4ZD1 GASOLINE ENGINE 0 1 - 1

SECTION 01

4ZD1 GASOLINE ENGINE

INDEX

CONTENTS PAGE

General description 01 — 2
Main data and specifications 01 — 4
Major parts fixing nuts and bolts 01 — 7
Engine repair kit 01 — 11
Engine assembly 01 — 12
Removal and installation 01 — 12
Disassembly 01 — 15
Inspection and repair 01 — 26
Reassembly 01 — 46
Oil pump 01 — 66
Water pump 01 — 69
Radiator 01 — 71
Thermostat 01 — 73
Diagnosis 01 — 75
Special tools 01—110
0 1 - 2 4ZD1 GASOLINE ENGINE

GENERAL DESCRIPTION
ENGINE
 4ZD1 GASOLINE ENGINE 0 1 - 3

LUBRICATING SYSTEM

COOLING SYSTEM
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MAIN DATA AND SPECIFICATIONS

Engine model
4ZD1
Items

ENGINE
Engine type Gasoline, Water-cooled, 4-cycle cross-flow
Valve Mechanism Single over-head camshaft (belt drive)
Combustion chamber type Hemispherical type
No. of cylinders - Bore x Stroke mm(in.) 4 - 89.3 x 90 (3.52 x 3.54)
Piston displacement liters (cu.in.) 2.25(138)
Compression ratio (to 1) 8.3
Engine dimensions
(length x width x height) mm(in.) 676 x 653 x 752 (26.63 x 25.72 x 29.62)
Engine weight: dry kg (lbs.) 148(326)

PISTON
Type Without T slot
Material LO-EX
Number of rings 2 - 1
(compression — Oil rings)

VALVE SYSTEM
Intake valve open at B.T.D.C. degree 21
close at A.B.D.C. degree 65
Exhaust valve open at B.B.D.C. degree 55
close at A.T.D.C. degree 20
Valve clearance Intake mm(in.) 0.15/0.20 (0.006/0.008)
Cold/Hot Exhaust mm(in.) 0.25/0.30 (0.010/0.012)
Valve head diameter Intake mm(in.) 42.4 (1.67)
Exhaust mm(in.) 36.0 (1.42)

IGNITION SYSTEM
Firing order 1-3-4-2
Ignition timing B.T.D.C. degree/rpm 6/800 (Federal), 6/900 (California)
Distributor type Full transistorized
Type of advance Centrifugal and vacuum
Spark plugs mm NGK BPR 6ES-11
Spark plug size mm(in.) M14 P=1.25 (0.050)
Spark gap mm(in.) 1.05 (0.040)
 4ZD1 GASOLINE ENGINE 0 1 - 5

Engine model
4ZD1
Items

LUBRICATION S Y S T E M
OIL PUMP
Type Trochoid type
Delivery volume liters/min.(gal./min.) More than 16.0 (4.223) 34.7 (9.1 59)
At pump speed rpm 3000
Pressure of delivery kg/cm2(psi) 4.0 (56.9)
Oil temperature °C(°F) 50(122)
Engine oil SAE30
2
Relief valve opening pressure kg/cm (psi) 4 . 0 - 5 . 0 ( 5 6 . 9 - 71.1)
OIL FILTER
Type Cartridge-high-media paper element
Over-flow valve opening pressure kg/cm2(psi) 0.8 - 1 . 2 ( 1 1 . 4 - 1 7 . 1 )
Oil capacity (qts) 4.9 (5.2)
Crankcase (less filter) 3.8 (4.0)
Crankcase (with filter) 4.2 (4.4)

COOLING SYSTEM
RADIATOR
Type Tubes with corrugated fins
2
Filler cap valve opening pressure kg/cm (psi) 1.05 (14.9)
WATER PUMP
Type Centrifugal limpeller type
Delivery volume liters/min.(gal./min.) 190(50)
At pump speed (rpm) 6 f 000
Water temperature Normal
THERMOSTAT
Type Wax-pellet with jiggle valve
Valve opening temperature °C(°F) 82(180)
Valve wide open temperature °C(°F) 95 (203)
Fan pulley ratio 1.23
Fan outside diameter — number of blades Without A/C 330-4
with A/C 3 9 0 - 7
Fan belt type V-belt

FUEL SYSTEM
Carburetor type 2-barrel down draft
Carburetor model DFP384 (California only), DCR384 (Federal only)
Fuel pump type Mechanical diaphragm
Fuel filter type Cartridge-paper element

AIR CLEANER
Type Wet-paper

BATTERY
Type 55D23R
Voltage (V) -Capacity (amp.) 12-60
0 1 - 6 4ZD1 GASOLINE ENGINE

Engine model
4ZD1
Items
_
CHARGING SYSTEM
Altenator type Stator diode rectified alternator (4x4, LT1 50— 1 88)
(4x2, LT150-187)
Voltage-capacity (V-AH) 12-50
Drive and rotation V-belt, clockwise viewed from front
Speed ratio to engine (to 1) 2.14
Regulator type IC Integrated in alternator

STARTER MOTOR
Type Magnet shift, reduction type
Voltage-Output (V-kW) 1 2 - 1.0
Gear ratio 9:115
 4ZD1 GASOLINE ENGINE 0 1 - 7

MAJOR PARTS ; FIXING NUTS AND BOLTS

CYLINDER HEAD, CYLINDER AND OIL PAN

kg-m(ft.lbs)
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PISTON AND CRANKSHAFT

kg-m(ft.lbs)
 4ZD1 GASOLINE ENGINE 0 1 - 9

TIMING SPROCKET, GEAR CASE, WATER PUMP, FRONT COVER AND REAR COVER
kg-m(ft.lbs)
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INTAKE MANIFOLD AND EXHAUST MANIFOLD

kg-m(ftlbs)
 4ZD1 GASOLINE ENGINE 0 1 - 1 1

ENGINE REPAIR KIT

1. Gasket; Cylinder head cover 11. Seal; Crankshaft rear

2. Gasket; Cap, head cover 1 2. Gasket; Water pump
3. Gasket; Cylinder head 1 3. Gasket; Retainer to block
4. Gasket; Oil drain, oil pan 14. Gasket; Adapter to block
5. Seal; Oil camshaft frt. 1 5. Gasket; O-ring oil pump
6. Gasket; Outlet pipe to inl. manif. 1 6. Gasket; Heat insulation
7. Gasket; O-ring, water pipe 1 7. Repair kit; Head overhaul
8. Gasket; Inlet manifold 1 8. Gasket; Crank case, fit
9. Gasket; Exh. manifold 1 9. Gasket; Crank case, rear
10. Seal; Crankshaft front 20. Gasket; oil pan
0 1 - 1 2 4ZD1 GASOLINE ENGINE

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

REMOVAL

Removal steps
1. Remove battery cables.
2. Scribe position of the hinges on the engine hood, remove the
four bolts attaching the hinges to the engine hood and
remove the engine hood.
3. Remove the undercover and drain the cooling system by
opening the drain plugs on the radiator and on the cylinder
block.
4. Drain the engine oil.

