INTRODUCTION

GENERAL ASBESTOS warning label on the container.

Discard asbestos material safely.

This section has the description and the repair proce-

dures for the engine and the fuel system. Removal, dis-
CAUTION
Disconnect the battery cables before doing any
assembly, cleaning, assembly, installation, specifica-
disassembly and repair to the engine or parts of the
tions and troubleshooting procedures are included.
electrical system.

DANGER The diodes and resistors in the electrical system can

be damaged if the following cautions are not
Some gaskets used in this engine can contain
followed:
asbestos or other fibers. Breathing asbestos dust is a
cancer or lung disease hazard. Do not create dust! Do not disconnect the battery when the engine
Use vacuum equipment for asbestos or follow the is running. The voltage surge can damage the
cleaning procedure described below. electronic devices in the circuit.
Do not disconnect an electric wire before the
Use a hand scraper to remove old gasket
engine is stopped and the switches are OFF.
material. Do not use a power tool or
compressed air. Do not cause a short circuit by connection of
the electric wires to the wrong terminals.
Make sure the gasket material is wet with Make sure a correct identification is made of
water or oil to prevent particles in the air. the wire before it is connected.
Discard all asbestos material in a closed Make sure a battery is the correct voltage and
container while it is still wet. Put an polarity before it is connected.

7 2 1 3 9 10

1. FILL CAP FOR ENGINE OIL

2. THERMOSTAT HOUSING
3. FUEL INJECTION PUMP
4. DRAIN PLUG, ENGINE OIL
5. CRANKSHAFT PULLEY
6. FAN
7. COOLANT PUMP
8. STARTER
9. HOSE, PCV
6 10. INLET MANIFOLD
11. OIL SUMP
12. TIMING CASE

12
11
4
FIGURE 1. ISUZU 4JB1 DIESEL ENGINE

1
 Do not check for current flow by making a
spark because the electronic devices in the
circuit can be damaged.
DESCRIPTION
The Isuzu 4JB1 diesel engine is a fourcylinder engine
with a displacement of 2771 cm3 (169 in3). The firing
order is 1342. The No. 1 cylinder is toward the end
of the engine with the fan. The serial number of the en-
gine is on the side of the engine block near the No. 4 cyl-
inder location.
This diesel engine has direct fuel injection. Diesel fuel is
injected into the cylinder at the beginning of each power
stroke of the piston. A glow plug is also installed in the
cylinder head for each cylinder. These glow plugs are
cold start aids to make the diesel engine easier to start
when the engine is cold.
The fuel injection pump, Model VE, is made by Diesel
Kiki. This fuel injection pump has one plunger assem-
bly that supplies fuel to the four fuel injectors. A me-
chanical governor controls the maximum engine speed.
The operation of this governor is described in the Fuel
System later in this section.
The valves, valve guides, and valves seats can be re-
placed during engine repairs. The valve and valve guide
are a set and must be replaced as a unit.
The crankshaft has five main bearings. The main bear-
ing in the center of the crankshaft is also the thrust bear-
ing and has thrust washers (thrust bearings) on each side
of the main bearing. The bearing journals have had a
special process called tufftrided and can not be re-
paired by grinding. The crankshaft must be replaced.
The pistons have three piston rings. Each of the two
compression rings have a special shape designed for its
position on the piston. The third piston ring is the oil
control ring. The cylinder liners are chrome plated.
FUEL SYSTEM
Description
NOTE: Special tools and training are needed to repair
the fuel injection pump. A fuel injection pump is nor-
mally sent to an authorized Diesel Kiki repair station if
2
repairs are necessary. Fuel injectors also require special
equipment and training for repair. Most users have a
special repair service do this work. The repair of the
fuel injection pump and the fuel injectors is not de-
scribed in this section.
A description of the fuel system for the fuel injection
pump, Model VE is included in the following para-
graphs.
Check the timing of the fuel injection pump as described
in CHECKS AND ADJUSTMENTS. During installa-
tion of the fuel injection pump, remove the air from the
fuel system as described in CHECKS AND ADJUST-
MENTS.
Operation, Fuel Injection Pump,
Model VE (See FIGURE 2.)
The parts of the fuel system include the fuel tank, injec-
tion pump and governor, fuel filters, and injectors. A ba-
sic diagram of the fuel system with the fuel injection
pump, Model VE is shown in FIGURE 2.
The solenoid valve is controlled by the ignition switch.
When the ignition switch is turned to ON, the coil in the
solenoid valve is energized. The solenoid valve opens to
permit fuel to flow into the pressure chamber for the
plunger (2). When the ignition switch is turned to OFF,
the solenoid valve closes and stops the flow of fuel. The
solenoid valve permits the engine to be stopped quickly
when the ignition switch is turned to OFF.
The drive shaft (6) is turned by the gear train in the en-
gine. The fuel pump (4) is a rotary vane pump that pulls
fuel from the fuel tank through the water separator. The
pressure of the fuel oil from the fuel pump increases
when the speed of the drive shaft increases. The regula-
tor valve controls the pressure of the fuel oil to the speci-
fications set by the manufacturer. The fuel oil flows into
the inlet for the distributor head (17) to the pressure
chamber for the plunger (2). The cam disk (13) rotates
the plunger (2) and moves the plunger in and out of the
plunger barrel. The plunger (2) increases the pressure of
the fuel oil. The rotation of the plunger aligns the pas-
sages with the ports in the distributor head (17). Each
port in the distributor head has a fuel line connected to a
fuel injector. The fuel flows to the fuel injector.
 7 10

4
1
5

9
2
6

3 12627
1. FUEL INJECTOR
2. PLUNGER
3. FUEL TANK 7. FUEL FILTER/WATER 13. CAM DISK
4. FUEL PUMP SEPARTOR 14. TIMER
(VIEW ROTATED TO MAKE 8. OVERFLOW VALVE 15. PLUNGER SPRING
CLEARER) 9. SOLENOID VALVE 16. DELIVERY VALVE
5. REGULATOR VALVE 10. CONTROL LEVER 17. DISTRIBUTOR HEAD
6. DRIVE SHAFT FOR GEAR, 11. FLY WEIGHT 18. GOVERNOR LEVER
FUEL INJECTION PUMP 12. ROLLER HOLDER 19. ADJUSTMENT SCREW,
FULL LOAD
10
8

11

19

18
9
6
17

12

13

14
15 16 12628

FIGURE 2. THE FUEL SYSTEM, FUEL INJECTION PUMP, MODEL VE

3
The overflow valve (9) in the injection pump is a by
pass valve that permits some fuel oil to return to the fuel
tank. The overflow valve keeps the fuel oil at a constant
pressure in the plunger chamber so that the fuel flow to
the fuel injectors is even.
See FIGURE 3. A control sleeve (6) slides on the plung-
er and partially opens a passage in the plunger to control
the amount of fuel oil sent to the fuel injectors. This con-
trol sleeve is controlled by both the control lever (1) and
the mechanical governor (3). The control lever (1) is
connected to the accelerator pedal for the lift truck.

1. CONTROL LEVER
2. SHAFT, CONTROL LEVER
3. GOVERNOR
4. FLYWEIGHT (4)
5. GOVERNOR SLEEVE
6. CONTROL SLEEVE
7. PLUNGER
8. BALL JOINT
9. ASSEMBLY, GOVERNOR LEVER
12630 10. ADJUSTMENT SCREW, FULL LOAD
11. RETAINER PIN
12. GOVERNOR SPRING

FIGURE 3. SPEED CONTROL, FUEL INJECTION PUMP, MODEL VE

REPAIRS

FUEL INJECTION PUMP
Removal
1. Disconnect the battery cables at the battery.
2. Remove clamps as necessary so that the fuel lines are
not bent. Remove the fuel line between the fuel filter and
the fuel injection pump.
3. Remove the fuel lines from the fuel injection pump
and the fuel injectors that returns fuel to the fuel tank.
4. Disconnect the throttle cable from the control lever on
the fuel injection pump.
5. Remove the bolts that hold the fuel injection pump to
the engine. Move the fuel injection pump away from the
timing gear case so that the drive gear is disengaged
from the timing gear train.
NOTE: A liquid sealant was applied between the fuel
injection pump and the timing gear case. Sometimes it is
necessary to lightly hit the fuel injection pump with a
soft hammer to loosen it from the timing gear case.
Installation
NOTE: The timing gears must be correctly installed in
the engine before the fuel injection pump is installed.
CAUTION
Do not turn the crankshaft or the camshaft if the tim-
ing gears have been removed and the valve mecha-
nism is installed. If either shaft is turned, damage
will occur to the valve mechanism. To prevent dam-
age to the valve mechanism, remove the rocker arm
assembly when working on the timing gears.
NOTE: If the engine is installed in the lift truck, the let-
ters on the timing gears can be difficult to see to align the
position of the gears. Some service people use a light
and a mirror to see the letters on the timing gears.

4
1. See FIGURE 4. Remove the access cover for the cam-
shaft timing on the timing gear cover. Slowly turn the
crankshaft clockwise. Align the pointer (1) with the O
mark (2) on the camshaft gear.
1 2
1. POINTER
2. MARK, CAMSHAFT TIMING GEAR
FIGURE 4. ALIGNMENT, CAMSHAFT TIMING
GEAR
2. See FIGURE 5. Remove the access cover for the tim-
ing of the fuel injection pump on the timing gear cover.
Put a thin coat of liquid sealant on both surfaces of the
gasket that is installed between the fuel injection pump
and the timing gear case. Install the fuel injection pump
on the timing gear case. Align the O mark (2) on the
gear with the pointer (1) as the fuel injection pump is in-
stalled.
1 Special Tools: Remover Tool For The Fuel Injectors,
2
1. POINTER
2. MARK, GEAR FOR FUEL INJECTION PUMP
FIGURE 5. ALIGNMENT, GEAR FOR THE
FUEL INJECTION PUMP
3. Install the bolts that fasten the fuel injection pump to
the timing gear case and engine. Tighten the bolts to 19
N.m (14 lbf ft).
4. Install the oil pipe between the fuel injection pump
and the oil sump.
5. Install the fuel lines from the fuel injection pump and
the fuel injectors that returns fuel to the fuel tank.
6. Install the clamps as necessary so that the fuel lines
are not bent. Install the fuel line between the fuel filter
and the fuel injection pump.
7. Connect the throttle cable to the control lever on the
fuel injection pump.
8. If installation and alignment of the timing gears are
complete, install the access covers for the camshaft gear
and the gear for the fuel injection pump.
9. See the procedure Remove Air From The Fuel Sys-
tem before starting the engine.
REMOVAL AND INSTALLATION OF THE
ENGINE
NOTE: The removal and installation procedures for the
engine are not included in this section. See the section,
THE FRAME for the procedures to remove and install
the engine.
CYLINDER HEAD AND VALVE
MECHANISM (See FIGURE 6.)
Cylinder Head, Removal
Isuzu Part No. 5884020340
NOTE: The following procedure is for removal of the
cylinder head when the engine is in the lift truck. If the
engine has been removed from the lift truck, many of the
following disconnections and removals will already be
done.
1. Disconnect the battery cables at the battery.
2. Drain the cooling system.
3. Disconnect the air filter from the inlet manifold. Re-
move the air filter and air duct.
4. Remove the fan guard from the radiator. Loosen the
alternator support bracket to remove the tension in the
drive belt for the cooling fan.
5
 2
3
1

4
6
7
5 8

2
18
9 19

1. BOLT, VALVE COVER (2) 20

2. GROMMET (2) 10
3. SOUND SHIELD
4. GROMMET (2)
5. SOUND SHIELD, RUBBER
6. SCREW (4)
7. PCV VALVE 15
8. OIL FILL CAP 14
9. ROCKER ARM COVER 16
13
10. GASKET 11
11. LIFTING EYE 12 17
12. VALVE GUIDE (8)
13. SPRING SEAT (8)
14. SEAL, VALVE STEM (8)
15. BOLT, CYLINDER HEAD (18) 21
16. SEAL CUP
17. LIFTING EYE
18. BREATHER PIPE
19. SPRING CLIP 22
20. RUBBER HOSE, PCV 27
21. GLOW PLUG (4) 24
22. CONNECTOR, GLOW PLUG
23. GASKET, CYLINDER HEAD 25 23
24. SEAL CUP (7) 26
25. VALVE SEAT, EXHAUST (4)
26. VALVE SEAT, INLET (4)
27. SEAL CUP

FIGURE 6. CYLINDER HEAD ASSEMBLY

6
5. Remove the cooling fan and spacer. Remove the distortion in the cylinder head. Loosen the cylinder
pulley for the cooling fan and the drive belt. head bolts in the sequence shown in FIGURE 7. Do
not completely loosen the bolts during the first se-
6. Remove the alternator and its mount.
quence.
7. Remove the fuel lines between the components on the
cylinder head and the fuel injection pump. If the engine 17. Remove the cylinder head bolts. Lift the cylinder
must be completely disassembled for repairs, remove head from the engine block.
fuel injection pump as described in the procedure FUEL
INJECTION PUMP, Removal.
6 14 15 7
8. Remove the fuel filter. 10 18 11
2 3
9. Disconnect the exhaust manifold from the cylinder
head. 1 9 17 12 4
5 13 16 8
10. Remove the coolant hose from the coolant pump to
the cylinder head. Remove the thermostat housing. Re-
move the clamps for the engine wiring that are on the
thermostat housing and the side of the cylinder head. FIGURE 7. LOOSENING SEQUENCE FOR
REMOVAL OF THE CYLINDER HEAD
11. Remove the glow plug connectors. Remove the glow
plugs from the cylinder head. 18. Remove the cylinder head gasket.

