
7453.1
8433.8
9414.4
10395.1
686.5
1667.1
2647.8
3628.5
4609.1
5589.8
6570.5
7551.2
8531.8
9512.5
10493.2
784.5
1765.2
2745.9
3726.5
4707.2
5687.9
6668.6
7649.2
8629.9
9610.6
10591.2
882.6
1863.3
2843.9
3824.6
4805.3
5786.0
6766.6
7747.3
8728.0
9708.6
10689.3
10
20
30
40
50
60
70
80
90
100
KPa
KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

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

TORQUE
FOOT POUNDS TO KILOGRAMMETERS
ft. lbs.
10
20
30
40
50
60
70
80
90
100
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
ft lbs.
0
1.383
2.765
4.148
5.530
6.913
8.296
9.678
11.061
12.443
13.826
0.138
1.521
2.903
4.286
5.669
7.051
8.434
9.816
11.199
12.582
13.964
0.277
1.659
3.042
4.424
5.807
7.190
8.572
9.955
11.337
12.720
14.103
0.415
1.797
3.180
4.563
5.945
7.328
8.710
10.093
11.476
12.858
14.241
0.553
1.936
3.318
4.701
6.083
7.466
8.849
10.231
11.614
12.996
14.379
0.691
2.074
3.457
4.839
6.222
7.604
8.987
10.370
11.752
13.135
14.517
0.830
2.212
3.595
4.977
6.360
7.743
9.125
10.508
11.890
13.273
14.656
0.968
2.350
3.733
5.116
6.498
7.881
9.263
10.646
12.029
13.411
14.794
1.106
2.489
3.871
5.254
6.636
8.019
9.402
10.784
12.167
13.549
14.932
1.244
2.627
4.010
5.392
6.775
8.157
9.540
10.923
12.305
13.688
15.070
10
20
30
40
50
60
70
80
90
100
kg-m
KILOGRAMMETERS TO FOOT POUNDS

kg-m
10
20
30
40
50
60
70
80
90
100
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
0
72.33
144.66
216.99
289.32
361.65
433.98
506.31
578.64
650.97
723.30
7.23
79.56
151.89
224.22
296.55
368.88
441.21
513.54
585.87
658.20
730.53
14.47
86.80
159.13
231.46
303.79
376.12
448.45
520.78
593.11
665.44
737.77
21.70
94.03
166.36
238.69
311.02
383.35
455.68
528.01
600.34
672.67
745.00
28.93
101.26
173.59
245.92
318.25
390.58
462.91
535.24
607.57
679.90
752.23
36.17
108.50
180.83
253.16
325.49
397.82
470.15
542.48
614.81
687.14
759.47
43.40
115.73
188.06
260.39
332.72
405.05
477.38
549.71
622.04
694.37
766.70
50.63
122.96
195.29
267.62
339.95
412.28
484.61
556.94
629.27
701.60
773.93
57.86
130.19
202.52
274.85
347.18
419.51
491.84
564.17
636.50
708.83
781.16
65.10
137.43
209.76
282.09
354.42
426.75
499.08
571.41
643.74
716.07
788.40
10
20
30
40
50
60
70
80
90
100
kg-m
KILOGRAMMETERS TO NEWTONMETERS
kg-m
10
20
30
40
50
60
70
80
90
100
N-m
N-m
N-m
N-m
N-m
N-m
N-m
N-m
N-m
N-m
00
98.07
196.13
294.20
392.27
490.34
588.40
686.47
784.54
882.60
980.67
9.81
107.87
205.94
304.01
402.07
500.14
598.21
696.28
794.34
892.41
990.48
19.61
117.68
215.75
313.81
411.88
509.95
608.02
706.08
804.15
902.22
1000.28
29.42
127.49
225.55
323.62
421.69
519.76
617.82
715.89
813.96
912.02
1010.09
39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.70
823.76
921.83
1019.90
49.03
147.10
245.17
343.23
441.30
539.37
637.44
735.50
833.57
931.64
1029.70
58.84
156.91
254.97
353.04
451.11
549.18
647.24
745.31
843.38
941.44
1039.51
68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.12
853.18
951.25
1049.32
78.45
176.52
274.59
372.65
470.72
568.79
666.86
764.92
862.99
961.06
1059.12
88.26
186.33
284.39
382.46
480.53
578.60
676.66
774.73
872.80
970.86
1068.93
10
20
30
40
50
60
70
80
90
100
N-m
NEWTONMETERS TO KILOGRAMMETERS
N-m
100
200
300
400
500
600
700
800
900
1000
10
20
30
40
50
60
70
80
90
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
kg-m
00
10.197
20.394
30.591
40.788
50.985
61.182
71.379
81.576
91.773
101.970
1.020
11.217
21.414
31.611
41.808
52.005
62.202
72.399
82.596
92.793
102.990
2.039
12.236
22.433
32.630
42.827
53.024
63.221
73.418
83.615
93.812
104.009
3.059
13.256
23.453
33.650
43.847
54.044
64.241
74.438
84.635
94.832
105.029
4.079
14.276
24.473
34.670
44.867
55.064
65.261
75.458
85.655
95.852
106.049
5.099
15.296
25.493
35.690
45.887
56.084
66.281
76.478
86.675
96.872
107.069
6.118
16.315
26.512
36.709
46.906
57.103
67.300
77.497
87.694
97.891
108.088
7.138
17.335
27.532
37.729
47.926
58.123
68.320
78.517
88.714
98.911
109.108
8.158
18.355
28.552
38.749
48.946
59.143
69.340
79.537
89.734
99.931
110.128
9.177
19.374
29.571
39.768
49.965
60.162
70.359
80.556
90.753
100.950
111.147
100
200
300
400
500
600
700
800
900
1000