Removal air cleaner

1. Disconnect the PCV hose from the air cleaner body.
2. Disconnect the air hose from the AIR pump.
3. Remove the air duct from air cleaner.
4. Remove the bolts attaching the air cleaner and remove the
wing nut attaching the air cleaner.
5. Lift the air cleaner slightly and disconnect the TCA hose
(from thermosenser and hot idle compensator to intake
manifold), then remove the air cleaner assembly.

Removal of parts at left side of engine

1. Disconnect the TCA hot air hose and remove the manifold
cover.
2. Disconnect the generator wiring at the connector.
3. Remove the two nuts connecting the exhaust pipe to the
engine exhaust manifold, and disconnect the exhaust pipe.
4. Take the tension off of the clutch control cable by loosening
the adjusting nut.
5. Disconnect the heater hoses at heater core tubes.
6. Disconnect the oxygen sensor wiring at the connector.
(California only).
7. Disconnect the rubber hose at air switching valve and
vacuum switching valve (California only).
8. Remove the engine mounting nut.
 4ZD1 GASOLINE ENGINE 0 1 - 1 3

Removal of parts at right side of engine

1. Disconnect the cable grounding the cylinder block to the
frame.
2. Disconnect the fuel hoses from the carburetor.
3. Pull out the high-tension cable from the ignition coil.
4. Disconnect the vacuum hose from the connector at the rear
part of the intake manifold.
5. Disconnect rubber hoses at canister.
6. Disconnect the accelerator control cable from the carbure-
tor.
7. Disconnect the starter motor connections.
8. Disconnect the thermo-unit, oil pressure switch and distribu-
tor wiring at the connector.
9. Disconnect rubber hose at vacuum switch (California only).
10. Disconnect the thermo switch wiring at the connector.
11. Disconnect the ground wiring at the connector on the rear
part of intake manifold. (California only).
12. Disconnect the EFE heater wiring at the connector.
13. Disconnect the carburetor solenoid valve lead and automatic
choke wiring at the connector.
14. Disconnect the back-up light switch and transmission
switch wiring at the connector on the rear part of the engine.
15. Remove the engine mounting nut.
16. Raise the engine slightly and remove the left side engine
mounting stopper plate.

Removal of parts at front of engine

NOTICE: Remove the transmission from the engine before
engine removal from vehicle ( 4 x 4 only). Refer to
'Transfer case replacement procedure" section 05B
of this manual.
1. Disconnect compressor flex hoses (If equipped).
2. Disconnect the radiator reserve tank pipe at the radiator side.
3. Disconnect the radiator upper and lower hoses from the out-
let pipe and from the radiator, respectively.
4. Remove the radiator attaching bolts, and remove radiator.
5. Remove fan blade assembly.

Removal of interior parts

1. Take out the gearshift lever assembly.

Removal of parts under the floor

1. Remove the parking brake return spring and disconnect
brake cable.
2. Disconnect the propeller shaft from the transmission.
(Refer to "Propeller shaft replacement procedure" section
07 & 07A of this manual.)
3. Remove the clutch return spring.
4. Disconnect the clutch control cable from the clutch lever and
remove it from engine stiffener.
5. Remove the front side exhaust pipe bracket from the
transmission.
0 1 - 1 4 4ZD1 GASOLINE ENGINE

6. Disconnect the mounting clamp of front side exhaust pipe.

7. Disconnect the speedometer cable.
8. Remove the rear speedometer cable.
NOTICE: Check that the engine is slightly lifted before remov-
ing the rear engine mounting bolts.

Engine removal
1. Check to make certain all the parts have been removed or
disconnected from the engine.
2. Raise the engine toward front of the vehicle.
3. Remove the transmission assembly from the engine.

INSTALLATION

Installation steps
To install the engine in the vehicle, reverse the removal pro-
cedure.

Preparation for engine installation

1. Check harnesses for damage and correct or replace with
new ones as necessary.

2. Check the engine mounting rubbers for looseness or

damage and tighten or replace with new ones as necessary.

Steps to be followed after engine installation

1. Fill the engine cooling system.

2. Fill the engine crankcase with engine oil.

3. Check and adjust clutch pedal free play as necessary.

4. Start and let the engine run at idle and check for leakage.
5. Adjust the following.

a. Check and adjust fan belt tension as necessary.

b. Adjust valve clearances.

c. Adjust ignition timing.

d. Adjust engine idle.

 4ZD1 GASOLINE ENGINE 0 1 - 1 5

DISASSEMBLY

EXTERNAL PARTS (Right hand side)

Disassembly steps
1. Air cleaner assembly 6. Starter motor assembly
2. Carburator assembly 7. Oil filter and unit
3. EGR pipe 8. Oil pressure switch
4. Inlet manifold 9. Power steering pump and bracket
5. Distributor assembly 10. Air conditioning compressor (If so equipped)
0 1 - 1 6 4ZD1 GASOLINE ENGINE

EXTERNAL PARTS (Front and left hand side)

Disassembly steps
1. Engine mounting bracket 9. Exhaust manifold
2. Fan and clutch assembly 10. Air pump bracket "A"
3. V-belt; air pump 1 1 . Crankshaft pulley and water pump pulley
4. Air pump and bracket "B" 12. Water inlet pipe
5. V-belt; alternator 1 3. High-tension cord
6. Generator and bracket 14. Spark plug
7. Oil pan and oil level gauge 1 5. Air injection manifold
8. O2 sensor (California only)
* Installation engine assembly to engine
stand, then remove the engine hanger.
 4ZD1 GASOLINE ENGINE 0 1 - 1 7

MAJOR COMPONENTS (1)

Disassembly steps
1. Crankshaft pulley bolt A 6. Camshaft timing pulley
2. Timing belt cover 7. Camshaft boss
A 3. Timing belt A 8. Oil pump and pulley
A 4. Tension pulley and tension spring 9. Water pump
5. Crankshaft timing pulley 10. Front plate
0 1 - 1 8 4ZD1 GASOLINE ENGINE

Important operations

3. Timing belt
4. Tension pulley and tension spring
(1) Remove the tension spring.
(2) Loosen bolt (§), draw the tension pulley fully to the water
pump side.
(3) Remove the timing belt.
(4) Remove the tension pulley and tension spring.
(5) Remove the crank timing pulley and guide plate.

6. Camshaft timing pulley

Apply a detention to the pulley by putting a T-bar wrench or
other proper tool over the front-plate fitting bolt and loosen the
pulley fitting bolts.

Note: The timing belt must be off (removed from) the camshaft
timing pulley during both removal and installation of the
camshaft timing pulley.

8. Oil pump and pulley

Apply a detent with an inner hex, and loosen the oil pump pulley
bolt and remove the pulley.
Wrench; inner hex = 6 mm
 4ZD1 GASOLINE ENGINE 0 1 - 1 9

MAJOR COMPONENTS (2)

Disassembly steps
A 1. Flywheel A 6. Oil pipe assembly
2. Rear plate A 7. Front oil seal retainer
A 3. Rocker arm bracket and shaft A 8. Piston and connecting-rod
4. Camshaft and oil seal A 9. Crankshaft and bearing caps
A 5. Cylinder head and gasket
0 1 - 2 0 4ZD1 GASOLINE ENGINE

Important operations

1. Flywheel
Hold the crankshaft from turning using wooden bar and remove
the flywheel mounting bolts.
Remove the flywheel by tapping on it with a plastic hammer.
Flywheel is a heavy mass and should be handled carefully so as
not to drop it.