12. Remove the nuts, washers, and the bracket holders Valves, Removal
for the fuel injectors. See FIGURE 26. Use a slide ham-
1. Put the cylinder head on a flat work surface. Use a
mer and a remover tool to pull the fuel injectors from the
wood surface or a pad to prevent damage to the cylinder
cylinder head. Remove the Orings and gaskets. See
head. Use a valve spring compressor to compress the
FIGURE 25.
valve springs and remove the retainers. See FIGURE 8.
NOTE: A remover tool for the fuel injectors is available and FIGURE 9.
from Isuzu (Isuzu Part No. 5884020340).

13. Remove the inlet manifold. 1. VALVE SPRING COMPRESSOR

14. Remove the rocker arm cover and sound shields. 1

CAUTION
When the rocker arm assembly is removed, loosen
each bolt that holds the brackets in a minimum of
three steps in a sequence. This action is to prevent
bending the rocker arm shaft. Loosen the outer bolts
first and then work toward the center of the rocker
arm assembly.
FIGURE 8. VALVES, REMOVAL AND
15. Remove the rocker arm assembly. INSTALLATION
16. Remove the push rods. Keep the push rods in the cor-
2. Release the valve spring compressor. Remove the
rect order so that they will be installed in the same posi-
valve spring cap, valve spring, seal, and seat washer. Re-
tions.
move the valve from the cylinder head. If the valve will
be used again, make a mark on the valve head so that it
CAUTION can be installed again in the same position.
When the cylinder head is removed, loosen each bolt
in a minimum of three steps in a sequence to prevent 3. Repeat steps 1 and 2 to remove the other valves.

7
 Check the surface of the cylinder head for distortion at
the location for the inlet and the exhaust manifold. If the
1 amount of distortion is more an 0.20 mm (0.008 in), the
cylinder head needs repair.
2
See the complete specifications for the cylinder head in
the SPECIFICATIONS.

9742
6

1. RETAINERS 5. SEAT WASHER A

2. VALVE SPRING CAP 6. INLET VALVE E F
3. VALVE SPRING 7. EXHAUST C D
4. OIL SEAL VALVE
B
FIGURE 9. VALVE COMPONENTS

FIGURE 10. CHECK THE CYLINDER HEAD

Cylinder Head, Inspection And Repair FOR DISTORTION

1. Clean the carbon from the combustion chambers and

Valves, Inspection And Repair
the valve ports.
1. Inspect the valves for burned or damaged areas in the
2. Clean the valve guides.
seat surfaces. Inspect for cracks and damaged or worn
3. Clean the push rods and rocker arms. valve stems.

4. Use an abrasive wheel to clean the heads of the valves.
5. See the DANGER note for asbestos on page 1 of this
section. Clean the surfaces of the cylinder head where
the gaskets fit.
6. Inspect the cylinder head for cracks in the exhaust
ports, combustion chambers, and external surfaces.
7. Check the surface of the cylinder head for distortion.
Use a straight edge and a thickness gauge as shown in
FIGURE 10. Do the measurement in the positions
shown. If the amount of distortion is more than 0.2 mm
(0.008 in), the cylinder head needs repair. If the amount
of distortion is more than 0.4 mm (0.016 in), replace the
cylinder head.
2. Check the clearance of each valve stem in its valve
guide. Use the following procedure:
a. Use a micrometer to measure the diameter of the
valve stem in three places: top, center, and bot-
tom. Use a hole gauge to measure the bore in the
valve guide.
b. Another method of measuring the clearance of
the valve stem in its valve guide is to use a dial in-
dicator as shown in FIGURE 11. Put the dial indi-
cator so that it can measure the sidetoside
movement of the valve stem. Lower the valve
away from its valve seat approximately 3 mm
(0.1 in). Move the valve stem from sidetoside
and check the measurement on the dial indicator.

8
 9727

FIGURE 11. CHECK THE CLEARANCE FIGURE 12. VALVE GUIDES, REMOVAL
BETWEEN VALVE GUIDE AND VALVE

c. The maximum clearance between the valve

stems and their valve guides is shown in the A
SPECIFICATIONS.

d. If the clearance between the valve stem and its

valve guide is greater than the specification, the
valve and valve guide must be replaced as a set.

3. Measure the diameter of the valve stem at three

points. See FIGURE 108. If diameter of the valve stem
is less than the specifications shown in the SPECIFICA-
TIONS.
9743

3. Use a valve spring tester to check the valve springs. A
typical tester is shown in FIGURE 109. The specifica-
tions for the valve springs are shown in the SPECIFI-
CATIONS, FIGURE 109.
4. If the valves need grinding, see the valve specifica-
tions in FIGURE 108.
Valve Guides, Replacement
Special Tools: Valve guide replacer (HYSTER Part
No. 320910 or Isuzu Part No.
9852312120)
Remove the valve guides with the special tool as shown
in FIGURE 12.
Use the special tool to install the valve guides as shown
in FIGURE 13. Apply clean engine oil to the valve
guide during installation. Install the valve guide so that
it extends 13 mm (0.512 in) above the surface of the cyl-
inder head.
DIMENSION A = 13 mm (0.512 in)
FIGURE 13. VALVE GUIDES, INSTALLATION
Valve Seats, Inspection
1. Check the valve seats for wear and damage. Before
any work is done on the valve seats, make sure the valve
guides are good.
2. Check the depth of the valve below the face of the cyl-
inder head. The service limit for the depth of the inlet
valve head below the surface of the cylinder head is 1.28
mm (0.050 in). The service limit for the depth of the ex-
haust valve head below the surface of the cylinder head
is 1.20 mm (0.047 in). See the SPECIFICATIONS,
FIGURE 107. If the measurement of the depth is more
than the specification, replace the valve seat.
3. Check the width of contact from the valve. If the
width is more than 2.0 mm (.08 inch), repair the valve
seat. The specifications for the valve seats are shown in
FIGURE 107.

9
4. A correction for minimum wear and damage to the Valve Seats, Removal
valve and valve seat can be done by a process called
1. Use an electric welder and weld a small bead on the
lapping. When the valve seats are lapped, keep the
circumference of the valve seat. See FIGURE 15. Make
valve seat as narrow as possible. Make sure all of the
sure that you do not weld between the valve seat and the
lapping compound is removed from the valve and valve
cylinder head.
seat when the process is completed.
2. Let the cylinder head cool for 5 to 15 minutes, then use
5. Damaged valve seats can be repaired with a cutter a small prybar or a screwdriver to remove the valve seat.
tool. See FIGURE 14. If the valve seat can not be re-
paired so that the valve depth is within the specifica- 1
3
tions, the valve seat must be replaced. 2
1

Repair
Special Tools: Cutter for inlet valve seats
Cutter for exhaust valve seats
Pilot for use with valve seat cutters
Handle for valve seat cutters

1. WELD BEAD 1. USE A SCREWDRIVER

1. Use a cutter with 15, 45, and 75 blades. Install the 2. VALVE SEAT TO REMOVE THE
correct cutter into the valve seat that is to be repaired. 3. CYLINDER HEAD VALVE SEAT
Carefully turn the cutter in a clockwise direction. Re-
FIGURE 15. VALVE SEAT REMOVAL
move only the minimum metal to repair the valve seat.
Keep the valve seat as narrow as possible. Valve Seats, Installation
1. Clean the bore for the valve seat.
2. Use a press to install a new valve seat. See
FIGURE 16.
3. After installation, check the depth of the valve and the
width of contact. See FIGURE 107.

FIGURE 14. CUTTER FOR VALVE SEATS 2

2. When the valve seat has been cut, remove the cutter
and pilot. Clean the valve port area and remove any par-
1. ADAPTER
ticles. 2. VALVE SEAT
3. PRESS
3. Use the lapping process to make sure the valve and
valve seat fit tightly together. FIGURE 16. VALVE SEAT INSTALLATION

Valve Springs, Inspection

4. Check the valve depth. If the valve seat is badly dam-
aged or worn, replace the valve seat as described in the Check the valve springs for damage. The specifications
following paragraphs. for the valve springs are shown in FIGURE 109.

10
Valves, Installation
Special Tools: Valve Seal Installation Tool
Isuzu Part No. 5884020330)

1. Use engine oil to lubricate the inner surface of the oil

seal for the valve stem. A special tool is available to in-
stall the oil seal on the valve guide. Install the oil seal on
the valve guide. See FIGURE 17.

FIGURE 19. INSTALL THE RETAINERS FOR

THE VALVE SPRING

Push Rods, Inspection

Put the push rod on a flat plate as shown in FIGURE 20.

FIGURE 17. INSTALLATION, OIL SEAL FOR
THE VALVE STEM
2. Lubricate the valve stems with engine oil. Install the
valves in their correct positions in the cylinder head.
Roll the push rod on the flat plate and check the variation
with a spacer gauge. If a push rod is more than 0.3 mm
(0.012 in) from straight, it must be straightened or re-
placed.
Check the ends of the push rod for wear and damage. Re-
place a worn or damaged push rod.

3. Install the seat washer, valve spring, and valve spring

cap on a valve stem. One end of the valve spring has a
spot of pink paint. See FIGURE 18. This end of the
valve spring must be installed next to the cylinder head.

1. PAINT SPOT
FIGURE 20. CHECK FOR A BENT PUSH ROD

1
FIGURE 18. VALVE SPRING
4. Use the spring compressor to compress the valve
spring. See FIGURE 19. Install the retainers that hold
the valve spring assembly to the valve stem. Repeat step
2 through step 4 for all of the valves.
Rocker Arms,
Disassembly And Inspection
Disassemble the rocker arm assembly. See FIGURE 21.
Remove the snap ring from the end of the shaft. Push the
spring, rocker arms and the brackets from the shaft.
Make sure to keep the parts in their correct order. See the
specifications for the rocker arms and rocker arm shaft
are shown in the SPECIFICATIONS.

11
 14

13
10

9 12
7 11

6
8
5

4
3

1. CAM FOLLOWER (TAPPET) (8)

2. PUSH ROD (8)
3. END PLUG (2)
4. SNAP RING (2)
5. ROCKER ARM (8)
2 6. ADJUSTMENT SCREW (8)
7. JAM NUT (8)
8. BRACKET, ROCKER ARM SHAFT (4)
9. WASHER (4)
10. ROCKER ARM BOLT (3)
11. WASHER, ROCKER SPRING (6)
12. SPRING (3)
1 13. ROCKER ARM SHAFT
14. CAPSCREW (1)

FIGURE 21. ROCKER ARM ASSEMBLY

9724
1. Check the rocker arm shaft as shown in FIGURE 22.
Turn the shaft and make a note of the highest and the
lowest reading on the dial indicator. If the difference be-
tween the readings is less than 0.6 mm (0.024 inch), use
a press to straighten the shaft. Do not apply heat to the
shaft. If the difference between the readings is greater
than 0.6 mm (0.024 inch), replace the shaft.

2. Check the rocker arm shaft for wear. Use a microme-

ter and measure the diameter of the shaft at the locations
for the rocker arms. If the diameter at any of the loca-
FIGURE 22. CHECK THE ROCKER ARM tions is less than 18.85 mm (0.742 inch), replace the
SHAFT rocker arm shaft.

12
3. Inspect the rocker arms for wear. Find the clearance and tighten the bolts to a final torque of 103 N.m (76 lbf
between the rocker arm and the rocker arm shaft. If the ft).
clearance is more than 0.2 mm (0.008 inch), replace the
rocker arm or the rocker arm shaft. Make sure the oil
ports are clean. See FIGURE 23. 13 5 4 12
17 9 1 8 16
1

18 10 2 7 15
14 6 3 11

1
1. OIL PORT
See the SPECIFICATIONS for the internal diameter
of the rocker arm
FIGURE 23. CHECK THE ROCKER ARM
4. Make sure the surfaces are not worn or damaged
where the rocker arm pushes on the valve stem. Use an
oil stone to remove minor wear patterns. A badly worn
or damaged rocker arm must be replaced.
5. Check the push rods for damage and replace as neces-
sary.
FIGURE 24. TIGHTENING SEQUENCE FOR
THE CYLINDER HEAD BOLTS
5. Lubricate the push rods with engine oil and then in-
stall them in the engine.
CAUTION
When the rocker arm assembly is installed, tighten
each bolt that holds the brackets in a minimum of
three steps in a sequence. This action is to prevent
bending the rocker arm shaft. Tighten the inner
bolts first and then work away from the center of the
rocker arm assembly.

Rocker Arm Shaft, Assembly 6. Install the rocker arm assembly. Tighten the bolts
1. The largest oil hole in the rocker arm shaft goes to- evenly to a final torque of 54 N.m (40 lbf ft). Tighten the
ward the fan end of the engine. bolts for the inner brackets first.

2. Assemble the rocker arm assembly as shown in 7. Install the glow plugs in the cylinder head. Tighten the
FIGURE 21. Apply engine oil to the parts during assem- glow plugs to 23 N.m (17 lbf ft). Install the glow plug
bly. connector.