TEMPERATURE
FAHRENHEIT TO CENTIGRADE
F
-60
-58
-56
-54
-52
-50
-48
-46
-44
-42
-40
-38
-36
-34
-32
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-51.1
-50.0
-48.9
-47.8
-46.7
-45.6
-44.4
-43.3
-42.2
-41.1
-40.0
-38.9
-37.8
-36.7
-35.6
-34.4
-33.3
-32.2
-31.1
-30.0
-28.9
-27.8
-26.7
-25.6
-24.4
-23.3
-22.2
-21.1
-20.0
-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
-18.9
-17.8
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.6
6.7
7.8
8.9
10.0
11.1
12.2
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
162
164
166
168
170
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6
66.7
67.8
68.9
70.0
71.1
72.2
73.3
74.4
75.6
76.7
172
174
176
178
180
182
184
186
188
190
192
194
196
198
200
202
204
206
208
210
212
214
216
218
220
222
224
226
228
77.8
78.9
80.0
81.1
82.2
83.3
84.4
85.6
86.7
87.8
88.9
90.0
91.1
92.2
93.3
94.4
95.6
96.7
97.8
98.9
100.0
101.1
102.2
103.3
104.4
105.6
106.7
107.8
108.9
230
232
234
236
238
240
242
244
246
248
250
252
254
256
258
260
262
264
266
268
270
272
274
276
278
280
282
284
286
110.0
111.1
112.2
113.3
114.4
115.6
116.7
117.8
118.9
120.0
121.1
122.2
123.3
124.4
125.6
126.7
127.8
128.9
130.0
131.1
132.2
133.3
134.4
135.6
136.7
137.8
138.9
140.0
141.1
288
290
292
294
296
298
300
302
304
306
308
310
312
314
316
318
320
322
324
326
328
330
332
334
336
338
340
342
344
142.2
143.3
144.4
145.6
146.7
147.8
148.9
150.0
151.1
152.2
153.3
154.4
155.6
156.7
157.8
158.9
160.0
161.1
162.2
163.3
164.4
165.6
166.7
167.8
168.9
170.0
171.1
172.2
173.3
346
348
350
352
354
356
358
360
362
364
366
368
370
372
374
376
378
380
382
384
386
388
390
392
400
410
420
430
440
174.4
175.6
176.7
177.8
178.9
180.0
181.1
182.2
183.3
184.4
185.6
186.7
187.8
188.9
190.0
191.1
192.2
193.3
194.4
195.6
196.7
197.8
198.9
200.0
204.4
210.0
215.6
221.1
226.7
CENTIGRADE TO FAHRENHEIT
C
-50
-49
-48
-47
-46
-45
-44
-43
-42
-41
-40
-39
-38
-37
-36
-35
-34
-33
-32
-31
-30
-29
-28
-27
-26
-25
-24
-23
-22
-21
-20
-19
-58.0
-56.2
-54.4
-52.6
-50.8
-49.0
-47.2
-45.4
-43.6
-41.8
-40.0
-38.2
-36.4
-34.6
-32.8
-31.0
-29.2
-27.4
-25.6
-23.8
-22.0
-20.2
-18.4
-16.6
-14.8
-13.0
-11.2
-9.4
-7.6
-5.8
-4.0
-2.2
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
-0.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
32.0
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0
51.8
53.6
55.4
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
172.4
174.2
176.0
177.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
213.8
215.6
217.4
219.2
221.0
222.8
224.6
226.4
228.2
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
230.0
231.8
233.6
235.4
237.2
239.0
240.8
242.6
244.4
246.2
248.0
249.8
251.6
253.4
255.2
257.0
258.8
260.6
262.4
264.2
266.0
267.8
269.6
271.4
273.2
275.0
276.8
278.6
280.4
282.2
284.0
285.8
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
287.6
289.4
291.2
293.0
294.8
296.6
298.4
300.2
302.0
303.8
305.6
307.4
309.2
311.0
312.8
314.6
316.4
318.2
320.0
321.8
323.6
325.4
327.2
329.0
330.8
332.6
334.4
336.2
338.0
339.8
341.6
343.4
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
210
220
230
240
250
345.2
347.0
348.8
350.6
352.4
354.2
356.0
357.8
359.6
361.4
363.2
365.0
366.8
368.6
370.4
372.2
374.0
375.8
377.6
379.4
381.2
383.0
384.8
386.6
388.4
390.2
392.0
410.0
428.0
446.0
464.0
482.0
Copyright reserved for this manual may not be