3. Rocker arm bracket and shaft

Sequentially loosen and remove the rocker arm shaft tightening
nuts from the outermost one, and remove the rocker arm shaft
with the bracket as an assembly.

5. Cylinder head and gasket

Loosen the head bolts evenly from the outermost one using an
extension bar wrench and thereby remove the cylinder
head. Remove also the gasket at this time.
Wrench ; inner hex = 10 mm

6. Oil pipe assembly

Remove the oil pipe assembly fitting bolts and draw the pipe out
from the cylinder block.
 4ZD1 GASOLINE ENGINE 0 1 - 2 1

7. Front oil seal retainer

Front oil seal replacement.
Remove the front oil seal with driver.

Attach the oil seal using a special tool

Front oil seal installer : J-26587

8. Piston and connecting-rod

(1) Remove carbon adhering to the upper section of the cylinder
bore.

(2) Draw out the piston while pushing the end of the connect-
ing-rod.
(3) Remove the connecting-rod bearing.

9. Crankshaft and bearing caps

Loosen and remove the crankshaft bearing caps in the order indi-
cated in the figure.
Remove the crankshaft.
0 1 - 2 2 4ZD1 GASOLINE ENGINE

MINOR COMPONENTS

PISTON AND CONNECTING-ROD ASSEMBLY

Disassembly steps
A 1. Piston rings 3. Piston
A 2. Piston pin 4. Connecting-rod with bearing

Important operations

1. Piston rings
Remove the piston rings with a piston ring expander.
 4ZD1 GASOLINE ENGINE 0 1 - 2 3

2. Piston pin
Remove the piston pin using a piston pin service set piston sup-
port with a press.
Remover and installer : J-24086
1. Remover : J-24086-8
2. Bass fixture : J-24086-8
3. Piston support : J-24086-75
0 1 - 2 4 4ZD1 GASOLINE ENGINE

ROCKER ARM SHAFT

Disassembly steps
1. Nut; rocker arm bracket 4. Shaft; rocker arm
2. Bolt; rocker arm bracket 5. Rocker arm
3. Spring ; rocker arm 6. Bracket; rocker arm shaft
 4ZD1 GASOLINE ENGINE 0 1 - 2 5

CYLINDER HEAD

Disassembly steps
• 1. Split collar 4. Oil controller
2. Upper spring seat 5. Valve
3. Valve spring 6. Lower spring seat

Important operations

1. Split collars
Compress the spring with valve spring compressor and remove
the split collars.
When compressing the spring, push the valve up by your hand.
Valve spring compressor : J-26513-A
0 1 - 2 6 4ZD1 GASOLINE ENGINE

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through
inspection.

Note: Wash and clean each parts deteched to remove all dirt, carbon, contaminated oil, rust, fur and other foreign mat-
ters. Ample care should be taken to avoid damage when removing carbon adhering to the piston, cylinder head,
valve, and other parts. Employ compressed air to remove foreign matters in the oil hole of each parts, and corn-
firm there is no choking.

CYLINDER HEAD

Visual check
Remove carbon adhering to the lower face while taking care not
to damage the valve seat and other parts, and check for cracks
and damage.

Distortion of lower face

Make six measurements on the four sides and the diagonals, and
if the limit is exceeded make necessary correction or replace-
ment.
mm (in.)
Maximum
Standard Limit repairable
limit

0.05(0.003) or less 0.2(0.008) 0.4(0.016)

Distortion of manifold face

Make measurement in a manner similar to that for the cylinder
head. If the limit is exceeded make necessary correction.
mm(in.)
Standard Limit
0.05 (0.002) or less 0.4 (0.016)
 4ZD1 GASOLINE ENGINE 0 1 - 2 7

Combustion chamber
Remove adhering carbon and inspect the combusition chamber
inside, spark plug hole, valve seat insert engagement section and
other parts. If there is a crack or considerable damage replace it
with a new one.

CYLINDER BODY

Distortion of upper face

Make measurements on the four sides and the diagonals with a
straightedge and thickness gauge as shown in the figure. If the
limit is exceeded make necessary correction or replacement.
mm(in.)
Maximum
Standard Limit repairable
limit
0.05(0.002) or less 0.2(0.008) 0.4(0.016)

Cylinder bore
Measure the cylinder bore diameter at points approximately 8 to
70mm from the upper end in directions in line with and at a right
angle to the crankshaft.
mm(in.)
Standard Limit Max. bore dia
89.30-89.34
0.2 (0.008) 90.34 (3.557)
(3.518-3.520)

Reboring is necessary if the amount of wear is greater than

0.2mm over standard size, or if scuffing or trace of seizure is
noticeable.
All cylinder should be rebored even if only one cylinder fails to
meet standard. Replace the cylinder block if bore diameter
exceeds max. bore dia. specified above.

Remove steps at upper part of cylinder walls with a ridge reamer

whenever the engine is overhauled.
Valve seat thickness
Head edge thickness:
mm(in.)
Standard Limit

Inlet 1.1 (0.0433) 0.8 (0.0315)

Exhaust 1.3 (0.0512) 1.0 (0.0394)

 4ZD1 GASOLINE ENGINE 0 1 - 2 9

VALVE GUIDE

Valve stem diameter

Set a dial gauge as shown in the figure and measure the
clearance between the valve guide and valve stem.
mm(in.)
Standard Limit
0.023 - 0.056 0.2 (0.0079)
Intake
(0.009 - 0.0022) or more

0.038 - 0.070 0.25 (0.0097)

Exhaust
(0.0015 - 0.0031) or more

Note: If the clearance between the valve stem outer circum-

ference and valve guide exceeds the limit replace the
valve and valve guide as a pair.

Valve guide replacement

Hit the valve guide out from the combustion chamber side to the
cam side using a valve guide remover.

Valve guide remover : J-26512-1

Apply engine oil to the outer circumference of the valve guide

and hit it in, with a valve guide installer, until the top end of the
installer hits the cylinder head.
mm(in.)
Height of valve guide
16.1 - 16.3
upper-end from cylinder
(0.634 - 0.642)
head upper face (A)

Valve guide installer J-26512

J-26512-1
J-26512-2
0 1 - 3 0 4ZD1 GASOLINE ENGINE

VALVE SEAT

Valve seat insert

Attach a new valve to the cylinder head and measure the amount
of sinking from the head surface with a depth gauge. If the limit
is exceeded replace the valve seat insert.
mm(in.)
Standard Limit
1.0 (0.039) 1.7 (0.067)

If the seat contact surface is damaged or made rough or if the

wear of the contact width exceeds the limit make necessary
correction.
mm(in.)
Standard Limit
1 . 2 - 1 . 6 (0.048 - 0.063) 2.0 (0.078)

Correction of valve seat

Remove carbon from the seat surface, cut to the minimum
extent to remove flaws and roughness of the seat surface with
1 5°, 45° and 75° valve seat cutters, and thus correct the contact
width to a standard value.