3. Install the rocker arm assembly to the cylinder head

during installation of the cylinder head. 1. GASKET 3
2. ORING
Cylinder Head, Installation 3. FUEL INJECTOR 5
4. HOLDER BRACKET
4
1. Clean the surface of the cylinder head and the surface 5. WASHER
of the engine block.
2. Install the cylinder head gasket on the engine block so
that the TOP mark is up. Do not use a sealant on the 2
gasket. 1

3. Install the cylinder head on to the engine block. Care-

fully align the cylinder head gasket and cylinder head.
4. Lubricate the threads of the cylinder head bolts with
engine oil. Install and tighten the bolts in two sequences.
Tighten the bolts to a torque of 83 N.m (62 lbf ft) in the
sequence shown in FIGURE 24. Use the sequence again
FIGURE 25. FUEL INJECTOR ASSEMBLY
8. See FIGURE 25. Install gaskets (1) and Orings (2)
for each fuel injector. Install the fuel injectors (3) and the
holder brackets (4) to the cylinder head. Install the nuts

13
and washers (5) for the holder brackets. Tighten the nuts
to 38 N.m (28 lbf ft). See FIGURE 26.
FIGURE 26. TIGHTEN THE NUT FOR THE
HOLDER BRACKET FOR THE FUEL INJECTOR
11. Install the fuel lines and the fuel filter. See
FIGURE 29. Connect the fuel injection lines to the fuel
injectors and temporarily tighten the sleeve nuts.
NOTE: If the fuel injection pump is installed at this
step, install the fuel lines and the fuel filter. If the fuel
injection pump is not installed, do this step after the fuel
injection pump is installed.
Install the support clips in their original positions so that
there is no stress on the fuel injection lines. A stress on
the fuel injection line can cause a break during opera-
tion. When the fuel injection lines and the support clips
are in the correct position, tighten the sleeve nuts to 35
N.m (26 lbf ft).

9. Install a new gasket for the inlet manifold. Install the

gasket so that the end with the sharp corners is toward
the fan end of the engine. Install the inlet manifold. See
FIGURE 27.

FIGURE 29. INSTALLATION OF THE FUEL

INJECTION LINES
12. Install the thermostat housing to the cylinder head.
See FIGURE 30.

FIGURE 27. INLET MANIFOLD 1 1. COVER

2. GASKET
INSTALLATION
3. THERMOSTAT
4. GASKET
10. Install a new gasket for the exhaust manifold. Install 2 5. MANIFOLD
6. CLAMP
the exhaust manifold. Tighten the capscrews for the ex-
haust manifold evenly in a minimum of three steps and 3
in the sequence shown in FIGURE 28. Connect the ex-
haust pipe to the exhaust manifold. 4

1 8 5
5 4 6

FIGURE 30. THERMOSTAT HOUSING

13. Install the coolant pump. See FIGURE 96. Tighten
6 2 3 7 the capscrews for the coolant pump to 20 N.m (15 lbf ft).
FIGURE 28. INLET MANIFOLD 14. Install the coolant hoses to the thermostat housing
INSTALLATION and coolant pump.

14
15. Adjust the valves as described in Checks and Adjust-
ments.
16. Install the rocker arm cover and the sound shields.
17. Install the front and rear engine lifting eyes.
23. Install the pulley for the cooling fan and the drive
belt. Install the cooling fan. Adjust the drive belt to the
correct tension.
24. Install and connect the air cleaner.

18. Install the oil pipe from the fuel injection pump to the
engine block. TIMING GEAR CASE

19. Install the alternator and its adjustment bracket.

20. Install a new engine oil filter.
21. Install the oil pressure switch if it was removed.
22. Connect the coolant hoses. Fill the cooling system
with coolant.
Removal (See FIGURE 31.)
The engine is normally removed from the lift truck to re-
move the timing gear case. There are separate covers on
the timing gear case that can be removed to check the
timing indicators.

1. CAPSCREW 12
2. WASHER
3. CRANKSHAFT DAMPER PULLEY 10
4. CAPSCREW (4) 11
5. COVER, TIMING CHECK (2) 9
6. COVER, SOUND SHIELD
7. SOUND SHIELD, RUBBER
8. OIL SEAL, CRANKSHAFT
9. COVER, TIMING GEAR CASE
10. ORING
11. DOWEL PIN (2) 7
12. TIMING GEAR CASE 8
6 13
5

4 14
5
15
16 19 20
17
18
2
1 21

3 22

26 23
24
13. CAPSCREW (2) 25
14. GASKET, 27
TIMING CHECK COVER (2)
22. SHAFT, IDLER GEAR B
15. CAPSCREW (4)
23. IDLER GEAR B
16. WASHER (7)
24. WASHER
17. CAPSCREW (1) (6)
25. CAPSCREW
18. CAPSCREW (2)
27 26. OIL PIPE, TIMING GEAR
19. RETAINER PLATE
27. CAPSCREW (2)
20. IDLER GEAR A
28 28 28. WASHER (2)
21. SHAFT, IDLER GEAR A

FIGURE 31. TIMING GEAR CASE

15
1. Use a puller to remove the crankshaft damper pulley
and dust seal. See FIGURE 32. Use a block of wood
next to the flywheel to prevent the crankshaft from turn-
ing.
The maximum amount of clearance between each of the
gears is 0.3 mm (0.012 inch). Use the following proce-
dure:
a. Set a dial indicator so that it can measure the rota-
tion of the gear to be checked.
b. Hold the two gears to be checked in a fixed posi-
tion.
c. Rotate the gear to be checked to its limit in each
direction. Read the maximum and minimum val-
ues on the dial indicator. If the clearance is greater
than the limit shown in the SPECIFICATIONS,
one or both of the gears must be replaced.

5. Use a thickness gauge to measure the clearance be-

tween idler gear A and its retainer plate. See
FIGURE 34. The service limit for the clearance be-
FIGURE 32. REMOVE THE CRANKSHAFT tween the parts is 0.2 mm (0.008 in). See the SPECIFI-
DAMPER PULLEY CATIONS.

2. Remove the sound shield cover and the rubber sound

shield from the timing case cover.

5 6

FIGURE 34. CHECK THE CLEARANCE

3 BETWEEN IDLER GEAR A AND THE
RETAINER PLATE
2 6. Remove idler gear B and its shaft.
1
1. CRANKSHAFT GEAR 7. Remove idler gear A and its retainer plate and shaft.
2. IDLER GEAR A
3. IDLER GEAR B
4. CAMSHAFT TIMING GEAR CAUTION
5. CAVITY FOR COOLANT PUMP Do not turn the camshaft or the crankshaft when the
6. OPENING FOR FUEL INJECTION PUMP idler gear is removed and the valve mechanism is in-
FIGURE 33. TIMING GEAR ARRANGEMENT stalled. If either shaft is turned, damage will occur to
the valve mechanism. To prevent damage to the
3. Remove the capscrews that hold the timing gear cover valve mechanism, remove the rocker arm assembly
to the timing gear case. Remove the timing gear cover. when working on the timing gears.

4. Use a dial indicator to check the clearance between 8. See FIGURE 35. Remove the bolts that hold the
the gears in the timing gear arrangement before remov- thrust plate for the camshaft gear. Carefully pull the
ing the gears. See FIGURE 33. camshaft timing gear, camshaft, and thrust plate from

16
the engine. Make sure the camshaft journal, cam lobes,
and bearing surfaces are not damaged during disassem-
bly. See Camshaft, Disassembly And Inspection for ad-
ditional information on the camshaft.
FIGURE 35. CAPSCREWS FOR THE THRUST
PLATE FOR THE CAMSHAFT GEAR
9. If the crankshaft gear must be removed, use a puller to
remove the crankshaft gear. Remove the woodruff key
from the crankshaft.
FIGURE 36. REMOVE THE CRANKSHAFT OIL
SEAL
10. Remove the capscrews that hold the timing gear case
to the engine block. Remove the timing gear case and
gasket.
11. Remove the crankshaft oil seal from the timing gear
case. See FIGURE 36.
Inspection, Idler Gear A And Idler Gear
Shaft (See FIGURE 37.)
1. Measure the inner diameter of idler gear A. If the
clearance between the idler gear and the idler gear shaft
is greater than the specifications shown in the SPECIFI-
CATIONS, replace the idler gear.
2. Use a micrometer to measure the outer diameter of the
idler gear shaft. If the idler gear shaft is less than the
specifications shown in the SPECIFICATIONS, replace
the idler gear shaft.
FIGURE 37. INSPECTION, IDLER GEAR A
AND IDLER GEAR SHAFT
Inspection, Idler Gear B Bearings
Measure the bearings in the shaft for idler gear B as
shown in FIGURE 38. If the measurements are not
within the specifications, replace the bearings.
1 = 0.04 to 0.06 mm (0.016 to 0.024 in)
2 = 23.7 to 24.0 mm (0.933 to 0.945 in)
FIGURE 38. BEARING REPLACEMENT, IDLER
GEAR B
Installation
Special Tools: Oil Seal Installation Tool
Isuzu Part No. 5884020610)
17
1. Install the crankshaft oil seal in the timing gear case.
Lubricate the lip of the oil seal with engine oil. Use the
installation tool for the oil seal to install the oil seal in the
timing gear case. Install the oil seal 1 mm (0.039 in) into
the front of the timing gear case. See FIGURE 39.
4

3
1 mm
(0.039 in)
2 7
1
6
5
1. CRANKSHAFT GEAR
2. IDLER GEAR A
FIGURE 39. INSTALL THE CRANKSHAFT OIL 3. IDLER GEAR B
SEAL 4. CAMSHAFT GEAR
5. ALIGN X ON IDLER GEAR A WITH XX
ON THE CRANKSHAFT TIMING GEAR
2. See FIGURE 31. Install the timing gear case (12) to 6. ALIGN Y ON IDLER GEAR A WITH YY
the engine block. Use a new gasket during installation. ON THE CAMSHAFT TIMING GEAR
Tighten the capscrews evenly to 20 N.m (15 lbf ft). 7. ALIGN Z ON IDLER GEAR B WITH Z ON
IDLER GEAR A
3. See Camshaft, Installation for additional information
FIGURE 40. ALIGNMENT OF THE TIMING
to install the camshaft assembly into the engine block. GEARS
See FIGURE 35. Carefully install the camshaft timing
gear, camshaft, and thrust plate into the engine block.
Make sure the camshaft journal, cam lobes, and bearing 7. See FIGURE 40. Lubricate idler gear B with en-
surfaces are not damaged during assembly. Tighten the gine oil. Install idler gear B on its shaft so that the Z
bolts that hold the thrust plate for the camshaft gear to 20 marks on both timing gears are aligned. Install the wash-
N.m (15 lbf ft). Check that the camshaft turns smoothly. er and capscrew on tining gear B. Tighten the caps-
Turn the camshaft so that the YY mark on the cam- crew to 110 N.m (81 lbf ft).
shaft timing gear is toward the center axis of idler gear 8. Install the oil pipe for the timing gear. See
A. FIGURE 31.
4. Install the idler gear shaft for idler gear A. Make 9. Install the timing case cover. Do the following proce-
sure the oil port is toward the top of the engine. dure:
5. Turn the crankshaft so that the XX mark on the a. Before the timing case cover is installed, apply a
crankshaft gear is toward the top of the engine. 3 mm x 5 mm ( 0.012 in x 0.20 in) strip of liquid
sealant to the woodruff key for the crankshaft
6. Lubricate idler gear A with engine oil. Install idler pulley as shown in FIGURE 41.
gear A so that the X and Y marks can be seen. As
idler gear A is installed, align the X mark with the b. Install the Oring in the groove in the timing case
XX mark on the crankshaft gear, and align the Y cover.
mark with the YY mark on the camshaft timing gear.
See FIGURE 40. c. Install an tighten the capscrews to the following
specifications:
Install the retainer plate and the two capscrews. Tighten M8x1.25 = 15 N.m (11 lbf ft)
the capscrews to 20 N.m (15 lbf ft). M12x1.25 = 80 N.m (60 lbf ft)

18
 and washer. Tighten the capscrew to 195 N.m (145 lbf
ft).
1
2
CAMSHAFT

Camshaft, Removal

See TIMING GEAR CASE, REMOVAL for informa-

1. WOODRUFF KEY
2. CRANKSHAFT
FIGURE 41. APPLY LIQUID SEALANT TO THE
WOODRUFF KEY
10. Install the rubber sound shield and the sound shield
cover.
11. Install the crankshaft damper pulley with dust seal.
Use a block to prevent the crankshaft from turning.
Align the crankshaft damper pulley with the woodruff
key and install it in the crankshaft. Install the capscrew
tion about removal of the camshaft from the engine
block.
Camshaft, Disassembly And Inspection
1. Before the camshaft assembly is disassembled, use a
spacer gauge to measure the clearance between the
thrust plate and the camshaft journal. See FIGURE 43.
2. Remove the camshaft timing gear. Put the camshaft in
a vise with soft jaws. Be careful that the camshaft is not
damaged. Remove the capscrew and washer. [The caps-
crew was tightened to 108 N.m (80 lbf ft).] Use a puller
to remove the camshaft timing gear from the camshaft.