reproduced or copied, in whole or in part, without the
written consent of ISUZU MOTORS LIMITED.
WORKSHOP MANUAL (INDUSTRIAL)

4LE2
(IDE-2330)
Issued by
ISUZU MOTORS LIMITED

Powertrain Service & Parts
Powertrain Operations
6-26-1, Minami-oi, Shinagawa-ku,Tokyo, 140-8722, Japan
TEL 03-5471-1111
First edition Sep., 1999
107-02K
IDE-2330
PRINTED IN JAPAN

08 Isuzu 4le2 GB

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INDUSTRIAL

2003 ISUZU MOTORS LIMITED

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

GENERAL REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES ON THE FORMAT OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN DATA AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANGULAR NUT AND BOLT TIGHTENING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE ON MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GENERAL REPAIR INSTRUCTIONS

NOTES ON THE FORMAT OF THIS MANUAL

) show the order of disassembling or reassembling.

Water Outlet Pipe (5)

Water pump ASM (8)

Pulley; Fan (4)

Belt; Fan (3)

7. Measurement criteria are defined by the terms standard and limit.

Important Operation Requiring Extra Care

Specified Torque (Tighten)

Special Tool Use Required for Recommended

Commercially Available Tool Use Required or

10. Direction used in this Manual are as follows:

(2) Right side view

MAIN DATA AND SPECIFICATIONS

4-cycle, verlical in-line, water cooled, OHV

Timing drive system

No. of cylinders - bore stroke

Overall length width height

691 449 616

Highspeed diesel fuel (SAE No.2)

Lubricant capacity: In total

About 8.7 (9.2)

(Note) These specifications may be subject to change without notice.

TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE SPECIFICATIONS

FLANGED HEAD BOLT

ANGULAR NUT AND BOLT TIGHTENING METHOD

1. Carefully wash the nuts and bolts to remove all oil

2. Apply a coat of molybdenum disulfide grease to the

3. Tighten the nuts and bolts to the specified torque

4. Draw a line [A-B] across the center of each bolt.

6. Draw another line [F-G] on the face of each of the

7. Use a socket wrench to tighten each nut or bolt to

Example: Specified Angle and Tightening Rotation

One full turn

TIGHTENING TORQUE ON MAJOR COMPONENTS

2. CYLINDER HEAD AND CYLINDER HEAD COVER

(Apply engine oil.)

(Apply Locktite No.262 to this part.)

(Apply engine oil.)

4. CYLINDER BLOCK AND OTHER COMPONENTS (2)

(Apply engine oil.)

5. CYLINDER BLOCK AND OTHER COMPONENTS (3)

Rotate 3/4 turn after

(With PTO provided)

Packin; nozzle holder

Packin; joint bolt

2. LOCATIONS WHERE SEALANT IS APPLIED

Condition for use

Air inlet pipe

Cylinder head cover