Apply compound to the valve seat surface and fit while turning
the valve and hitting light. Insvre that the whole circumference
contacts the valve in the center of the valve seat surface and that
the valve seat contact width is a standard value.
 4ZD1 GASOLINE ENGINE 0 1 - 3 1

Valve seat insert replacement

1. Arc-weld, at several points, a rod to draw it out into the valve
seat while taking care to avoid damage to the aluminum
apply section.
2. When the cylinder head heated by welding is cooled by air
for 2 to 5 minutes, the valve seat shrinks because of local
cooling of the valve seat. So give a shock to the welded
rod and draw it out.
3. Clean the valve seat press-fit section on the cylinder head
side while taking care to avoid damage to it, heat and expand
the insert press-fit section using steam or other means, and
press fit horizontally the valve seat cooled and contracted
with dry ice or other means.

Standard fitting , .
, mmdn.) 0.08-0.12 (0.0032-0.0047)
interference

FLYWHEEL

Flywheel
Check the flywheel's friction face with the clutch driven plate for
cracks and damage.
mm(in.)
Standard Limit
43.45 (1.711) 42.45 (1.671)

If damage or considerable wear is found in the surfaces of the

ring gear teeth, replace it with a new one.

Ring gear replacement

Remove the ring gear by hitting with a hammer through a brass
rod placed between it and the hammer.
0 1 - 3 2 4ZD1 GASOLINE ENGINE

Heat and expand the ring gear evenly with a gas burner or other
means an tap it into the flywheel.
Note: After shrink fitting comfirm that the ring gear is in close
contact with the flywheel.

INLET AND EXHAUST MANIFOLD

Inlet manifold
Check the cylinder head fitting face of the intake manifold for
distortion.

Limit mm(in.) 0.4 (0.016)

Exhaust manifold
Check the cylinder head fitting face of the exhaust manifold for
distortion.

Limit mm(in.) 0.4 (0.016)

 4ZD1 GASOLINE ENGINE 0 1 - 3 3

ROCKER ARM SHAFT AND ARM ASSEMBLY

Rocker arm shaft

Visually inspect for damage or other abnormal conditions.
Run-out:
mm(in.)
Standard Limit
0.2 (0.008) or less 0.4 (0.016)

Make measurement on four rocker arm fitting positions, and if

the limit is exceeded replace it with a new one.
Diameter:
mm(in.)
Standard Limit
20.5 (0.807) 20.35(0.801)

Clearance between rocker arm shaft and rocker arm

Measure the inner diameter of the rocker arm, and if the
clearance between it and the outer diameter of the rocker arm
shaft exceeds the limit, replace the rocker arm or shaft.
mmtin.)
Standard Limit
0.005-0.045(0.0020-0.001 8) 0.2 (0.0078)
0 1 - 3 4 4ZD1 GASOLINE ENGINE

CAMSHAFT ASSEMBLY

When the limit is exceeded in the following inspection, replace

the camshaft.

Camshaft diameter and hight of camlobe

Journal diameter
mm(in.)
Standard Limit
Journal
34.0(1.339) 33.8(1.332)
diameter
Height of
36.85(1.452) 36.35(1.432)
camlobe
Taper 0.05(0.002) or less 0.05(0.002)

Run out:
mm(in.)
Standard Limit

0.05(0.002) or less 0.1(0.004)

Clearance between journal and bearing

Tighten the rocker arm shaft bracket with predetermined torque
and make measurement.

Torque kg-m(ft.lbs.) 2 . 1 - 2 . 3 (15.2-16.6)

Clearance between journal and bearing:

mm(in.)
Standard Limit

0.065 - 0.110
0.15 (0.0059)
(0.0026 - 0.0043)

End play
mm(in.)
Standard Limit

0.05 - 0.15 0.2 (0.0079)

(0.0002 - 0.0059)
 4ZD1 GASOLINE ENGINE 0 1 - 3 5

Distributor drive gear

Check for wear or damage.

CRANK SHAFT PILOT

Crankshaft pilot bearing and sleeve

Turn the pilot bearing with your finger and check for bearing
backlash or abnormal noise.

When an abnormality is noted, remove the pilot bearing using a

pilot bearing puller and replace it with a new one.
Pilot bearing remover : J-23097
Sleeve remover : J-33950

Attach the pilot bearing using a pilot bearing installer.

Pilot bearing installer : J-26516-A
Sleeve installer : J-29818
0 1 - 3 6 4ZD1 GASOLINE ENGINE

CRANKSHAFT AND BEARINGS

Crankshaft and bearings

Check the faces of the crankshaft journals, crankpins and oil seal
fitting faces for wear and damage and oil passages for restric-
tions.

Check for run-out by turning the crankshaft slowly with the

probe of a dial indicator set against the No. 3 journal.
Run out:
mm(in.)
Standard Limit

0.03 (0.0012) or less 0.1 (0.004)

Measure the journal and pin diameters for front and back (I and II
shown in the figure) in two directions of A and B.
Crankshaft journal and pin diameter:
mm(in.)
Journal dia. Pin dia.

Standard 55.920-55.935 48.925-48.940

(2.2032-2.2038) (1.9276-1.9282)

Limit for use 55.420 (2.184) 48.425 (1.908)

When the wear of the journal or pin exceeds the limit, replace the
crankshaft.
Crankshaft journal and pin taper:
mm(in.)
Journal Pin

Limit for use 0.05 (0.002) 0.05 (0.002)

When the limit is exceeded correct with a grinder and replace

with an undersized bearing.
 4ZD1 GASOLINE ENGINE 0 1 - 3 7

If the amount of wear is beyond the value specified, correct with

crankshaft grinder and install undersize bearings.

Crankshaft bearing
Bearing tension free width:
mm(in.)
Limit

Cranksaft bearing More than 59.25 (2.334)

Connecting-rod bearing More than 52.25 (2.059)

Attach the bearing normally to the body and bearing caps and
tighten the bearing cap with predetermined torque and measure
the inner diameter.

Torque kg-m(ftlbs.) 9 - 1 1 (65.1 - 79.5)

Clearance between journals and bearings:

mm(in.]
Standard Limit
0.015 - 0.066
0.12 (0.0047)
(0.0006 - 0.0026)

Attach the bearing normally to the larger end of the connecting-

rod and tighten the connecting-rod cap with predetermined tor-
que and measure the inner diameter.

Torque kg-m(ft.lbs.) 5.8 - 6.2 (41.9 - 44.8)

Clearance between pins and bearings:

mm(in.)
Standard Limit
0.011 - 0.065
(0.0004 - 0.0026) 0.12 (0.0047)
0 1 - 3 8 4ZD1 GASOLINE ENGINE

Measurement of clearance using plastigage

Clean the journal cap and bearing.
Lay a plastigage over the full width of the bearing.

Tighten the bearing cap with predetermined torque.

Torque kg-m(ft.lbs.) 9 - 1 1 (65.1 - 79.5)

Do not turn the crankshaft

Check the width of plastigage stuck to either crankshaft or bear-

ing against the scale printed on the container of the plastigage.