2
3

6 1. CAMSHAFT
2. WOODRUFF KEY
3. CAPSCREW (2)
7
4. THRUST PLATE
5. CAMSHAFT TIMING GEAR
6. WASHER
7. CAPSCREW

FIGURE 42. CAMSHAFT ASSEMBLY

19
 1. SPACER
GAUGE
2. THRUST PLATE
3. CAMSHAFT
JOURNAL

3
2 FIGURE 45. CAMSHAFT BEARING
1 INSPECTION

FIGURE 43. MEASURE THE CLEARANCE
BETWEEN THE CAMSHAFT JOURNAL AND
THRUST PLATE
3. Remove the thrust plate.
4. Use a micrometer to check the wear of the camshaft.
Measure the areas of the camshaft as shown in
FIGURE 110. If any of the measurements are less than
the specifications shown in the SPECIFICATIONS and
FIGURE 110., replace the camshaft.
5. Check the run out of the camshaft as shown in
FIGURE 44. Rotate the camshaft and look at the dial in-
dicator. If the difference between the highest and lowest
reading is more than 0.10 mm (0.004 in), replace the
camshaft. See the SPECIFICATIONS.
2. Check the clearance between the bearings and the
camshaft. If the clearance between the inside diameter
of the bearing and the outside diameter of the camshaft
journal is greater than 0.12 mm (0.005 in), replace the
camshaft bearings. See the SPECIFICATIONS.
CAUTION
During installation of the camshaft bearings, the oil
ports in the bearing must be aligned with the oil ports
in the engine block. If the ports are not correctly
aligned, the bearing surfaces will not be lubricated
and will fail.

FIGURE 46. CAMSHAFT BEARING

9748
FIGURE 44. CAMSHAFT INSPECTION
Camshaft Bearing Replacement
Special Tools: Camshaft Bearing Replacer Tool
Isuzu Part No. 5884020380)
1. Inspect the surface of the bearings for wear and dam-
age. See FIGURE 45. See the SPECIFICATIONS. Re-
place the bearings as necessary.
REPLACEMENT
Cam Followers (Tappets)
1. Keep the cam followers in an arrangement so that they
will be installed again in the same position in the engine
block. Inspect the contact surface of the cam follower
for damage and wear. A cam follower will have a
smooth ring where it rubs on the camshaft lobe. A cam
follower with a damaged surface must be replaced. Re-
place a cam follower as necessary.
2. Measure the outside diameter of the cam followers as
shown in FIGURE 47. Replace a cam follower that has

20
specifications less than shown in the SPECIFI-
CATIONS.
3. Measure the diameter of hole for the cam follower in
the engine block as shown in FIGURE 48. Install a new
cam follower if the clearance between the cam follower
and the engine block is greater than the SPECIFICA-
TIONS.
FIGURE 47. CAM FOLLOWER INSPECTION
FIGURE 48. CAM FOLLOWER INSPECTION
Camshaft, Assembly
1. Install the thrust plate.
2. Put the camshaft in a vise with soft jaws. Be careful
that the camshaft is not damaged during assembly. Align
the camshaft timing gear with the woodruff key and in-
stall the timing gear on the camshaft. Make sure the tim-
ing marks on the timing gear are away from the camshaft
so that they can be seen after installation. Lubricate the
capscrew with engine oil and install the capscrew and
washer. Tighten the capscrew to 112 N.m (83 lbf ft).
Camshaft, Installation
1. The cam followers must be installed before the cam-
shaft. Lubricate the cam followers with engine oil and
install them in the engine block.
2. Lubricate the bearings for the camshaft with engine
oil.
CAUTION
If the camshaft bearings were replaced, make sure
the oil ports are aligned before installation of the
camshaft. If the oil ports are not aligned, the bear-
ings will not have correct lubrication.
3. Carefully install the camshaft in the crankcase.
4. Tighten the bolts that hold the thrust plate to the tim-
ing gear case to a torque of 20 N.m (15 lbf ft).
5. Check that the camshaft will rotate smoothly in the
engine block.
LUBRICATION SYSTEM
Oil Pump, Removal And Disassembly
(See FIGURE 49.)
1. Remove the dipstick. Drain the engine oil.
2. Remove the oil sump.
3. Remove the oil pump with the oil tube from the crank-
case.
21
 assembly and the vane. See the specifications in the
SPECIFICATIONS.
6 7

4
FIGURE 50. CHECK THE END CLEARANCES
OF THE ROTOR
3
3. Check the clearances between the rotor and the vane.
8 If the clearance is greater than 0.20 mm (.008 inch), re-
place the rotor and vane set. See FIGURE 51. See the
specifications in the SPECIFICATIONS.

1. OIL TUBE
ASSEMBLY
2. STRAINER
2 ASSEMBLY
3. COVER
4. VANE
5. OIL PUMP BODY
6. PINION
7. PINION PIN
8. ROTOR AND
DRIVE SHAFT

FIGURE 49. OIL PUMP ASSEMBLY

Oil Pump, Inspection

1. Remove the strainer assembly, the pump cover and
the vane.
2. If the oil pump is worn so that the performance is de-
creased, the oil pump must be replaced. Check the end
clearance of the rotor. See FIGURE 50. If the clearance
is greater than 0.15 mm (0.006 inch), replace the rotor
FIGURE 51. CHECK THE CLEARANCES
BETWEEN THE ROTOR AND THE VANE
4. Check the clearances between the vane and the pump
body. See FIGURE 52. If the clearance is greater than
0.40 mm (.016 inch), replace the oil pump. See
FIGURE 52. See the specifications in the SPECIFICA-
TIONS.

22
 FIGURE 52. CHECK THE CLEARANCE FIGURE 54. CHECK THE ROTOR DRIVE
BETWEEN THE VANE AND PUMP BODY SHAFT

If the rotor must be removed from the drive shaft, use a

5. Remove the pinion pin from the drive shaft to remove
the rotor and the pinion. See FIGURE 53. The pinion
has only one hole for the installation of the pinion pin. If
the pinion must be removed, drill a another hole in the
pinion opposite the end of the pinion pin. Use a hammer
and driver to remove the pinion pin.
hammer and driver to remove the pin. See FIGURE 55.
When the rotor is installed on the drive shaft, the pin
must not extend from the surface of the rotor as shown in
FIGURE 56.

FIGURE 53. REMOVE THE PINION PIN FIGURE 55. ROTOR REMOVAL

6. Use a micrometer to measure the outer diameter of the

drive shaft as shown in FIGURE 54. Use a dial indicator
to measure the inner diameter of the pump body. If the
clearance between the drive shaft and the pump body is
greater than 0.20 mm (0.008 inch), replace the oil pump. FIGURE 56. ROTOR INSTALLATION

23
Oil Pump, Assembly And Installation
(See FIGURE 49. And FIGURE 57.)
1. Install the new drive shaft and rotor into the pump
body.
2. Install the pinion on the drive shaft. Use a 5 mm (0.20
inch) drill to make an aligned hole through the pinion
and drive shaft. Install the pinion pin. Use a high
strength threadlock material (Hyster Part No. 226414 or
Locktite 271) to help hold the pinion pin in the hole.
3. Install the cover.
4. Install the strainer assembly. Install the oil tube so
that it is loosely fastened to the oil pump.
FIGURE 57. INSTALLATION, OIL PUMP
5. Install the oil pump in the crankcase. Use a new O
ring on the oil tube. Connect the oil tube and tighten the
fittings.
6. Install the oil sump.
FIGURE 58. INSTALLATION, OIL SUMP
24
Oil Sump, Installation
1. Apply a liquid gasket to the arches of bearing cap No.
5 as shown FIGURE 58. Apply a liquid gasket to the
arches of the timing gear case as shown in FIGURE 58.
2. Install the gasket for the oil sump. Make sure the gas-
ket fits completely into the groove of bearing cap No. 5
and the corners where it joins the engine block. See
FIGURE 59.
FIGURE 59. INSTALLATION, OIL SUMP
3. Install the oil sump and tighten the capscrews. Tight-
en the capscrews in a sequence beginning at the middle
and working toward each end of the oil sump Tighten
the capscrews to 19 N.m (14 lbf ft).
Oil Filter Assembly
The oil filter has a regulator valve to control the oil pres-
sure to the oil filter. See FIGURE 60.
Replace the oil filter as described in the section, PERI-
ODIC MAINTENANCE. Change the oil filter at the
same time engine oil is changed. Use the correct oil ac-
cording to the specifications. Install a new filter car-
tridge. Apply clean oil to the gasket of the new filter car-
tridge. Turn the filter until the gasket touches, then
tighten 1/2 to 3/4 turn with your hand. Start the engine.
Check the area around the oil filter for leaks.
The operation of the regulator valve can be checked
when the engine can be operated. Install an oil pressure
gauge in the oil passage near the oil filter. Run the engine
and check the oil pressure gauge for an indication when
the regulator valve opens. If the regulator pressure is not
correct according to the SPECIFICATIONS, replace the
regulator valve.
 1
2
3 6
1
3
4
2
6
7
5
4
5

12
6

11
10 7

8 9 8
1. FILTER CARTRIDGE
2. BODY, OIL FILTER
3. GASKET 8. REGULATOR VALVE
4. PLUG 9. PLUG
5. ORING 10. PLUG
6. ORING 11. GASKET
7. ORING 12. CAPSCREW (2)

FIGURE 60. OIL FILTER ASSEMBLY

PISTONS AND CONNECTING RODS

(See FIGURE 61.) 9
10 8
NOTE: See the sections on Cylinder Liners for the se-
lection and fitting of pistons to new cylinder liners. 1. COMPRESSION RING NO. 1
2. COMPRESSION RING NO. 2
3. OIL CONTROL RING
Pistons And Connecting Rods, Removal 4. PISTON
5. PISTON PIN
1. Remove the cylinder head as described in Cylinder
6. SNAP RING (2)
Head, Removal. 7. CONNECTING ROD
8. BEARING HALF (2)
2. Remove the oil sump. 9. BEARING CAP
10. NUT (2)
3. Clean the carbon from the top of each cylinder.
FIGURE 61. PISTON AND CONNECTING ROD
4. Remove the bearing caps from the connecting rods. ASSEMBLY
Keep the bearings in their order in which they were in-
stalled. Keep each bearing cap with its connecting rod. Disassembly
5. Push the piston and connecting rod assembly from the 1. During disassembly of the piston and connecting rod
top of the cylinder. Keep the piston and connecting rod assemblies, keep each set of parts with its assembly. Put
assemblies in an arrangement so that they can be in- a piston and connecting rod assembly in a vise with soft
stalled in the engine again in the same order from which jaws. Be careful that the assembly is not damaged in the
they were removed. vise.

25
2. Use a piston ring expander to remove the piston rings. 9739

3. Use snap ring pliers to remove the snap rings at each

end of the piston pin. Use a hammer and a brass driver to
remove the piston pin as shown in FIGURE 62.

9736

FIGURE 63. CHECK THE END CLEARANCE OF

THE PISTON RING

2. Measure the clearance between the piston ring and the

groove in the piston as shown in FIGURE 64. See the
SPECIFICATIONS for the clearance of the piston rings
in their grooves.
FIGURE 62. PISTON PIN, REMOVAL

Pistons, Inspection And Repair

Visually inspect the pistons for wear and cracks. Re-

place a piston that is worn or has damage.

NOTE: If the cylinder liner is worn or damaged, check

the clearance between the piston and the cylinder liner
9738
after the cylinder liner has been replaced.

FIGURE 64. CLEARANCE BETWEEN THE

Piston Rings, Inspection
PISTON RING AND THE GROOVE

1. Measure the end clearance of each piston ring as
shown in FIGURE 63. Install the piston ring into the
cylinder where it will be used. Use a thickness gauge to
measure the end clearance. Make sure the piston ring is
perpendicular to the cylinder wall when the end clear-
ance is measured. See the SPECIFICATIONS for the
end clearance of the piston rings. If the end clearance for
any of the piston rings is greater than the specifications,
replace the piston ring.
Piston Pins, Inspection And Repair
1. Inspect the piston pins for wear. Measure the diameter
of the pin. If the diameter of the piston pin is less than the
size shown in the SPECIFICATIONS, replace the piston
pin.
2. Measure the diameter of the piston pin hole in the pis-
ton. If the clearance between the piston pin and piston is
greater than the specifications, replace the worn parts.

26
Connecting Rods, Inspection And Repair
1. Clean and inspect the parts for wear and damage.
Check the alignment of the connecting rods with a test
fixture. See FIGURE 65.
100 mm 100 mm
Alignment (4 in) (4 in) Alignment
+ 0.015 mm
_ +
_ 0.015 mm
(+_ 0.006 in) (+_ 0.006 in)
The large and small bores in the connecting rod
must be square and parallel with each other within
the limits of + 0.20 mm (0.008 in). The measure-
ment is made at 100 mm (4.0 in) on each side of
the axis of the connecting rod. The alignment must
be within the limits of + 0.15 mm (0.006 in).
FIGURE 65. CHECK THE ALIGNMENT OF THE
CONNECTING ROD
2. Check the clearance between the bushing in the con-
necting rod and the piston pin. The maximum clearance
is shown in the SPECIFICATIONS. If the bushing is
worn, use a press to remove the bushing from the con-
necting rod. Use the press to carefully install a new
bushing. Use a reamer to increase the inner diameter of
the bushing to the standard size for the piston pin.
9730
FIGURE 66. CHECK THE CLEARANCE
BETWEEN THE CONNECTING ROD AND
THE CRANKSHAFT
3. Install the connecting rod in its position on the crank-
shaft. Check the axial clearance between the connecting
rod and the crankshaft as shown in FIGURE 66. See the
SPECIFICATIONS. The maximum clearance is 0.35
mm (0.014 inch).
New Pistons, Selection
CAUTION
The correct piston grade must be selected to keep the
clearances correct between the cylinder liner and
piston or the engine will be damaged.
If a new piston must be installed because of damage or a
new cylinder liner was installed, the following proce-
dure must be used to select the correct piston:
a. Measure the bore of the cylinder after it is in-
stalled (see Replacement Of A Cylinder Lin-
er). See FIGURE 67. The measurements are
made at the following points in the cylinder liner:
point 1 = 20 mm (0.79 in)
point 2 = 160 mm (6.30 in)
FIGURE 67. MEASURE THE BORE OF THE
CYLINDER LINER
b. Measure the outside diameter of the piston as
shown in FIGURE 68. The measurement is made
on the piston skirt approximately 70 mm (2.76 in)
below the top of the piston.
c. The piston grade and cylinder liner to piston
clearances are shown in the SPECIFICATIONS.
27
 2. Use snap ring pliers to install one of the snap rings in
the piston. Heat the piston in an oil bath to approximate-
ly 77C (170F) for easier installation of the piston pin.
Push the piston pin into the piston and connecting rod.
Install the other snap ring. Check that the connecting rod
moves smoothly on the piston pin.

