         

         
           

          


 







 General Information 0A-1

GENERAL INFORMATION
General Information
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2
Reading the model . . . . . . . . . . . . . . . . . . . . . . . 0A-6
General information . . . . . . . . . . . . . . . . . . . . . . 0A-7
0A-2 General Information

General Information
Service Precautions
In order to carry out work safely
1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical
system, always remove the minus side cable from
the battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.

WSHK0190

6. All regular tools, gauges and special tools should

be regularly inspected, and prepared before
starting work. Do not use bent spanners, hammers
with damaged edges, chipped chisels, or any other
faulty or damaged tools.

4. Do not perform painting work or leave the engine

running for long periods of time in an enclosed or
badly ventilated indoor workshop.
5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may
cause damage to the parts or injury to the person
using the tool.
7. Always pay close attention to safety and handling
requirements when using grinders, cranes,
welders, and other such equipment.
Moreover, always wear the correct protective
garments and use the necessary safety tools for
the job in hand.
 General Information 0A-3

WSHK0191 WSHK0192

8. Always check that there are no fuel leaks when

performing maintenance work on the fuel system. Replacement parts and part numbers.
(It may cause a fire.) 1. Always replace packing, oil seals, o-rings, caulking
lock nuts, folding lock plates, split pins and other
such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to
revisions. Therefore, parts should always be
checked against a parts catalogue before use.

Liquid gasket
1. Each time you disassemble parts that use liquid
gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to
completely remove oil, water, and dirt etc. from the
various surfaces. Using the specified type of liquid
gasket, apply new liquid gasket to each of the
surfaces before reassembling the parts.
2. In order to make it easier to clean liquid gasket
9. Pay close attention to the risk of ignition if you are surfaces, apply gasket remover liquid (Pando-
handling parts that carry a high voltage. 391D made by Three Bond Co., Ltd.) and leave
Furthermore, any oil or grease spilt onto rubber the part to stand for approximately 10 minutes,
parts must be wiped off immediately, as it will after which the old liquid gasket residue will be
cause deterioration of the rubber. easier to remove.
However, this should not be used on resin
components or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when re-
installing the liquid gasket parts to each other. If
there are gaps between the two parts, re-apply the
liquid gasket. Some parts, especially the oil pan,
use the same size studs as a guide to eliminate the
need for knock pin positioning etc.
5. Re-install these parts within 7 minutes of applying
the liquid gasket.
0A-4 General Information
If more than 7 minutes passes, remove the
previous liquid gasket and re-apply it.
6. Please wait for at least 30 minutes since the last
part is installed before starting the engine.

Liquid gasket

Seal section Product name Manufacturer's name

Between cylinder block and – Flywheel housing 1207B Three Bond
Between cylinder block and – Flywheel housing and –
1207B Three Bond
Crankcase
Between cylinder block and – Crank case 1207B Three Bond
Between cylinder block and – Front cover 1207B Three Bond
Cylinder block, head plug nipple, unit, switches 262 Loctite

• Always use the liquid gasket products listed above,

or a liquid gasket identical to the ones listed above.
• Use the correct quantity of liquid gasket. Always
follow the handling instructions for each product.

Application procedure
1. Wipe the contact surfaces clean of all water,
grease or oil. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.

Notes:
If there are special regulations concerning the
application procedure in the repair document, please
follow those regulations.

Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
Important:
screw thread section clean of water, grease, and
After tightening the bolt, do not apply excessive torque
oil. The contact surfaces should be dry.
or try to rotate the bolt until at least one hour has
2. Apply Loctite to the top 1/3 of the screw. passed, and the Loctite has hardened.
3. Tighten the bolt to the correct tightening torque.
Procedure for using the Plastigauge

Type Measurable range mm (in)

PG-1 (Green) 0.025 – 0.076 (0.001 – 0.003)
PR-1 (Red) 0.051 – 0.152 (0.002 – 0.006)
PB-1 (Blue) 0.102 – 0.229 (0.004 – 0.009)