Measure play at thrust bearing installed on bearing cap No. 3

using a feeler gauge.
Crankshaft end play:
mm(in.)
Standard Limit
0.06 - 0.25
0.3 (0.012)
(0.0024 - 0.0099)
 4ZD1 GASOLINE ENGINE 0 1 - 3 9

PISTON AND PISTON RING

Pistons
If there is a crack, streak, or considerable wear fround in the
piston, replace it with a new one.
Clearance between piston and cylinder bore (at Grading piston
and measuring position).
If the clearance exceeds the limit, select and use an oversized
piston.

0.045 - 0.065
Standard mm(in.)
(0.0018 - 0.0026)

Piston grading position (from piston head)

Piston grading position mm(in.) 42 (1.65)

Take measurement in direction at a right angle to the piston pin

hole.

Reboring Procedure of Cylinder Block

1. Determine size of oversize pistons to be installed according
to largest bore diameter.
2. When the oversize is determined, measure the outside
diameter of the pistons at a grading point below the upper
face of the piston (grading positions) and in a direction at
right angles to the crankshaft.
Calculate the cylinder bore diameter to be obtained after
reboring by the following formula:
Cylinder bore diameter (after boring)
= D + C-H
D: Oversize piston diameter (mm)
C: Piston clearance (0.035 — 0.055 mm)
H: Allowance for honing (0.03 mm or less)
0 1 - 4 0 4ZD1 GASOLINE ENGINE

mm
Grading position 42

STD piston 89.255 - 89.295

0/S piston 0.50 89.755 - 89.795

0/S piston 1.00 90.255 - 90.295

Allowance for honing 0.01 - 0.03

Variance of bore diameter 0.02 or less

(Reference) Grade of cylinder Bore and Piston (STD size)

Grade Cylinder bore diameter Piston diameter

(A) 89.300 - 89.320 89.255 - 89.275

(C) 89.321 - 89.340 89.276 - 89.295

Piston ring
Remove carbon adhering to the piston ring and inspect the
piston ring for damage.
Put the ring in the cylinder, push it in with the head of the piston
to the section of minimum inner diameter, and measure the abut-
ment clearance. If the limit is exceeded replace it with a new
one.
mmlin.
Standard Limit

0.30-0.45
1 st compression ring 1.5 (0.059)
(0.012-0.018)

0.25-0.40
2nd compression ring 1.5 (0.059)
(0.010-0.016)

0.20-0.70
Oil ring 1.5 (0.059)
(0.008-0.028)

Clearance between piston ring and ring groove:

Remove carbon in the gaps between the piston ring grooves and
rings, and measure the outer circumference at several points
with a thickness gauge.
mm(in.)
0.025-0.060
1 st compression ring 0.15 (0.006)
(0.001-0.0024)

0.020-0.055
2nd compression ring 0.15 (0.006)
(0.001-0.0024)
 4ZD1 GASOLINE ENGINE 0 1 - 4 1

r Piston ring tension

Measure the piston ring tension with a piston ring tester. If the
tension is beyond the limit replace the piston ring with new one.
kg (lbs.)
Standard Limit
1.11-1.59
1 st compression ring 0.8 (1.764)
(2.448-3.506)
0.89-1.31
2nd compression ring 0.6 (1.323)
(1.962-2.889)

3.05-4.35
O-ring 2.0 (4.410)
(6.725-9.592)

Piston ring size mark

1 st comp. ring 2nd comp. ring Oil ring

STD None None Red

O/S 0.50 50 50 Blue

O/S 1.00 100 100 Yellow

0 1 - 4 2 4ZD1 GASOLINE ENGINE

CONNECTING-ROD AND PISTON PIN

Connecting-rod and piston pin

Connecting-rod
Measure distortion and parallelism between the larger end hole
and smaller end hole using a connecting-rod aligner.
If the limit is exceeded replace it with a new one.
Connecting-rod aligner (Per length of 100 mm (3.97 in.)
mm(in.)
Standard Limit

Distortion 0.05 or less 0.2

(0.002 or less) (0.008)

Parallelism 0.05 or less 0.15

(0.002 or less) (0.006)

Piston pin
Visually inspect for damage, wear or the abnormal conditions.
Outside diameter:
mm(in.)
Standard Limit
23.0 (0.906) 22.97 (0.905)

Clearance between piston pin and connecting-rod small end.

mm(in.)
Standard Limit
0.008 - 0.020
0.05 (0.002)
(0.0003 - 0.0008)

Note: If the limit is exceeded replace the piston pin or connect-

ing-rod to bring the clearance into the standard value
range.
 4ZD1 GASOLINE ENGINE 0 1 - 4 3

TIMING BELT TIMING PULLEY AND TENSION SPRING

INSPECTION AND REPAIR

TIMING BELT

Caution in handling

1. Do not bend in less than 20 mm in radius.

2. Avoid twisting or kinking the belt and keep it free from

water, oil, dust and other foreign matter.

Visual check
The belt must be replaced if cracks are found in the side and rear
faces.

Also replacement is necessary when abnormal wear is found in

the side face.
0 1 - 4 4 4ZD1 GASOLINE ENGINE

Replacement is necessary when fabric is found to be cracked or

disintegrated.

Replacement is also necessary when cogs are found to have

abnormal wear.

Take measurements at 3 — 5 points around the circumference

of the belt. The belt must be replaced even if a single measure-
ment is beyond the limit.

Limit of rubber hardness (HS) 90

Rubber hardness tester

The timing belt is a vital part of the engine and should be main-
tained properly.
 4ZD1 GASOLINE ENGINE 0 1 - 4 5

Timing pulley and tension spring

Visual check
If uneven wear, crack or wear exceeding the limit is found in the
pulley, replace it with a new one.

Timing pulley
Outside diameter:
mm(in.)
Pulley Standard Limit

Crankshaft 65.33 (2.574) 65.23 (2.570)

Oil pump 113.84 (4.485) 113.74 (4.481)

Camshaft 132.03 (5.202) 131.93 (5.198)

Tension pulley
Check the roller for excessive wear and damage.
Check to see that the roller rotates smoothly.
Check to see that there is no play in the pulley shaft/fixing plate
caulked area.
Outside diameter:
mm(in.)
Standard Limit
60.00 (2.364) 59.80 (2.356)

Tension spring
Check for tension:

Set length Set force

Tension 78.8 mm 23.8 - 25.8 kg

(3.105 in.) (172 - 186 lbs.)

If the set length or set force is out of the specified range, replace
the tension spring with a new one.
0 1 - 4 6 4ZD1 GASOLINE ENGINE

REASSEMBLY

MINOR COMPONENTS

PISTON AND CONNECTING-ROD ASSEMBLY

Reassembly steps
A 1. Connecting-rod with bearing A 3. Piston pin
• 2. Piston • 4. Piston ring

Important operations

1. Connecting-rod

2. Piston
Apply engine oil to the piston and connecting-rod and then touch
the piston hole with finger to check if insertion is possible.
 4ZD1 GASOLINE ENGINE 0 1 - 4 7

Bring the capital letter ISUZU side of the connecting-rod into

agreement with the cut-out front mark of the piston.