3. Use a piston ring expander to install the piston rings as

shown in FIGURE 70. During installation, make sure
the mark on the piston rings is toward the top of the pis-
ton. Make sure there is no gap on either side of the ex-
pander coil before the oil control ring is installed. Make
FIGURE 68. MEASURE THE PISTON sure the piston rings will move smoothly in their
grooves after they are installed.
Pistons And Connecting Rods, Assembly
And Installation
Special Tools: Piston ring expander
Piston installation tool
(piston ring compressor)

CAUTION
The engine will be damaged if the pistons and con-
necting rods are installed in the wrong direction.
1. Assemble the connecting rod and the piston. Make
sure that the connecting rod is installed in the piston as
shown in FIGURE 69. Hold the connecting rod in a vise
1. OIL CONTROL RING
while the piston is installed. 2. COMPRESSION RING NO. 2
3. COMPRESSION RING NO.1
1

1. THE PISTON MUST BE FIGURE 70. ASSEMBLY OF THE PISTON

INSTALLED IN THE RINGS
ENGINE WITH THE
NOTCH MARK TOWARD
THE COOLANT PUMP 4. Apply clean engine oil to the piston rings and the jour-
2. THE ISUZU CAST nals for the connecting rods. When a piston is installed
MARK MUST BE into its cylinder, arrange the gaps in the piston rings so
INSTALLED IN THE that they are 120 degrees apart from each other. See
SAME DIRECTION AS 2
THE NOTCH MARK ON
FIGURE 71.
THE PISTON.
5. Install the upper half of the bearing in the connecting
rod. Make sure the parts are clean. Rotate the crankshaft
so that the bearing journal for piston being installed is at
BDC.

FIGURE 69. PISTON AND CONNECTING ROD 6. Apply a thin coat of molybdenum disulfide grease to
ARRANGEMENT the piston skirts. Use a piston ring compressor and in-
stall the piston assemblies into their correct cylinders.
WARNING During installation, the small mark on the top of the pis-
Hot parts. Wear protective clothing and gloves to ton must be toward the end of the engine with the cool-
prevent burns. ing fan. See FIGURE 69. or FIGURE 71.

28
 4. Remove the oil pump.
FAN END OF ENGINE
5. Remove the bearing caps for the connecting rods.

C A 6. Remove the caps for the main bearings. Remove the

outer caps first and work toward the center cap.

7. Before removing the crankshaft, measure the clear-

ance between the crankshaft and thrust bearings at the
B middle main bearing location. See FIGURE 72. Move
A POSITION OF THE GAP FOR THE the crankshaft fully forward before making the mea-
OIL RING surement. The maximum amount of clearance (axial
B POSITION OF THE GAP FOR THE
SECOND COMPRESSION RING clearance) is shown in the SPECIFICATIONS. If the
C POSITION OF THE GAP FOR THE amount of axial clearance is greater than the specifica-
FIRST COMPRESSION RING
tion, then the thrust bearings must be replaced.
FIGURE 71. ARRANGEMENT OF THE PISTON
RINGS ON THE PISTON 8. Remove the crankshaft. Keep the main bearings for
the crankshaft in their correct order.
CAUTION
The number on the bearing cap must be the same
number as the connecting rod. The arrow marks of
all the bearing caps must point toward the fan end of
the engine.

NOTE: See the section How To Check The Clearance

Between The Crankshaft Bearings And Their Journals
when the bearing for the connecting rod is installed.

7. Install the bearing in the bearing cap for the connect-

9749
ing rod. Apply clean engine oil to the bearing surface
and then install the bearing and bearing cap on the con-
necting rod. Tighten the nuts 84 N.m (62 lbf ft). FIGURE 72. CHECK THE CLEARANCE
BETWEEN THE CRANKSHAFT AND THRUST
8. Install the cylinder head as described in Cylinder BEARINGS
Head, Installation.

9. Install the oil pump. See Oil Pump, Assembly And Crankshaft, Inspection And Repair
Installation and FIGURE 57. 1. Carefully clean the crankshaft. There must not be any
10. Install the oil sump. See Oil Sump, Installation oil on the surfaces to be inspected.
and FIGURE 58. 2. Visually inspect the crankshaft for wear, cracks or
other damage. Replace the crankshaft if it has cracks. In-
CRANKSHAFT AND MAIN BEARINGS spect the oil seal surfaces for wear and damage
Crankshaft, Removal NOTE: The surface of the crankshaft has been hard-
ened by a process called tufftrided (a nitriding treat-
1. Remove the flywheel and flywheel housing. See ment) to increase its surface strength. Worn or damaged
Flywheel, Removal. journal surfaces of the crankshaft can not be repaired by
grinding.
2. Remove the timing gear case as described in Timing
Gear Case, Removal.
3. The following procedure can be used to check the ni-
3. Remove the oil sump. trided surface of the crankshaft:

29
 a. Prepare a test solution of 5 to 10% solution of am- 4. Check the crankshaft as shown in FIGURE 74. Rotate
monium cuprous chloride dissolved in distilled the crankshaft one turn and check the reading on the dial
water. indicator. If the difference between the highest and the
lowest reading is more than 0.06 mm (0.002 inch), re-
b. This procedure will not give correct results if pair or replace the crankshaft.
there is any oil on the surfaces to be inspected.
Hold the surface to be tested as level as possible
to prevent the test solution from flowing from the
small test area.

c. See FIGURE 73. Carefully apply a drop of the

test solution to the surface to be inspected. Do not
apply the test solution to any surface within ap-
proximately 10 mm (0.4 in) of an oil port. 9734

FIGURE 74. CRANKSHAFT INSPECTION

1. Carefully apply a drop of the test solution to the
surface of the bearing journal or other surface to be
inspected.
2. Do not apply the test solution to any surface
within approximately 10 mm (0.4 in) of an oil port.
5. Use a micrometer to measure the journals for the bear-
ings of the crankshaft. Make the measurements at the
positions shown in the SPECIFICATIONS. (See
FIGURE 112.)

1 Crankshaft Timing Gear, Replacement

2
1. Use a puller to remove the crankshaft timing gear as
shown in FIGURE 75. Remove the woodruff key from
the crankshaft.

FIGURE 73. CHECK THE NITRIDED SURFACE

OF THE CRANKSHAFT

d. Wait approximately 30 to 40 seconds. If the test

area becomes the color of copper, the nitrided
surface is worn and the crankshaft must be re-
placed. If the test surface does not change color,
the nitrided surface is good.
FIGURE 75. CRANKSHAFT TIMING GEAR,
e. Use steam to clean the test solution immediately
REMOVAL
after the test. The test solution will cause corro-
sion and damage the crankshaft if it is not re- 2. Install the woodruff key in the crankshaft. Align the
moved immediately after the test. slot in crankshaft timing gear with the woodruff key. In-

30
stall the crankshaft timing gear as shown in the envelope for the Plastigage to measure the width of
FIGURE 76. the plastic at its widest point. The scale will indicate the
clearance in millimetres or thousandths of an inch.

FIGURE 77. PLASTIGAGE ON A BEARING

FIGURE 76. CRANKSHAFT TIMING GEAR, JOURNAL
INSTALLATION
7. If the clearance is greater than the specifications, se-
How To Check The Clearance Between lect a new undersize bearing set and install it. Measure
The Crankshaft Bearings And Their the clearance again. If the clearance can not meet speci-
Journals fications with the available undersize bearings, the
crankshaft must be replaced.
1. Use Plastigage or equivalent to check the clearance.
The procedure is similar for both connecting rod bear-
ings and main bearings. If the engine has been removed
from the lift truck put the engine so that the crankshaft is
up. The weight of the crankshaft must be against the up-
per bearing half so that the total clearance can be mea-
sured correctly. If the engine is still in the lift truck, the
crankshaft must have a support to remove any additional
clearance between the upper bearing half and its journal.
2. All main bearing caps must be installed and their
capscrews tightened to the specifications.
FIGURE 78. MEASURE THE PLASTIGAGE
3. Check the rear main bearing first. Remove the cap for ON A BEARING JOURNAL
the rear main bearing. The procedure for checking the 8. If the clearance is within specifications, lubricate the
clearance of the other bearings is similar. bearing with engine oil and install the main bearing and
4. Clean the oil from the bearing half and journal to be bearing cap. Tighten the capscrews on the main bearing
checked. Put a piece of Plastigage across the full width cap to the correct specifications.
of the bearing journal as shown in FIGURE 77. Do not 9. Turn the crankshaft to make sure it rotates smoothly.
rotate the crankshaft when the Plastigage is between the
main bearing and its journal. Crankshaft, Installation
1. Before installation of the crankshaft, make sure all the
5. Install the main bearing cap and tighten the
capscrews. (See TORQUE SPECIFICATIONS.) The passages for oil in the crankshaft are clean.
capscrews must be tightened to their final torque or NOTE: See the following section How To Check The
there will be an error in the measurement. Clearance Between The Crankshaft Bearings And Their
Journals when the crankshaft is installed.
6. Remove the main bearing cap. The Plastigage will be
compressed and wider and will adhere to either the main 2. Clean the main bearings. Install the main bearings in
bearing or its journal. See FIGURE 78. Use the scale on the crankcase. The upper main bearings have an oil pas-

31
sage and an oil groove. The lower bearing half has a
smooth surface. Apply clean engine oil to the surface of
the bearings.
3. Carefully install the crankshaft.
4. Install the thrust bearings at the No. 3 main bearing
location. Make sure that the oil grooves in the thrust
bearings are toward the crankshaft. See FIGURE 79.
Push one end of the thrust bearing until both ends are
even with the surface of the crankcase.
2
3
2
1 POSITION
1. THRUST WASHER
2. OIL GROOVES
3. THE OIL GROOVES MUST BE
INSTALLED TOWARD THE THRUST
SURFACE OF THE CRANKSHAFT
FIGURE 79. INSTALLATION OF THE THRUST
WASHERS
CAUTION
It is very important that the thrust bearings are in-
stalled correctly. If they are installed wrong, the
crankshaft will be damaged because it will not re-
ceive correct lubrication. Install the thrust bearings
so that the oil grooves are toward the thrust surface
of the crankshaft.
32
5. Install the main bearings into the bearing caps. Apply
clean engine oil to the surface of the bearings and install
the bearing caps. The arrow marks of all the bearing
caps must point toward the fan end of the engine.
6. Apply silicon adhesive to the crankcase at the No. 5
main bearing position as shown in FIGURE 80.
FIGURE 80. APPLY SILICON SEALANT TO
THE CRANKCASE AT NO. 5 MAIN BEARING
NOTE: The No.2 and No. 4 bearing caps have the same
shape. The bearing cap that has the arrow mark on it is
the No. 2 bearing cap. The No. 4 bearing cap does not
have a mark.
During installation of the main bearing caps, adjust the
position of the No. 1 and No. 5 caps. The outer surface
of each bearing cap must be even with the surface of the
crankcase. Tighten the bolts for the main bearing caps to
a torque of 95 N.m (70 lbf ft) while the crankshaft is ro-
tated. Start at the No. 3 main bearing and work toward
each end of the crankshaft so that the No. 1 and No. 5
main bearing caps are tightened last. Repeat the tighten-
ing sequence and tighten the bolts to a final torque of
167 N.m (123 lbf ft).
7. Install the oil seals in the grooves of the No. 1 and No.
5 main bearing caps. Apply a sealant to them during in-
stallation. Use a screwdriver to push the seals approxi-
mately 0.5 mm (.020 inch) below the surface of the
crankcase. See FIGURE 81.
8. Install the timing gear case as described in Timing
Gear Case, Installation.
 10. Install the oil pump. See Oil Pump, Assembly And
Installation and FIGURE 57.

11. Install the oil sump. See Oil Sump, Installation

and FIGURE 58.

12. Install the flywheel housing and flywheel.

FLYWHEEL AND RING GEAR,

H2.003.00XL (H4060XL)

FIGURE 81. INSTALLATION, CRANKSHAFT
OIL SEAL
9. Install the connecting rods as described in Connect-
ing Rods, Assembly And Installation.
NOTE: The engine for the H2.003.00XL
(H4060XL) has a chain drive assembly for the hydrau-
lic pump. See THE HYDRAULIC PUMP DRIVE
ASSEMBLY, 1900 SRM 339 for additional informa-
tion.