Example: Procedure for measuring the clearance

between the connecting rod bearing and crank pin.
• Clean the connecting rod and bearing, and install
the bearing to the rod.
• Cut the plastigauge to the same width as the crank
pin, and while avoiding the oil pore of the crank pin
lay the gauge parallel to the pin.
 General Information 0A-5
• Line up the marks on the connecting rod and cap • Cut the plastigauge to the same size as the journal
and install the crank pin, apply molybdenum width, and while avoiding the oil pore of the journal
disulfide to the thread section and bearing surface lay the gauge parallel to the journal.
of the fastening bolt, and rotate both cap and bolt • Gently rest the crank case on the cylinder block,
to the correct torque. apply molybdenum disulfide to the thread section
and bearing surface of the fastening bolt, and
Important: tighten in sequence to the correct torque.
Do not move the connecting rod while using the
plastigauge. Important:
• Gently remove the cap and connecting rod, and Do not rotate the crankshaft while using the
measure the crushed width of the plastigauge plastigauge.
(clearance between rod and pin) using the scale • Gently remove the crankcase, and measure the
printed on the bag. crushed width of the plastigauge (clearance
between bearing and journal) using the scale
printed on the bag.

Example: Measuring the clearance between the crank

bearing and crank journal
• Clean the clamp face of the cylinder block and
crankcase bearing, and also the bearing, and
install the cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
and rotate it approximately 30 degree to stabilize it.
0A-6 General Information
Reading the model
Engine number stamping position
4HK1

WSHK0185
 General Information 0A-7
6HK1

WSHK0186

General information
Terminology, description of abbreviations
Terminology definitions
Term Explanation
Maintenance standard The generic name for reference values required for maintenance, such as nominal
dimension, selection of a reference point, and limit.
Nominal dimension Shows the standard value at the point of manufacture that does not include the
common difference.
Selection of a reference point Shows the standard value after assembling, repairing, or adjusting.
Limit When this value (dimensions) is reached, it shows that the part has reached its full
limit and must be replaced or repaired.
Front rear, left right, upper These show each orientations of parts installed to the vehicle when looking from
lower the vehicle's forward direction.
Unit Units written to SI conventions (mainly torque, pressure, force)
[Example] Length: mm, Torque: N m {kgf m}
Warning Items that carry the warning mark pose a danger to life or threat of serious injury if
not strictly observed.
Caution Items that carry the caution mark may cause injury or lead to accidents if not strictly
observed.
Important Items that carry the important mark may cause the vehicle to break down, or may
prevent the guaranteed normal operation of the system or related parts if not strictly
observed.
0A-8 General Information

Term Explanation
Notes Items that should receive special mention within a work procedure.

Description of abbreviations Abbreviation Description

FWD Forward
Abbreviation Description Forward
AC Alternating Current F/C Fuel Cut
Alternating Current Fuel Cut
ACC Accessory GND Ground
Accessory Earth
ACG Alternating Current Generator IC Integrated Circuit
Alternating current generator Integrated circuit
API American Petrol Institute ID Plate Identification plate
American Petroleum Institute Identification plate, ID plate
ASM (Assy) Assembly IN Intake, Intake
Assembly Intake
ATDC After Top Dead Center ISO International Organization for
After Top Dead Center Standardization
International Organization for
BAT, BATT Battery
Standardization
Battery
I/PUMP Injection Pump
BRG, Brg Bearing
Injection Pump
Bearing
JIS Japanese Industrial Standard
BKT, BRKT Bracket
Japanese Industrial Standard
Bracket
L/H, LH Left Hand
BTDC Before Top Dead Center
Left hand side
Before Top Dead Center
M/V Magnetic Valve
CO Carbon Oxide
Magnetic valve
Carbon Monoxide
NOx Nitrogen Oxide
CONN Connector
Nitrogen Oxide
Connector
N-TDC Number - Top Dead Center
CPU Central Processing Unit
Top dead center rotational frequency
Central processing unit
OPT Option
C/U Control Unit
Option
Control unit
P Pole(S)
DC Direct Current
Pole
Direct current
PCV Pump Control Valve/ Positive
DI Direct Injection
Crankcase Ventilation
Direct injection
Pump control valve/ Positive crankcase
ECU Engine Control Unit / Electronic Control ventilation
Unit
PM Particulate Matter
Engine control unit / control unit
Particulate matter
ECM Engine Control Module
PS Pre-Stroke
Engine control module
Pre-stroke
EGR Exhaust Gas Recirculation
PTO Power Take Off
Exhaust gas recirculation
Power take off
Exh, EXH Exhaust
QOS Quick On System
Exhaust
Rapid preheating system
Ft, FRT Front
Rr, RR Rear
Front
Rear
 General Information 0A-9

Abbreviation Description SI (International System of Units)