Insert the piston pin into puh rod, then screw these parts into
guide rod.

3. Piston pin
Press in the piston pin using a piston pin service set piston sup-
port and installer and a press.
Remover and installer : J-24086
1. Installer : J-24086-9
2. Base fixture :J-24086-12
3. Pin guide : J-24086-5
4. Piston support : J-24086-75

4. Piston ring
Install the oil control ring assembly in the order of expander ring,
lower side rail and upper side rail.
Assembly the piston rings to the piston so that the T mark is
turned up.
0 1 - 4 8 4ZD1 GASOLINE ENGINE

After installation of piston rings, apply engine oil to the circum-

ference of the rings and check that each ring rotates smoothly.

ROCKER ARM SHAFT

Reassembly steps
1. Bracket; rocker arm 4. Spring ; rocker arm
2. Shaft; rocker arm 5. Nut; rocker arm bracket
3. Rocker arm

Important operations

2. Shaft; rocker arm

3. Rocker arm
Apply oil sufficiently to the rocker arm and shaft.
Place the longer end of the shaft on the exhaust side, the shorter
end on the inlet side, and the shaft mark to the front
 4ZD1 GASOLINE ENGINE 0 1 - 4 9

CYLINDER HEAD ASSEMBLY

Reassembly steps
1. Lower spring seat 4. Valve spring
2. Oil controller 5. Upper spring seat
3. Valve 6. Split collar
0 1 - 5 0 4ZD1 GASOLINE ENGINE

Important operation

1. Lower spring seat

2. Oil controller
Install the spring seat (lower) and fit the oil controller in the valve
guide.

Note: Be sure to set the inner projection of the oil controller in

the head groove of the valve guide.

3. Valve
Apply engine oil to the valve stem and insert it into the valve
guide.

4. Valve spring
Install the inner and outer springs with light green colored ends
turned to lower seat or install the valve springs with their close
pitched end down.

6. Split collars
Compress the spring with the aid of valve spring compressor,
then install the valve collars properly.
When compressing the spring, push the valve up by your hand.
Valve spring compressor : 26513-A
 4ZD1 GASOLINE ENGINE 0 1 - 5 1

MAJOR COMPONENTS (1)

Reassembly steps
1. Crankshaft bearing and thrust 6. Flywheel
bearing 7. Oil pipe assembly
2. Crankshaft bearing cap and bearing 8. Front oil seal retainer
3. Piston and connecting-rod 9. Cylinder head and gasket
4. Connecting-rod bearing cap and 10. Camshaft
bearing 1 1 . Rocker arm bracket
5. Rear plate 1 2. Rocker arm shaft
0 1 - 5 2 4ZD1 GASOLINE ENGINE

Important operation

1. Crankshaft, bearing and thrust bearing

Apply engine oil sufficiently to the inner surface of the bearing
and place the crankshaft on it.

Note: Assemble with the oil groove of the thrust washer turned
outward.

The bearing should be installed correctly in their respective posi-

tion, install the thrust bearing with the oil grooved side turned
outward.

Apply silicon gasket to the fit surface of No. 5 bearing cap and
assemble with care to avoid any misalignment between the rear
surface of the cylinder body and that of the bearing cap.

2. Crankshaft bearing cap and bearing

Apply engine oil to the threads and seating face of the
bolts. Install the bearing caps in sequence of cylinder numbers
with the arrow mark pointing to front of engine and semitighten
the bolts.
Then retighten the bolts to specification.

Torque kg-m(ftlbs.) 9 - 1 1 (65.1-79.5)

After tightening, check to make certain the crankshaft rotates

smoothly.
 4ZD1 GASOLINE ENGINE 0 1 - 5 3

Apply engine oil to the lip of the rear oil seal and set the oil seal in
place using an installer.
Crankshaft rear oil seal installer : J-29818

3. Piston and connecting-rod

Fit the bearing into the connecting-rod and bearing cap and apply
engine oil. Confirm that the opening portion of the piston ring is
positioned as shown in the figure and then apply engine oil to the
outer circumference of the piston.

Insert the piston and connecting-rod assembly into cylinder bore

with the front mark on the piston turned to the front of engine
using the piston ring compressor and hammer handle.
Piston ring compressor : J-8037

4. Connecting-rod bearing cap and bearing

Bring the matching (cylinder) number of the connecting-rod
bearing cap into agreement with that of the connecting-rod.

Apply engine oil to the threads, then install and tighten the bolt to
specification.

Torque kg-m(ft.lbs.) 5.8-6.2 (41.9-44.8)

After tightening bolt, check to make certain the crankshaft

rotates smoothly.
0 1 - 5 4 4ZD1 GASOLINE ENGINE

5. Rear plate
Install the rear plate in position by aligning it with dowel on the
cylinder body.

Torque kg-m(ft.lbs.) 4.0-6.0(2.89-4.34)

6. Flywheel
(1) Apply adhesive to the first thread of the bolt.
(2) Attach the flywheel, hold the crankshaft and tighten with
predetermined torque diagonally with the pallet of the
washer turned outward.
(3) Be sure to replace the flywheel fitting bolts with new ones
because they cannot be reused.

Torque kg-m(ft.lbs.) 5.5-6.5(39.8-46.9)

8. Front oil seal retainer

Apply engine oil to lipped portion of oil seal, then install the front
oil seal retainer by aligning it with the dowels on the cylinder
body together with gasket.
The gasket should be flush with the face of the cylinder face.

9. Cylinder head and gasket

Clean the upper face of the cylinder head and attach the dowels.

Turn the TOP mark of the cylinder head gasket upwards and
attach it so as to fit the dowel.
 4ZD1 GASOLINE ENGINE 0 1 - 5 5

Apply engine oil to the threaded sections of the head bolts and
temporarily tighten them in the order indicated in the figure,
followed by tightening with predetermined torque.
kg-m(ft.lbs.)
First step 8.0 (57.8)
Torque
Final step 9.0-11.0 (65.1-79.5)

10. Camshaft
Apply engine oil sufficiently to the journal of the camshaft and
the journal and thrust receivers of the head.
Turn the camshaft mark upward.

11. Rocker arm bracket

Apply silicon gasket beforehand to the front side of the fit sur-
face of No. 1 rocker arm bracket with the cylinder head.

12. Rocker arm shaft

Assemble the rocker arm assembly, with the matchmark turned
upward.

Attach the rocker shaft spring and tighten the shaft bracket in
the order indecated with predetermined torque.
kg-m(ft.lbs.)
No. 1 - 10 (Nut) 2.1-2.3 (15.2-16.6)
Torque
Bolt 0.6-1.0 (4.34-7.23)

After assembly apply enough drops of engine oil around the

rocker arm shaft and valve.
0 1 - 5 6 4ZD1 GASOLINE ENGINE

MAJOR COMPONENTS (2)

Reassembly steps
1. Front plate A 6. Crankshaft timing pulley and guide plate
A 2. Water pump A 7. Tension pulley and tension spring
A 3. Oil pump and pulley A 8. Timing belt
4. Camshaft boss A 9. Timing belt cover
A 5. Camshaft timing pulley A 10. Crankshaft pulley bolt
 4ZD1 GASOLINE ENGINE 0 1 - 5 7

2. Water pump
Tighten the water pump assembly with predetermined torque.

Torque kg-m(ft.lbs.) 1.4-2.4(10.1-17.4)

3. Oil pump and pulley

(1) Apply a generous amounts of engine oil to the rotor, then
install the rotor with the chamfered side turned to the
cylinder body.