1. FLYWHEEL HOUSING
2. OIL SEAL
3. SHIMS
1 4. DRIVE SPROCKET
5. LEAF CHAIN
6. SPECIAL BLOCK (UPPER)
7. SPECIAL BLOCK (LOWER)
8. BEARING
9. SNAP RING
10. DRIVEN SPROCKET
2

3
4
5

8
11742

10 7
9 8

FIGURE 82. CHAIN DRIVE ASSEMBLY, H2.003.00XL (H4060XL)

33
Flywheel, Removal 1. See FIGURE 84. Use a hammer and chisel to break
the ring gear. Make sure that you do not damage the fly-
1. Remove two of the capscrews for the flywheel. Install wheel.
alignment pins in these holes to keep the flywheel from
falling. (Use capscrews with the heads removed.) Re-
move the remaining capscrews for the flywheel. Do not
remove the drive sprocket.

2. Check that the leaf chain has not become worn and too
long. See FIGURE 83. The chain must be replaced if di-
mension X is greater than 31.8 mm (1.25 in).

1
FIGURE 84. RING GEAR REMOVAL

2. The ring gear must be heated before it can be installed

on the flywheel. Use an oven that has a temperature con-
trol. Make sure that the ring gear is not heated to more
3
than 200C (390F).

2 WARNING
1. STRAIGHT EDGE Hot parts. Wear protective clothing and gloves to
5 2. LEAF CHAIN prevent burns.
3. DRIVE SPROCKET
4. DIMENSION X
8857 (CHAIN PUSHED DOWN) 3. Install the ring gear on the flywheel. Make sure that
5. DRIVEN SPROCKET the chamfer on the teeth is in the correct direction to-
ward the starter.
FIGURE 83. CHAIN LENGTH
Flywheel, Installation
3. Remove the drive sprocket. Do not let the shims fall.
NOTE: The engine for the H2.003.00XL
Remove the shim set and keep the shims together. Re-
(H4060XL) has a chain drive assembly for the hydrau-
move the oil seal.
lic pump. See THE HYDRAULIC PUMP DRIVE
4. Remove the driven sprocket assembly and the leaf ASSEMBLY, 1900 SRM 339 for additional informa-
chain. If the bearings need replacing, use a puller to re- tion.
move the bearings from the sprocket.
1. Install the flywheel housing and flywheel as follows:
5. If the special blocks need replacing, remove the two
a. If the flywheel housing was removed, install it
capscrews that hold each block to the housing.
on the engine. Use Locktite 222 or Permatex
6. Check the flywheel and ring gear for damage. High Tack sealant on the both sides of the wash-
ers and install the capscrews. Tighten the M10 x
Ring Gear, Replacement 1.25 x 40 capscrews to 55 N.m (41 lbf ft). Tighten
the M12 x 1.5 x 30 capscrews to 94 N.m (69 lbf
WARNING ft). Install the seal in the flywheel housing. Use a
Wear eye protection for this operation to prevent eye sealant on the outside diameter of the seal. Install
injury from metal chips. You will be using a hammer the seal so that it is even with the inside edge (fly-
and chisel to break the ring gear. wheel side) of the flywheel housing.
Before the ring gear is removed, check the position of b. If new bearings are needed, install them on the
the chamfer on the teeth. driven sprocket. Install the special blocks in the

34
 flywheel housing. Tighten the capscrews for the tance from the housing to the face of the sprocket
blocks to 20 N.m (15 lbf ft). is dimension X as shown in FIGURE 85.

d. Install the driven sprocket and the chain. Make

sure the snap ring is on the bearing that fits in the
1. CRANKSHAFT
2. SHIMS torque converter housing. Install the flywheel on
3. FLYWHEEL the drive sprocket. Use Locktite 222 or Perma-
4. DRIVE GEAR tex High Tack sealant on the threads and install
5. DRIVEN GEAR
6. DIMENSION X = the capscrews for the flywheel. Tighten the
31.0 mm (1.22 in) capscrews to 120 N.m (90 lbf ft) in a cross pattern
as shown in FIGURE 86. Lubricate the chain and
sprockets with hydraulic oil.
4
3

2 FIGURE 86. TIGHTENING SEQUENCE

FLYWHEEL AND RING GEAR,

6 X H2.003.20XM (H4065XM)

Flywheel, Removal (See FIGURE 88.)

1. Remove the capscrews for the flywheel, then remove
the flywheel.

2. If necessary, remove the flywheel housing and the

braces.

Ring Gear, Replacement

WARNING
Wear eye protection for this operation to prevent eye
5 11748
injury from metal chips. You will be using a hammer
and chisel to break the ring gear.

FIGURE 85. ADJUSTMENT, CHAIN DRIVE Before the ring gear is removed, check the position of
ASSEMBLY, H2.003.00XL (H4060XL) the chamfer on the teeth.

c. Install the drive sprocket on the crankshaft 1. See FIGURE 84. Use a hammer and chisel to break
without the flywheel. Use shims between the the ring gear. Make sure that you do not damage the fly-
crankshaft and the drive sprocket so that the dis- wheel.

35
 3. Install the ring gear on the flywheel. Make sure that
the chamfer on the teeth is in the correct direction to-
ward the starter.

Flywheel, Installation (See FIGURE 88.)

1. Install the flywheel housing and flywheel as follows:

a. If the flywheel housing was removed, install it

FIGURE 87. RING GEAR REMOVAL
2. The ring gear must be heated before it can be installed
on the flywheel. Use an oven that has a temperature con-
trol. Make sure that the ring gear is not heated to more
than 200C (390F).
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
on the engine. Install the capscrews and bolt.
Tighten the special bolt (2) and nut first. Tighten
the nut to 46 N.m (34 lbf ft). Tighten the other
capscrews as shown in FIGURE 88.
b. Install the flywheel on the crankshaft. Apply an
adhesive sealant on the threads of the capscrews,
then install the capscrews for the flywheel. Tight-
en the capscrews to 120 N.m (89 lbf ft) as shown
in the sequence in FIGURE 88.

1 3 4
3 3 1. FLYWHEEL HOUSING
2. SPECIAL BOLT AND NUT,
4 2 46 N.m (34 lbf ft)
3. CAPSCREWS TO ENGINE
BLOCK (M10), 55 N.m (41 lbf ft)
4. CAPSCREWS TO ENGINE
BLOCK (M12), 94 N.m (69 lbf ft)

12767

TIGHTENING SEQUENCE

5
5. CAPSCREWS TO BRACES,
5
98 N.m (72 lbf ft)
5 5 6. FLYWHEEL CAPSCREWS,
6 120 N.m (89 lbf ft)

FIGURE 88. FLYWHEEL AND HOUSING, H2.003.20XM (H4065XM)

36
 2 5

1. FLYWHEEL HOUSING
2. FLYWHEEL
5 3. SUPPORT PLATE
4. DRIVE PLATE
5. BRACE

FIGURE 89. FLYWHEEL AND HOUSING, H2.003.20XM (H4065XM)

ENGINE BLOCK AND CYLINDER LINERS
Cylinder Liners, Inspection
Inspect the cylinder liner for wear and damage. Measure
the inside diameter of each cylinder liner to find the
amount of wear. Do the measurement of the liner at the
area that is approximately 15 mm (0.6 inch) below the
surface of the engine block. Measure the diameter in a
minimum of two directions: (XX) perpendicular to
the axis of the crankshaft and (YY) parallel to the axis
of the crankshaft. If the inside diameter of the cylinder
liner is more than the SPECIFICATIONS, replace the
cylinder liner.
2 and the special shaft tool to the bottom of the cylinder
CAUTION
The cylinder liners have a chrome surface. Do not try
to repair a cylinder liner that has damage. A dam-
aged cylinder liner must be replaced.
Replacement Of A Cylinder Liner
Special Tools: Cylinder liner remover tool,
Isuzu Part No. 5884020390
Cylinder liner installation tool,
Isuzu Part No. 5884020400
1. To remove the cylinder liner, install the remover tool
liner. Use a press to push the liner from the engine block.
See FIGURE 90.

2. Before installation of the cylinder liners, check the

1
1. CYLINDER LINER REMOVER,
ISUZU PART NO. 5884020390
2. PRESS
FIGURE 90. CYLINDER LINER REMOVAL
surface of the engine block for distortion. Make the
measurements at the positions shown in FIGURE 91. If
the amount of distortion is more than 0.2 mm (0.008 in),
replace the engine block.
CAUTION
9732 The cylinder liners can be easily damaged. Be careful
when handling them. Do not handle cylinder liners
more than necessary because a rust inhibitor has
been applied to their surface.

37

9744
A
E F
C D
B
FIGURE 91. CHECK THE SURFACE OF THE
ENGINE BLOCK FOR DISTORTION
3. Measure the inside diameter of the cylinder block
where the replacement cylinder liner will be installed. A
grade of cylinder liner will be selected according to this
measurement. Measure the diameter at WW, XX,
YY, and ZZ as shown in FIGURE 92. Make the
measurements at approximately 98 mm (3.86 in) below
the surface of the cylinder block. Calculate the average
value of the four measurements to find the correct cylin-
der bore. This measurement will be used with the mea-
surement in step 4 to select the correct grade of cylinder
liner.
FIGURE 92. MEASURE THE CYLINDER
BLOCK DIAMETER
4. Make an XX and YY measurement at three
points on the cylinder liner as shown in FIGURE 93.
38
The following measuring points are below the upper
surface of the cylinder liner:
point 1 = 20 mm (0.79 in)
point 2 = 90 mm (3.54 in)
point 3 = 160 mm (6.30 in)
FIGURE 93. MEASURE THE OUTSIDE
DIAMETER OF THE CYLINDER LINER
Calculate the average value of the six measurements to
find the correct grade of cylinder liner. The grades of
cylinder liners are shown in the SPECIFICATIONS (see
Cylinder Liners, Replacement).
5. Carefully clean the bore in the engine block where the
cylinder liner will be installed. Make sure the tools and
press are ready before installation of the cylinder liner is
begun. See the following paragraphs to make the prepa-
rations.
WARNING
Frozen carbon dioxide (dry ice) can cause injury.
Make sure gloves and protective clothing are worn
when handling the cold parts.
6. Cool the cylinder liner with frozen carbon dioxide
(dry ice). Insert the cylinder liner in its bore in the cylin-
der block. Do this work quickly and carefully so that the
cylinder liner is installed while it is cold. Use a press and
the special installation tool to install the cylinder liner.
See FIGURE 94. Make sure the alignment between the
cylinder liner and the cylinder block is correct during in-
stallation.
 CAUTION
The cylinder liners have a chrome surface. After in-
stallation of the cylinder liners, their surfaces must
1 not be machined.

8. Check the clearance between the cylinder liner and

the piston. See Pistons and Connecting Rods for more
information.
9731

1. INSTALLATION TOOL,
ISUZU PART NO. 5884020400
COOLING SYSTEM
FIGURE 94. CYLINDER LINER INSTALLATION

Coolant Pump, Removal

Alternative method. If frozen carbon dioxide (dry ice)
is not available, the cylinder liner can be installed with a
1. Drain the cooling system
press. This procedure is more difficult. Use a press and
the special installation tool to install the cylinder liner.
See FIGURE 94. Make sure the alignment between the 2. Remove the fan belt, the fan, and the pulley.
cylinder liner and the cylinder block is correct during in-
stallation. Use the press to apply 4900 N (1100 lbf) to in-
stall the cylinder liner in the bore. Use the press to apply 3. Remove the hoses from the coolant pump.
24 500 N (5513 lbf) to finish installation of the cylinder
liner in the cylinder block. 4. Remove the coolant pump from the engine.

7. Measure the position of the cylinder liner. The cylin-

der liner must extend 0.10 mm (0.004 in) above the sur- Coolant Pump, Disassembly
face of the cylinder block. See FIGURE 95. The differ- (See FIGURE 96.)
ence in the height of adjacent cylinder liners must be less
than 0.03 mm (0.0012 in).
CAUTION
Do not use a hammer to disassemble parts of the
coolant pump. Some parts are cast iron and can be
broken if they are hit with a hammer.

1. Remove the cover (2) and gasket (3) from the pump
body (1).

2. Use a press and adapter or a special puller (Hyster Part

No. 368758) to remove the hub (7).
9728

FIGURE 95. MEASURE THE CYLINDER LINER

3. Remove the set screw (10) that holds the bearing unit
POSITION
in the pump body.

39
 12
1. PUMP BODY 2
2. COVER
3. GASKET 14
4. IMPELLER 10 3
5. BEARING
6. SEAL 11
4
7. HUB
8. DEFLECTOR
9. JOINT (2)
1

6
8 10. SET SCREW
5 11. WASHER
12. SCREW (3)
7 13. PLUG
13 14. GASKET
9 15. CAPSCREW (2)
16. STUD (3)
17. NUT (3)
16 15 18. WASHER (3)
17
18

FIGURE 96. COOLANT PUMP

4. Use a press to push the shaft from the impeller (4) and
the seal (6).
Coolant Pump, Assembly And Installation
1. Install the bearing unit (5) so that the holes for the set
screw are aligned. See FIGURE 96. Install the set screw.
2. Install the seals. Apply a thin coat of liquid sealant to
the outer circumference of the seal (6) during installa-
tion.
3. Use a press to install the impeller. The clearance be-
tween the impeller and the pump body must be 0.3 to 0.6
mm (0.012 to 0.024 inch).
4. Install the rear cover.
5. Install the hub. Use a press to push the hub on the
shaft.
6. Install the coolant pump.
7. Adjust the tension of the fan belt as described in the
section PERIODIC MAINTENANCE.
Thermostat, Replacement (See
FIGURE 30.)
1. Drain the cooling system so that the coolant level is
below the thermostat position and disconnect the top
hose from the outlet connection.
2. Remove the capscrews and remove the outlet connec-
tion.
3. Remove the thermostat.
4. Make sure that the surfaces for the joint in the outlet
are clean. Install a new thermostat in the housing.
5. Use a new gasket and install the outlet connection.
Tighten the capscrews.
6. Connect the top hose and fill the cooling system.