R/H, RH Right Hand With regards the conversion to SI (International

Right hand side System of Units)
The introduction of the SI systems aims to
R/L Relay
internationally unify the metric system and the various
Relay
units used by different countries (traditional weights
STD Standard and measures, the foot pound method etc.), and to
Standard curb the confusion that occurs between the different
SW Switch units (conversion calculations etc.).
Switch The new calculating method which adopted SI units
was completely adopted in Japan in 1992, and is
TICS Timing & Injection rate Control System standardized by JIS-Z-8203.
A type of injection system All of the units in this manual are written in line with the
VGS Turbo Variable Geometry turbocharger International System of Units SI units, and conventional
System units are written in { } brackets.
Adjustable turbo, VGS turbo SI
W/L Warning Lamp French) Abbreviated name of Le Systeme International
Warning lamp d’Unites

Connection between main SI units and conventional units

SI Conventional Unit Item, unit conversion

Length m m Same as the conventional unit
Weight (Mass) kg kg Same as the conventional unit
Force N * kg, kgf 1 kgf = 9.80665 N
Torque Nm * kg m, gf m 1 kgf m = 9.80665 N m
Pressure Pa *kg/cm2, mmHg 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa
Dynamic force, horsepower W PS 1 PS = 0.74 kW
Capacity, air volume displacement m3 Litle, L, cc 1 Litle = 1 dm3, 1 cc = 1mLitle = 1cm3
Fuel consumption g/(kW h) g/(PS h) 1 g/(PS h) = 1.360 g/(kW h)

*1 Published service data may conveniently use kg for Conversion formula

force and mass (weight) instead of kgf. Length
*2 Some conversion results may be rounded off to 1 or
• km 0.6214 = mile
2 decimal places.
• m 3.281 = ft
Converting expressions of quantity
• mm 0.03937 = in
When converting, prefixes such as k (kilo) or m (mili) Pressure
are used.
• kPa 0.0101972 = kg/cm2
M Mega 106 1,000,000 • kPa 0.145038 = psi
k Kilo 103 1,000 • MPa 10.197162 = kg/cm2
• MPa 145.03774 = psi
h Hecto 102 100
Tightening torque
d Deci 10-1 0.1 • N m 0.101972 = kg m
c Centi 10-2 0.01 • N m 0.737562 = lb ft
Speed
m Milli 10-3 0.001
• kg/h 0.6214 = MPH
Micro 10-6 0.000001 Temperature
• C 1.8 + 32 = F
• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa
• 40 mmHg = 5,332 Pa = 5.3 kPa
0A-10 General Information
Table of standard Isuzu tightening torque
The tightening torque values in the table below apply to
all situations unless a special tightening torque is
specified.
Isuzu standard bolts, nuts

N m {kgf m}
Strength 4.8
7T
classification 4T
Bolt head
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
section shape
* M10 1.5 19.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1}
68.1 ~ 102.1 {6.9 ~
M12 1.25 49.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}
10.4}
* M12 1.75 45.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6}
76.5 ~ 114.7 {7.8 ~ 83.0 ~ 124.5 {8.5 ~ 93.2 ~ 139.3 {9.5 ~ 100.8 ~ 151.1 {10.3 ~
M14 1.5
11.7} 12.7} 14.2} 15.4}
71.6 ~ 106.9 {7.3 ~ 77.2 ~ 115.8 {7.9 ~ 88.3 ~ 131.4 {9.0 ~ 94.9 ~ 142.3 {9.7 ~
* M14 2
10.9} 11.8} 13.4} 14.5}
104.0 ~ 157.0 {10.6 ~ 115.6 ~ 173.3 {11.8 ~ 135.3 ~ 204.0 {13.8 ~ 150.1 ~ 225.2 {15.3 ~
M16 1.5
16.0} 17.7} 20.8} 23.0}
100.0 ~ 149.1 {10.2 ~ 109.4 ~ 164.2 {11.2 ~ 129.4 ~ 194.2 {13.2 ~ 142.5 ~ 213.8 {14.5 ~
* M16 2
15.2} 16.7} 19.8} 21.8}
151.0 ~ 225.6 {15.4 ~ 195.2 ~ 293.2 {19.9 ~
M18 1.5 — —
23.0} 29.9}
151.0 ~ 225.6 {15.4 ~ 196.1 ~ 294.2 {20.0 ~
* M18 2.5 — —
23.0} 30.0}
206.0 – 310.0 {21.0 ~ 269.7 ~ 405.0 {27.5 ~
M20 1.5 — —
31.6} 41.3}
190.2 ~ 286.4 {19.4 – 249.1 ~ 374.6 {25.4 ~
* M20 2.5 — —
29.2} 38.2}
251.1 – 413.8 {25.6 ~ 362.8 ~ 544.3 {37.0 ~
M22 1.5 — —
42.2} 55.5}
217.7 ~ 327.5 {22.2 ~ 338.3 ~ 507.0 {34.5 ~
* M22 2.5 — —
33.4} 51.7}
358.9 ~ 539.4 {36.6 ~ 430.5 ~ 711.0 {43.9 ~
M24 2 — —
55.0} 72.5}
338.3 ~ 507.0 {34.5 ~ 406.0 ~ 608.0 {41.4 ~
* M24 3 — —
51.7} 62.0}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.
 General Information 0A-11