(2) Apply engine oil to the O-ring and insert it into the groove in
the housing. Attach the rotor after applying generous
amounts of engine oil.

Torque kg-m(ftlbs.) 1.4-2.4(10.1-17.4)

Wrench ; inner hex = 6 mm

(3) Check if it turns smoothly. If not replace the cartridge

assembly.
(4) Attach the pulley and tighten with predetermined torque.

Torque kg-m(ft.lbs.) 6.7-8.7(48.4-62.9)

5. Camshaft timing pulley

Apply a detention to the pulley by putting a T-bar wrench or
other proper tool over the front plate upper fitting bolt and
tighten with predetermined torque.

Torque kg-m(ftlbs.) 6.7-8.7(48.4-62.9)

0 1 - 5 8 4ZD1 GASOLINE ENGINE

6. Crankshaft timing pulley

Attach the guide plate and assemble with the brim side of the
timing pulley turned upward.

7. Tension pulley and tension spring

Insert the tension pulley into stud A, set the tension spring in
plate, and temporarily tighten bolt B after pulling it fully to the
water pump side.

8. Timing belt
Install the timing belt in the sequence indicated below.
(1) Bring the matchmark of the crankshaft timing pulley into
agreement with that of the front oil seal retainer.

(2) Bring the matchmark of the camshaft timing pulley into

agreement with that of the front plate. Keep the rocker arm
altogether in a free state.

Note: At this point the No. 4 cylinder comes to its compression

upper dead center.

(3) Lay the timing belt over the crank pulley, oil pump pulley,
cam pulley, and tension pulley in said order while avoiding
loosening between them.
 4ZD1 GASOLINE ENGINE 0 1 - 5 9

(4) Loosen bolt B, tighten the belt by the force of the tension
spring, and then tighten bolt B temporarily.
Note: At this point check if the matchmark of the crankshaft is
in agreement with that of the camshaft timing pulley.

(5) Temporarily attach the crank pulley. Turn the crankshaft

two revolutions in the opposite direction of normal rotation
to bring the crankshaft setting mark into agreement with the
crankshaft pulley setting mark loosen bolt B and tighten the
belt with the tension pully. Tighten bolt B to the specified
torque.

Torque kg-m(ft.lbs.) 1.4-2.4(10.1-17.4)

9. Timing belt cover (upper and lower)

Attach the timing belt cover and tighten with predetermined tor-
que.

Torque kg-m(ft.lbs.) 0.5-1.0(3.6-7.2)

10. Crankshaft pulley bolt

Apply a detention to the crankshaft and tighten with predeter-
mined torque.

Torque kg-m(ft.lbs.) 10.5-13.5(75.9-97.6)

Valve clearance adjustment

Bring either the No. 1 or No. 4 piston to top dead center on the
compression stroke. Do this by turning the crankshaft to align
mark on crankshaft pulley with timing mark.
Hold crankshaft in above position and adjust clearance of the
valves indicated.
0 1 - 6 0 4ZD1 GASOLINE ENGINE

Adjust the valve clearance in the following manner using a feeler

gauge.
mm(in.J
Intake (cold) 0.15 (0.006)

Exhaust (cold) 0.25 (0.010)

C y l i n d e r No.
Valve 1 2 3 4

Intake O O • •

Exhaust O • O •

Note: O When piston in No. 1 cylinder is at TDC on compres-

sion stroke.
• When piston in No. 4 cylinder is at TDC on compres-
sion stroke.
 4ZD1 GASOLINE ENGINE 0 1 - 6 1

EXTERNAL PARTS (Right hand side)

Reassembly steps
1. Inlet manifold 6. Starter motor assembly
2. Oil filter and unit 7. EGR pipe
3. Oil pan 8. Power steering pump and bracket
4. Distributor assembly 9. Aircon compressor (If so equipped)
5. Head cover 10. Oil pressure switch
0 1 - 6 2 4ZD1 GASOLINE ENGINE

Important operations

1. Inlet manifold bolt

Tighten the intake manifold with predetermined torque.

Torque kg-m(ft.lbs.) 1.9-2.5(13.7-18.1)

Be absolutely certain to apply an adequate amount of silicon

gasket to the area indicated by the arrow in the illustration.

3. Oil pan
Install the bolts in sequence commencing with the bolts on
center.

Torque kg-m(ftlbs.) 1.5 — 2.1 (10.8 — 15.2)

Carefully note the position of the crankcase front and rear

arches.
Insert the packing.
Minimize the packing level as much as possible.
 4ZD1 GASOLINE ENGINE 0 1 - 6 3

4. Distributor
(1) Move the No. 4 piston (cylinder) to the top dead center posi-
tion on the compression stroke.
(2) Apply engine oil to the O-ring.
(3) Check to see that the setting marks on the distributor shaft
and the cylinder head are aligned.

5. Head cover
Apply silicon gasket to the arched portion of the camshaft bear-
ing cap.
Tighten the head cover with predetermined torque.

Torque kg-m (ft. lbs.) 0.8-1.2(5.78-8.7)

0 1 - 6 4 4ZD1 GASOLINE ENGINE

EXTERNAL PARTS
(Front and left hand side)

Reassembly steps
1. Water inlet pipe 8. V-belt air pump
2. Air pump bracket " A " • 9. O2 Sensor (California only)
A 3. Exhaust manifold 10. Air injection manifold
4. Air pump and bracket " B " 11. Spark plug
5. Generator and bracket 1 2. High-tension cord
6. Crankshaft pulley and water 1 3. Fan and clutch assembly
pump pulley 14. Oil level gauge
7. V-belt generator 1 5. Engine mounting bracket
 4ZD1 GASOLINE ENGINE 0 1 - 6 5

Important operation

3. Exhaust manifold
Tighten the exhaust manifold with predetermined torque.

Torque kg-m(ftlbs.) 1.9-2.5(13.7-18.1)

9. O2 Sensor (California)
Apply rubber sealant to the threads before installation.

Torque kg-m(ft.lbs.) 3.9-4.7 (28.2-34.0)

0 1 - 6 6 4ZD1 GASOLINE ENGINE

OIL PUMP

DISASSEMBLY

Disassembly steps
1. Nut 6. Inner rotor
2. Oil pump pulley 7. Shaft
3. Outer rotor 8. Housing
4. Key 9. Oil seal
5. Pin (Shaft-Rotor)
 4ZD1 GASOLINE ENGINE 0 1 - 6 7

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through
inspection.

Visually inspect the disassembled parts for wear, damage, or

other abnormal conditions.