40
 CHECKS AND ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT 1. Remove the valve cover. Rotate the crankshaft until
the number 1 piston is at TDC on the compression
NOTE: Before you check the clearance of the valves, stroke as indicated by the timing marks on the crank-
check the torque of the bracket bolts for the rocker arm shaft pulley. See FIGURE 98. In this position, both
assembly. The correct torque is 54 to 58 N.m (40 to 43 rocker arms for the number 1 cylinder will be loose.
lbf ft).
2. Adjust the valves that are marked A in the table of
Number 1 cylinder is at the end of the engine with the FIGURE 97. Do the adjustments when the engine is
cooling fan. The exhaust valve is the first valve in the se- cold. The correct valve clearance for all valves is 0.40
quence. mm (0.016 in).
The valve clearance is measured between the top of the
3. Rotate the crankshaft 360 until the TDC timing mark
valve stem and the rocker arm as shown in FIGURE 97.
is aligned again as shown in FIGURE 98. At this posi-
Valve clearance (cold)
tion, the number 4 piston will be at TDC on the com-
Inlet 0.40 mm (0.016 in)
pression stroke. Adjust the valves that are marked B in
Exhaust 0.40 mm (0.016 in)
the table of FIGURE 97.

9723

CYLINDER FIGURE 98. TIMING MARKS

1 2 3 4
E I I E E I I E
A A A B A B B B CHECK THE TIMING OF THE FUEL
E = EXHAUST INJECTION PUMP, MODEL VE
I = INTAKE
A ADJUST THESE VALVES WHEN No. 1 PISTON 1. Remove the capscrew (2) from the center of the dis-
IS AT TDC ON THE COMPRESSION STROKE tributor head (1) as shown in FIGURE 99. Use a dial in-
B ADJUST THESE VALVES WHEN No. 4 PISTON dicator so that the movement of the plunger can be mea-
IS AT TDC ON THE COMPRESSION STROKE sured. The movement of the plunger can be measured
FIGURE 97. VALVE CLEARANCE through the hole in the distributor head where the
ADJUSTMENT capscrew was removed.

41
 12611

1
FIGURE 100. TIMING MARKS

1. CAPSCREW
2. DISTRIBUTOR HEAD
FIGURE 99. FUEL INJECTION PUMP,
MODEL VE
2. Rotate the crankshaft until the number one piston is at
TDC on the compression stroke. Read the mark for tim-
ing on the crankshaft pulley that is aligned with the indi-
cator on the gear case shown in FIGURE 100. Rotate the
crankshaft before and after TDC to find the maximum
movement of the plunger toward the end of the distribu-
tor head.
FUEL INJECTORS
The engine will run roughly if a fuel injector is damaged
or dirty. To find which fuel injector has a problem, oper-
ate the engine at approximately 1000 rpm. Loosen and
tighten the connection to the inlet of each fuel injector in
a sequence. When the connection to the fuel injector
with a problem is loosened, there will not be a change in
the engine speed.
WARNING
Do not put your hands on fuel lines under pressure.
Fuel oil can be injected into your body by the hy-
draulic pressure.

3. Rotate the crankshaft counterclockwise approximate-

ly 30. Now rotate the crankshaft clockwise slowly.

4. Stop rotating the crankshaft when the plunger is 0.50

mm (0.020 in) less than its maximum movement found
in step 2. 6
5 7
5. Read the mark for timing on the crankshaft pulley that
is aligned with the indicator on the gear case. See 4
FIGURE 100. The correct timing for injection is 16 3
BTDC. 2

6. If the timing is not correct, loosen the fuel injection

pump and rotate it as necessary. Repeat the procedure
1
described in step 5 until the timing is correct.
3. SPACER
7. Remove the dial gauge and install the capscrew in the 4. SPRING SEAT
distributor head. 1. RETAINING NUT 5. SPRING
2. INJECTION 6. ADJUSTMENT SHIM
NOZZLE 7. NOZZLE HOLDER
8. Remove the air from the fuel system. The procedure is
described in Remove the Air From the Fuel System. FIGURE 101. FUEL INJECTOR

42
Removal
1. Disconnect the high pressure line at the inlet to the
fuel injector. Do not bend the fuel line.
2. Remove the nuts, washers, and the bracket holders for
the fuel injectors. See FIGURE 104. Use a slide ham-
mer and a remover tool to pull the fuel injectors from the
cylinder head. Remove the Orings and gaskets. See
FIGURE 103.
NOTE: A remover tool for the fuel injectors is available
from Isuzu (Isuzu Part No. 5884020340).
Inspection
NOTE: The inspection and repair of fuel injectors re-
quire special tools and training. Many users have a spe-
cial repair service make repairs on fuel injectors. Fuel
injector nozzles that have damage or are dirty will cause
black smoke in the exhaust, a decrease in engine power,
and an increase in engine noise.
1. Carefully clean the parts of the fuel injector in a min-
eral oil solvent. The needle valves are specially fitted.
Do not use an abrasive on the fitted areas of the needle
valve. To prevent corrosion, do not touch the fitted ares
of the needle valve with your fingers.
WARNING
Make sure that the nozzle of the injector is away
from the operator during a test. Test oil can be
injected into your body by the hydraulic pressure.
5. Use an injector tester to check the pressure at which
the nozzle operates. The correct pressure is 18.14 MPa
(2630 psi).
6. See FIGURE 101. To change the pressure at which
the nozzle operates, add or subtract shims (6). Shims are
available in thicknesses of 0.025 mm (0.001 in). The
maximum number of shims that can be used in a fuel in-
jector is 40. Each shim will add or subtract approximate-
ly 370 kPa (53.6 psi) to the nozzle opening pressure.
Installation
1. See FIGURE 103. Install gaskets (1) and Orings (2)
for each fuel injector. Install the fuel injectors (3) and the
holder brackets (4) to the cylinder head. Install the nuts
and washers (5) for the holder brackets. Tighten the nuts
to 38 N.m (28 lbf ft). See FIGURE 104.
1. INJECTOR TESTER
2. FUEL INJECTOR

2. Carefully check all parts for wear and damage. See

FIGURE 101. The nozzle and needle valve (2) must be
replaced if there is any wear or damage. Hold the nozzle
2
and needle valve in a vertical position. Pull the needle
valve upward approximately 1/3 of its length and release
it. The needle must lower smoothly into its seat by its 1
own weight. If the needle valve does not pass this test,
the nozzle and needle valve (2) must be replaced.

3. The operation of the fuel injector must be checked

with an injection tester. See FIGURE 102. The injection
tester uses a special oil for calibration tests.
PATTERN NOT CORRECT
Special oils for calibration tests:
SHELL (UK) Calibration fluid C
2
SHELL (worldwide) Calibration fluid B
ESSO Calibration fluid IL 1838
CASTROL Calibration oil 8327 4
4. Check the spray pattern of the nozzle. See
FIGURE 102. If the spray pattern is not correct, the nee-
dle valve does not fit the valve seat correctly. Remove
carbon deposits or replace parts as required. FIGURE 102. CHECK THE FUEL INJECTORS

43
2. Install the high pressure fuel line and tighten the con- DIESEL FUEL FILTER
nections. Install the line clamps if they were removed.
3. Remove the air from the fuel system. See Remove NOTE: Engines that have a fuel injection pump, model
Air From The Fuel System. VE, have a water separator in the bottom of the fuel fil-
ter. A sender unit in the bottom of the fuel filter illumi-
1. GASKET nates an indicator light on the instrument panel if there is
3
2. ORING water in the water separator.
3. FUEL INJECTOR 5
4. HOLDER BRACKET
4
5. WASHER
Filter Replacement

2 1. See FIGURE 105. Disconnect the two sender wires

1 from the bottom of the fuel filter. Remove the fuel filter
FIGURE 103. FUEL INJECTOR ASSEMBLY
4. When the engine can be operated, check for fuel
leaks.
from its mount. Remove the parts that include the sender
unit from the bottom of the fuel filter.
2. Install the parts that include the sender unit in the new
fuel filter. Use a new Oring between the fuel filter and
the sender unit. Lubricate the Oring with diesel fuel
when it is installed. When the engine can be operated,
check for leaks.

Remove Air from the Fuel System

NOTE: The fuel injection pump will normally remove

FIGURE 104. TIGHTEN THE NUT FOR THE
HOLDER BRACKET FOR THE FUEL INJECTOR
small amounts of air from the fuel system when the en-
gine is started. If the fuel pump, fuel injection pump, or
the fuel filter is empty, it is necessary to disconnect a fit-
ting and fill the components of the fuel system before the
engine will start.

44
 a. Make sure there is fuel in the fuel tank.
1 1. HAND PUMP b. Loosen a fitting on the outlet of the fuel system
2. FILTER component that must be filled with fuel. Push the
3. WATER
SEDIMENT CAP plunger of the hand pump several times until the
4. SENDER, air is removed and the component is filled with
FLOAT ASSEMBLY fuel. Tighten the fitting.
5. ORING
6. WIRE
CONNECTION, THROTTLE LINKAGE, ADJUSTMENT
SENDER (2)
7. DRAIN VALVE 1. Adjust the throttle linkage so that the throttle plate is
AND HOSE fully open when the throttle pedal touches the floor.
2 Make the adjustment by changing the length of the cable
where it is installed to the bracket on the inlet manifold.
5
4 2. Adjust the stop for the throttle pedal so that the throttle
plate is completely closed when the pedal is released.
3
The stop is under the throttle pedal.

6
7 IDLE SPEED, ADJUSTMENT

12609
FIGURE 105. FUEL FILTER WITH A WATER
SEPARATOR
The fuel injection pump, Model VE, has a rotary vane
fuel pump inside of the fuel injection pump. The fuel in-
jection pump must be filled with fuel before the engine
will start. A hand pump is installed in the top of the fuel
filter. See FIGURE 105. This hand pump can be used to
fill the fuel system before trying to start the engine. The
following procedure is for diesel engines with a fuel in-
jection pump, Model VE:
The stop screw at the linkage for the throttle plate con-
trols the idle speed of the engine. Turn the screw as nec-
essary to get the specification. The correct idle speed for
the engine is 750 to 800 rpm for the H2.003.00XL
(H4060XL) units and 700 to 750 rpm for the
H2.003.20XM (H4065XM) units.
CHECK THE ELEMENTS FOR THE COLD
START AID SYSTEM
Check the condition of the glow plugs for the cold start
aid system. See the section THE ELECTRICAL SYS-
TEM for more information.

SPECIFICATIONS
Engine Data
1. ADAPTER
Power Rating at 2300 rpm = 40 kW (54 bhp) 5853170010
Type 4 stroke diesel 1
Firing order 1342
Displacement 2771 cm3 (169 in3)
Bore 93 mm (3.661 in)
Stroke l02 mm (4.016 in)
Compression ratio 18.2 : 1
Compression pressure at 200 rpm. See FIGURE 106.
FIGURE 106. CHECK THE COMPRESSION
Production 3038 kPa (441 psi)
PRESSURE
Service limit 2156 kPa (313 psi)

45
Fuel injection timing (static) 16 BTDC Angle of valve face (all) 45
Fuel injector nozzle pressure Depth of valve below cylinder head
18.14 MPa (2630 psi) 0.7 mm (0.027 in) minimum
Governed speed 2.5 mm (0.010 in) maximum
H2.003.00XL (H4060XL) 2200 to 2300 rpm
Valve specifications: See FIGURE 108.
H2.003.20XM (H4065XM) 2100 to 2200 rpm
Idle speed
H2.003.00XL (H4060XL) 750 to 800rpm
H2.003.20XM (H4065XM) 700750 rpm
Valve clearance (cold)
Inlet 0.40 mm (0.016 in)
Exhaust 0.40 mm (0.016 in)
Cooling System
DIAMETER OF VALVE STEM
Thermostat (begin to open) 76.5C (170F) 9719
Inlet:
Cylinder Head Production 7.949 to 7.961 mm
(0.3129 to 0.3134 in)
Maximum distortion of cylinder head.
Service limit) 7.88 mm (0.3102 in)
(See FIGURE 10.) Exhaust:
Production 0.05 mm (0.002 in) Production 7.921 to 7.936 mm
Service limit 0.20 mm (0.008 in) (0.3118 to 0.3124 in)
Maximum grinding allowance Service limit 7.88 mm (0.3102 in)
0.3 mm (0.012 in)
Thickness of cylinder head
Production 91.95 to 92.05 mm
(3.620 to 3.624 in)
Minimum thickness of head in service
91.65 mm (3.60 in)
Maximum distortion of cylinder head at the manifold
surfaces:
Production 0.05 mm (0.002 in) A = DEPTH OF VALVE
9764