N m {kgf m}
9.8
Strength classification 8.8
9T
Bolt head section
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
shape
5.6 ~ 11.2 {0.6 ~ 6.6 ~ 12.2 {0.6 ~
M6 1 — —
1.1} 1.2}
13.4 ~ 25.7 {1.4 ~ 15.3 ~ 28.4 {1.6 ~ 16.7 ~ 30.4 {1.7 ~ 18.1 ~ 33.6 {1.9 ~
M8 1.25
2.6} 2.9} 3.1} 3.4}
31.3 ~ 52.5 {3.2 ~ 35.4 ~ 58.9 {3.6 ~ 37.3 ~ 62.8 {3.8 ~ 42.3 ~ 70.5 {4.3 ~
M10 1.25
5.4} 6.1} 6.4} 7.2}
31.3 ~ 51.4 {3.2 ~ 34.5 ~ 57.5 {3.5 ~ 36.3 ~ 59.8 {3.7 ~ 40.1 ~ 66.9 {4.1 ~
* M10 1.5
5.2} 5.8} 6.1} 6.8}
69.3 ~ 104.0 {7.1 ~ 77.7 ~ 116.5 {7.9 ~ 75.5 ~ 113.8 {7.7 ~ 85.0 ~ 127.5 {8.7 ~
M12 1.25
10.6} 11.9} 11.6} 13.0}
64.8 ~ 96.1 {6.6 ~ 71.4 ~ 107.2 {7.3 ~ 71.6 ~ 106.9 {7.3 ~ 79.5 ~ 119.2 {8.1 ~
* M12 1.75
9.8} 10.9} 10.9} 12.2}
106.2 ~ 158.8 {10.8 114.9 ~ 172.3 {11.7 113.8 ~ 170.6 {11.6 123.4 ~ 185.1 {12.6
M14 1.5
~ 16.2} ~ 17.6} ~ 17.4} ~ 18.9}
100.6 ~ 149.8 {10.3 108.2 ~ 162.2 {11.1 106.9 ~ 160.0 {10.9 115.5 ~ 173.3 {11.8
* M14 2
~ 15.3} ~ 16.6} ~ 16.3} ~ 17.7}
154.3 ~ 232.5 {15.7 171.1 ~ 256.7 {17.4 160.0 ~ 240.3 {16.3 176.9 ~ 265.3 {18.0
M16 1.5
~ 23.7} ~ 26.2} ~ 24.5} ~ 27.1}
147.6 ~ 221.4 {15.0 162.5 ~ 243.8 {16.6 153.0 ~ 229.5 {15.6 168.5 ~ 252.7 {17.2
* M16 2
~ 22.6} ~ 24.9} ~ 23.4} ~ 25.8}
222.5 ~ 334.3 {22.7 229.5 ~ 345.2 {23.4
M18 1.5 — —
~ 34.1} ~ 35.2}
223.6 ~ 335.4 {22.8 230.5 ~ 346.2 {23.6
* M18 2.5 — —
~ 34.2} ~ 35.3}
307.4 ~ 461.7 {31.4 316.8 ~ 475.6 {32.3
M20 1.5 — —
~ 47.1} ~ 48.5}
284.0 ~ 472.1 {29.0 293.2 ~ 440.3 {29.2
* M20 2.5 — —
~ 43.5} ~ 44.9}
413.6 ~ 620.5 {42.2 424.6 ~ 636.5 {43.3
M22 1.5 — —
~ 63.3} ~ 64.9}
385.7 ~ 578.0 {39.3 394.2 ~ 592.3 {40.0
* M22 2.5 — —
~ 58.9} ~ 60.4}
490.8 ~ 810.5 {50.0 554.1 ~ 830.6 {56.5
M24 2 — —
~ 82.7} ~ 84.7}
462.8 ~ 693.1 {47.2 520.7 ~ 781.6 {53.1
* M24 3 — —
~ 70.7} ~ 79.7}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.
0A-12 General Information
Designations for Isuzu standard bolt heads