Insert the vane into the cylinder body and measure the top
clearance.

mm(in.)
Standard Limit
0.04 - 0.09
0.15 (0.006)
(0.002 - 0.004)

Measure the clearance between the slide surfaces of the outer

rotor and the cylinder body.
mm(in.)
Standard Limit
0.24 - 0.36
0.4 (0.016)
(0.009 - 0.014)
0 1 - 6 8 4ZD1 GASOLINE ENGINE

Clearance between the outer rotor and the inner rotor

mm(in.)
Standard Limit

0.13 - 0.15
0.2 (0.008)
(0.005 - 0.006)

REASSEMBLY

To assemble, follow the disassembly procedure in reverse order.

 4ZD1 GASOLINE ENGINE 0 1 - 6 9

WATER PUMP

REMOVAL AND INSTALLATION

Removal steps Installation steps

1. Bolts 2. Water pump assembly
2. Water pump assembly 1. Bolts
0 1 - 7 0 4ZD1 GASOLINE ENGINE

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through
inspection.

Visual check
Should any of the following problems occur, the entire water
pump should be replaced as a unit.
1. Cracks in the water pump body
2. Water leakage from the seal unit
3. Play or abnormal noise in the bearing
4. Cracks or corrosion in the impeller

Important operation — Installation

1. Bolt
Tighten the water pump assembly with predetermined torque.

Torque kg-m(ft.lbs.) 1.4-2.4 (10.1-17.4)

 4ZD1 GASOLINE ENGINE 0 1 - 7 1

RADIATOR

REMOVAL AND INSTALLATION

Removal steps Installation steps

1. Top hose To install, follow the removal procedure in reverse order.
2. Bottom hose
3. Hose ; surge tank
4. Fan shroud
5. Stay
6. Radiator assembly
0 1 - 7 2 4ZD1 GASOLINE ENGINE

INSPECTION AND REPAIR

Make necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered during
inspection.

(1) Radiator filler cap

Check the filler cap pressure valve opening pressure using a
radiator filler cap tester. If the measurement deviates from
the specified range, replace the cap assembly with a new
one.
Cap tester : J24460-01

Pressure valve
0.8 - 1.2 (12.8 - 17.1)
kg/cm2(lb/in2)(psi)

Check the condition of the vacuum valve at the center part of the
valve seat on the filler cap. Replace the cap with a new one if it is
found to be rusted or fouled.

Negative pressure
0.04 - 0.05 (0.6 - 0.7)
valve kg/cm2(psi)

Check to see if the vacuum valve can be operated smoothly by

hand. Clean or replace the valve with a new one if necessary.

(2) Inspection of the radiator for leakage

Check the cooling system for leakage at the following points
by applying a pressure of 2 kg/cm2 (28.5 psi) with a cap
tester:
• Leakage from the radiator
• Leakage from the water pump
• Leakage from the water hoses
• Check the rubber hoses for swelling.
Cap tester : J-24460-01

(3) Radiator core

Thoroughly clean the radiator core to remove deposits of
foreign matter from the front face and from between the
cooling fins.
If the cooling fins are found to be distorted, make correc-
tions taking care not to damage the joining portions between
the fins and the water tubes.

(4) Water hoses

Check the top and bottom hoses for deterioration, swelling,
or damage, and replace with new ones as necessary.
 4ZD1 GASOLINE ENGINE 0 1 - 7 3

THERMOSTAT

REMOVAL AND INSTALLATION

Removal steps Installation steps

1. Bolts 4. Thermostat
2. Water outlet pipe 3. Outlet pipe packing
3. Outlet pipe packing 2. Water outlet pipe
4. Thermostat 1. Bolts
0 1 - 7 4 4ZD1 GASOLINE ENGINE

Important operation — Installation

1. Bolts
Tighten the water pump assembly with predetermined torque.

Torque kg-m(ft.lbs.) 1.4-2.4 (10.1-17.4)

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through
inspection.

Submerge the thermostat assembly in water. Gradually

increase the temperature of the water. Observe and record the
temperature of the water at the time the valve first begins to
open. Then observe and record the temperature at which the
valve becomes fully open.

Valve opening temperature 80.5 - 83°C

Valve lift 8 mm or more at 95°C

Note: 1) It should take from three to five minutes for the valve
to first begin to open, depending on the initial tem-
perature of the water.
2) Do not directly apply heat to the thermostat during
this procedure.
Place wooden blocks at the bottom of the hot water
container or suspend the thermostat with wire or
rope into the container.
3) Frequently stir the hot water to ensure that the tem-
perature is constant throughout the container.
 4ZD1 GASOLINE ENGINE 0 1 - 7 5

DIAGNOSIS
HARD STARTING

Troubleshooting Procedure

Turn on headlights and starter switch.

Headlights go out or dim considerably. a) Battery undercharged,

b) Starting motor coil circuit shorted,
c) Starting motor parts defective.

Headlights stay bright a) Starting motor circuit open,

b) Starting motor coil open,
c) Starting switch defective.
0 1 - 7 6 4ZD1 GASOLINE ENGINE
 4ZD1 GASOLINE ENGINE 0 1 - 7 7

Spark Test

Remove the high-tension cable from any spark plug.

Hold the end of the high-tension cable close to the engine
block and while cranking engine, check to see if a spark
jumps across the gap.

Be sure to cover the high-tension cable with dry paper,

or some other good insulating material to prevent shock
before cranking the engine.

Spark jumps across the gap. a) Ignition timing incorrect,

b) Spark plug defective,
c) Fuel not reaching carburetor or engine,
d) Engine lacks compression.

No sparking takes place. a) Primary coil circuit shorting,

b) Distributor air gap incorrect,
c) Distributor points burned,
d) Primary coil circuit open or loosely connected.
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Trouble Shooting Procedure

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ROUGH ENGINE IDLING

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ENGINE LACKS POWER

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ENGINE NOISY

Troubleshooting procedure
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Troubleshooting procedure
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Trouble-shooting procedure
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Trouble-shooting procedure
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ABNORMAL COMBUSTION
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01-104 4ZD1 GASOLINE ENGINE

ENGINE OIL CONSUMPTION EXCESSIVE

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FUEL CONSUMPTION EXCESSIVE

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SPECIAL TOOLS

ESSENTIAL
OR ILLUSTRATION PARTS NO. PARTS NAME
AVAILABLE

J-26513-A Compressor ; valve spring

J-26512
J-26512-1 Remover ; guide pin and installer
J-26512-2 Adapter ; installer

J-24086 Service set ; piston pin

J-24086-8 Remover ;
J-24086-10 Base fixture
J-24086-75 Piston support
J-24086-9 Installer ;
J-24086-5 Pin guide

J-23097 Remover ; pilot bearing

J-33950 Sleeve remover

J-26516-A Installer ; pilot bearing

J-22928-A Installer ; oil seal rear

 4ZD1 GASOLINE ENGINE 0 1 - 1 1 1

ESSENTIAL
OR ILLUSTRATION PARTS NO. PARTS NAME
AVAILABLE

J-29818 Rear crankshaft seal installer

J-26587 Installer ; oil seal front cover

J-8037 Ring installer

J-24460-1 Tester ; radiator cap

MEMO