Service limit 0.20 mm (0.008 in) Inlet:

Maximum grinding allowance 0.40 mm (0.016 in) Production 0.73 mm (0.029 in)
Height of valve guide above surface of cylinder head Service limit 1.28 mm (0.050 in)
(see FIGURE 13.): 13.0 mm (0.51 in) Exhaust:
Production 0.70 mm (0.028 in)
Valve Specifications Service limit 1.20 mm (0.047 in)
Valve clearance adjustment at TDC for each cylinder: B = CONTACT WIDTH
0.40 mm (0.016 in) Inlet:
Valve seat specifications: See FIGURE 107. Production 1.7 mm (0.067 in)
Service limit 2.2 mm (0.087 in)
Exhaust:
1 2
Production 2.0 mm (0.079 in)
Service limit 2.5 mm (0.098 in)



C = THICKNESS OF VALVE HEAD
Inlet and Exhaust Valves:
Production 1.8 mm (0.07 in)
1. CYLINDER 

Service limit 1.5 mm (0.06 in)
HEAD
2. VALVE SEAT FIGURE 108. VALVE SPECIFICATIONS

FIGURE 107. VALVE SEAT SPECIFICATIONS

46
Clearance between inlet valve and guide Rocker Shaft Assembly
Production 0.039 to 0.069 mm Rocker arm shaft, diameter
(0.0015 to 0.0027 in) Production 18.98 to 19.0 mm (0.747 to 0.748 in)
Service limit 0.20 mm (0.008 in) Service limit l8.85 mm (0.742 in)
Clearance between exhaust valve and guide Rocker arms, clearance between bushing and shaft
Production Production 0.01 to 0.05 mm (0.0004 to 0.002 in)
0.064 to 0.093 mm (0.0025 to 0.0037 in) Service limit 0.2 mm (0.008 in)
Service limit 0.25 mm (0.010 in)
Rocker arms, bushing internal diameter:
Valve springs: See FIGURE 109. Production 19.01 to 19.03 mm (0.748 to 0.749 in)
Service limit 19.05 mm (0.750 in)
Cam followers (tappets), outside diameter:
A
Production 12.97 to 12.99 mm (0.510 to 0.511 in)
Service limit 12.95 mm (0.509 in)
Clearance between cam followers (tappets) and cylin-
der block:
Production 0.03 mm (0.001 in)
Service limit 0.1 mm (0.004 in)
B
9715 C Camshaft (See FIGURE 110.)

9740

A. VARIATION FROM VERTICAL

Production less than 1.5 mm (0.06 in)
Service limit 2.5 mm (0.984 in)
B.FREE LENGTH:
Standard 49.7 mm (1.96 in)
Service Limit 48.2 mm (1.90 in)
C. INSTALLATION HEIGHT:
THE VALVE SPRINGS NEED A MINIMUM
FORCE OF 290 to 326 N (63.8 to 71.7 lbf) TO 12631
COMPRESS THEM TO A HEIGHT OF 38.9 mm CAMSHAFT JOURNAL:
(1.53 in) Production 49.945 to 49.975 mm
(1.966 to 1.968 in)
Service limit 49.60 mm (1.953 in)
Maximum variation between (AA) and (BB)
or across surface 0.05 mm (0.002 in)
CAMSHAFT LOBE (X):
Production 42.08 mm (1.65 in)
Service limit 41.65 mm (1.64 in)

FIGURE 110. CAMSHAFT SPECIFICATIONS

Camshaft runout (see FIGURE 44.)
Production less than 0.02 mm (0.0008 in)
Service limit 0.10 mm (0.004 in)
Variation from front to rear of a cam lobe or a
FIGURE 109. VALVE SPRING SPECIFICATIONS bearing journal:

47
 Production less than 0.03 mm (0.001 in) Piston Grade C: 93.005 to 93.024 mm
Service limit 0.05 mm (0.002 in) (3.6616 to 3.6623 in)
Internal diameter of camshaft bearings: Piston ring end clearance (see FIGURE 63.):
Production Piston rings No. 1 and 2
50.00 to 50.03 mm (1.9685 to 1.9696 in) Production 0.2 to 0.4 mm (0.008 to 0.016 in)
Service limit 50.08 mm (1.9716 in) Service limit 1.5 mm (0.059 in)
Oil control ring 0.1 to 0.3 mm (0.004 to 0.012 in)
Clearance between journals and bearings
Service limit 1.5 mm (0.059 in)
Production 0.05 mm (0.002 in)
Service limit 0.12 mm (0.005 in) Piston ring clearance in groove (see FIGURE 64.)
Piston Ring No. 1
Axial Clearance between thrust plate and camshaft Production 0.09 to 0.125 mm (0.0035 to 0.0049 in)
journal Service limit 0.15 mm (0.006 in)
Production 0.050 to 0.114 mm (0.002 to 0.0045 in)
Piston Ring No. 2
Service limit 0.2 mm (0.008 in)
Production 0.05 to 0.075 mm (0.002 to 0.003 in)
Timing Gears Service limit 0.15 mm (0.006 in)
Clearance between gears (all) Oil Control Ring
Production 0.010 to 0.17 mm (0.0039 to 0.0067 in) Production 0.03 to 0.07 mm (0.0012 to 0.0028 in)
Service limit 0.30 mm (0.012 in) Service limit 0.15 mm (0.006 in)
Piston pin diameter
Axial clearance between idler gear A and
Production 31.0 mm (1.220 in)
the retainer plate (see FIGURE 34.):
Service limit 30.97 mm (1.219 in)
Production 0.007 mm (0.0028 in)
Service limit 0.30 mm (0.012 in) Diameter of piston pin hole in piston
Production
Clearance between idler gear A and idler gear shaft: 31.002 to 31.015 mm (1.2205 to 1.2211 in)
Production
Clearance between piston pin and piston
0.025 to 0.085 mm (0.0010 to 0.0033 in)
Production
Service limit 0.2 mm (0.008 in)
0.002 to 0.015 mm (0.00008 to 0.0006 in)
Inner diameter of idler gear A (see FIGURE 37.):
Production 45.0 to 45.03 mm (1.7717 to 1.7718 in)
Connecting Rods
Service limit 45.10 mm (1.7756 in) Clearance between piston pin and bushing in
connecting rod:
Production
0.008 to 0.020 mm (0.0003 to 0.0008 in)
Service limit 0.05 mm (0.002 in)
Piston pin, outside diameter
1 = 0.04 to 0.06 mm (0.016 to 0.024 in) Production
26.995 to 27.000 mm (1.0628 to 1.0630 in)
2 = 23.7 to 24.0 mm (0.933 to 0.945 in)
Service limit 26.97 mm (1.0618 in)
FIGURE 111. BEARING SPECIFICATIONS, Connecting rod alignment (see FIGURE 65.)
IDLER GEAR B
Crankshaft (See FIGURE 112.)
Pistons Crankshaft runout
Production less than 0.05 mm (0.002 in)
Select a piston grade that keeps the clearance between Service limit 0.08 mm (0.003 in)
pistons and cylinder liner within the following limits:
Clearance between main journals and main bearings
0.25 to 0.45 mm (0.0098 to 0.0177 in)
Production
The bore diameter of the installed cylinder liner is 0.035 to 0.080 mm (0.0014 to 0.0036 in)
Standard 93.021 to 93.060 mm (3.662 to 3.663 in) Service limit 0.11 mm (0.0043 in)
Piston Grade A: 92.985 to 93.004 mm Clearance between connecting rod journals and bear-
(3.660 to 3.662 in) ings

48
 Production Wear limit [measured 15 mm (0.60 in) below top
0.029 to 0.066 mm (0.0011 to 0.0026 in) of cylinder liner) Diameter:
Service limit 0.10 mm (0.0039 in) Production
Axial Clearance 93.021 to 93.060 mm (3.662 to 3.663 in)
Production 0.010 mm (0.0039 in) Service limit 93.10 mm (3.665 in)
Service limit 0.30 mm (0.012 in)
Cylinder Liners, Replacement*
If the cylinder bore diameter is
95.001 to 95.010 mm (3.740l9 to 3.74055 in)
use Grade 1
Outside diameter 95.011 to 95.020 mm
(3.74059 to 3.74094 in)
If the cylinder bore diameter is
Cylinder diameter 95.011 to 95.020 mm
(3.74059 to 3.74094 in)
use Grade 2
Outside diameter 95.021 to 95.030 mm
(3.74098 to 3.74133 in)
If the cylinder bore diameter is
Cylinder
9741
diameter 95.021 to 95.030 mm
(3.74098 to 3.74133 in)
use Grade 3
Outside diameter 95.031 to 95.040 mm
(3.74137 to 3.74173 in)
*See Engine Block And Cylinder Liners for information.

Diameter of main bearing journal Lubrication System

Production 69.917 to 69.932 mm
Capacity with filter 5.2 liter (5.5 qt)
(2.7526 to 2.7531 in)
Service limit 69.10 mm (2.7524 in) Oil pump, clearance between vane, rotor, and cover
Diameter of connecting rod journal (see FIGURE 50.):
Production 52.915 to 52.930 mm Production 0.02 to 0.07 mm
(2.0833 to 2.0839 in) (0.0008 to 0.0026 in)
Service limit 52.906 mm (2.0829 in) Service limit 0.15 mm (0.006 in)
Maximum difference between the measurements Oil pump, clearance between vane and rotor
for each bearing journal: (see FIGURE 51.):
Production 0.05 mm (0.002 in) or less Production less than 0.014 mm (0.006 in)
Service limit 0.08 mm (0.003 in)
Service limit 0.20 mm (0.008 in)
FIGURE 112. CRANKSHAFT SPECIFICATIONS Oil pump, clearance between vane and pump body
(see FIGURE 52.):
Cylinder Block Distortion Production 0.20 to 0.26 mm (0.008 to 0.011 in)
Cylinder block distortion (see FIGURE 91.): Service limit 0.40 mm (0.016 in)
Production less than 0.05 mm (0.002 in)
Oil pump, clearance between rotor shaft and pump
Service limit 0.2 mm (0.008 in)
body (see FIGURE 54.):
Cylinder Liners Production 0.04 mm (0.016 in)
Service limit 0.40 mm (0.008 in)
Extension of cylinder liner above surface of cylinder
block (See FIGURE 95.): 0.10 mm (0.004 in) Oil pressure at 2000 rpm and 80C (176F)
Difference in the installed height of adjacent cylinder 294 kPa (43 psi)
liners: less than 0.03 mm (0.0012 in) Relief valve pressure 422 to 461 kPa (61 to 67 psi)

49
 TORQUE SPECIFICATIONS
ITEM SPECIFICATION

CAMSHAFT GEAR CAPSCREW 108 N.m (80 lbf ft)

CAMSHAFT THRUST PLATE CAPSCREWS 20 N.m (15 lbf ft)
CONNECTING ROD CAP CAPSCREWS 84 N.m (62 lbf ft)
COOLANT PUMP CAPSCREWS 20 N.m (15 lbf ft)
CRANKSHAFT PULLEY CAPSCREW 195 N.m (145 lbf ft)
CYLINDER HEAD CAPSCREWS
1st step (new capscrew) 39 N.m (29 lbf ft)
2nd step (new capscrew) 86 N.m (64 lbf ft)
1st step (used capscrew) 84 N.m (62 lbf ft)
2nd step (used capscrew) 103 N.m (76 lbf ft)
ENGINE MOUNT TO BLOCK CAPSCREWS 40 N.m (30 lbf ft)
EXHAUST MANIFOLD CAPSCREWS 19 N.m (14 lbf ft)
FLYWHEEL CAPSCREWS
H2.003.00XL (H4060XL) 120 N.m (90 lbf ft)
H2.003.20XM (H4065XM) 120 N.m (90 lbf ft)
FLYWHEEL HOUSING CAPSCREWS, H2.003.00XL (H4060XL)
M10 x 1.25 x 40 55 N.m (41 lbf ft)
M12 x 1.5 x 30 94 N.m (69 lbf ft)
FLYWHEEL HOUSING CAPSCREWS, H2.003.20XM (H4065XM) See FIGURE 88.
FUEL INJECTOR BRACKET NUTS 38 N.m (28 lbf ft)
FUEL INJECTOR LINE SLEEVE NUTS 35 N.m (26 lbf ft)
GLOW PLUGS 23 N.m (17 lbf ft)
HYDRAULIC PUMP DRIVE BLOCK CAPSCREWS 20 N.m (15 lbf ft)
INLET MANIFOLD CAPSCREWS 19 N.m (14 lbf ft)
MAIN BEARING CAP CAPSCREWS 167 N.m (123 lbf ft)
OIL SUMP CAPSCREWS 19 N.m (14 lbf ft)
ROCKER ARM ADJUSTMENT NUTS 15 N.m (11 lbf ft)
ROCKER ARM BRACKET CAPSCREWS 54 N.m (40 lbf ft)
TIMING GEAR COVER CAPSCREWS
M8 x 1.25 15 N.m (11 lbf ft)
M12 x 1.25 80 N.m (60 lbf ft)
TIMING GEAR CASE CAPSCREWS 19 N.m (14 lbf ft)
TIMING GEARS
Idler Gear A 20 N.m (15 lbf ft)
Idler Gear B 108 N.m (80 lbf ft)
VALVE COVER CAPSCREWS 13 N.m (10 lbf ft)

50