Legend
1. Hexagon head bolt(4.8, 4T) 9. Hexagon head bolt(Un-refined 8.8)
2. Hexagon head bolt(4.8, 4T) 10. Hexagon head bolt(Un-refined 8.8)
3. Flange bolt(4.8, 4T) 11. Flange bolt(8.8)
4. Flange bolt(4.8, 4T) 12. Flange bolt(8.8)
5. Hexagon head bolt(7T) 13. Hexagon head bolt(9.8, 9T)
6. Flange bolt(7T) 14. Hexagon head bolt(9.8, 9T)
7. Hexagon head bolt (refined 8.8) 15. Flange bolt(9.8, 9T)
8. Hexagon head bolt (refined 8.8) 16. Flange bolt(9.8, 9T)

Flare nut

Pipe diameter tightening torque Flare nut 2 side width (mm)

(for medium and large
Old New
size vehicles)
Flare nut tightening torque (service 4.76 mm 12.8 ~ 18.6 {1.3 ~ 1.9} 14 14
standard value) N m {kgf m}
6.35 mm 23.5 ~ 49 {2.4 ~ 5.0} 17 17
8.0 mm 23.5 ~ 49 {2.4 ~ 5.0} 19 17
10.0 mm 44.1 ~ 93.2 {4.5 ~ 9.5} 22 19
12.0 mm 58.8 ~ 137.3 {6.0 ~ 14.0} 27 24
15.0 mm 78.5 ~ 156.9 {8.0 ~ 16.0} 30 30
 General Information 0A-13
Taper screw from connectors (brass)

N m {kgf m}
Screw size PT(R) 1/8 PT(R) 1/4 PT(R) 3/8 PT(R) 1/12
— 2.0 ~ 14.7 4.9 ~ 15.7 9.8 ~ 16.7 9.8 ~ 17.7
(0.2 ~ 1.5) (0.5 ~ 1.6) (1.0 ~ 1.7) (1.0 ~ 1.8)

Special Tool Classification

A; Essential tool
Servicing operation cannot be done with any other tools than the essential tool.

B; Recommended tool
Servicing work can be done with a general-purpose tool commercially available.
However, it is advisable to use the recommended tool as much as possible for a reduced work time and an improved
safety in work operations.

C; Available tool
Although it takes a more working time, servicing operations can be made with a tool commercially available as
substitute for the available tool.
0A-14 General Information
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-1

ENGINE
ENGINE MECHANICAL (4HK1, 6HK1)
TABLE OF CONTENTS
ISUZU DIESEL ENGINE (4HK1, 6HK1) . . . . . . . . 1A-3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-83
Precautions on Service Work. . . . . . . . . . . . . . . 1A-3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-89
Main Data and Specifications. . . . . . . . . . . . . . 1A-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-96
Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . 1A-14 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-103
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-14 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-103
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-15 Piston, Connecting Rod . . . . . . . . . . . . . . . . . .1A-105
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-16 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-105
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-105
Inlet Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .1A-106
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-23 Torque Specifications . . . . . . . . . . . . . . . . . . . 1A-116
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-25 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116
Turbocharger and Exhaust Manifold . . . . . . . . . . 1A-26 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-26 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-117
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-28 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-119
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-32 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-121
Timing Gear Train . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-121
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-35 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-122
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-123
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-124
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-51 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-126
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-53 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . .1A-128
Rocker Arm Shaft ASM . . . . . . . . . . . . . . . . . . . . 1A-54 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-128
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-54 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-128
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-54 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-130
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-55 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-135
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-57 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-135
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-58 Crankshaft Rear Oil Seal. . . . . . . . . . . . . . . . . . 1A-136
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-60 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-136
Camshaft ASM . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-61 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-136
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-61 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-137
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-62 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-140
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-63 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-65 Components . . . . . . . . . . . . . . . . . . . . . . . . . .1A-141
Fixing torque . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-67 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-141
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-67 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .1A-143
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-68 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .1A-143
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-70 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-143
Valve Stem Seal, Valve Spring . . . . . . . . . . . . . . 1A-71 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-148
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-71 Torque Specifications . . . . . . . . . . . . . . . . . . .1A-152
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-71 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-152
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-72 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-154
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-73 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-154
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-75 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-154
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-76 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-155
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-76 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-156
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-76 Lubrication System . . . . . . . . . . . . . . . . . . . . . .1A-159
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-80 Precautions on Service Work . . . . . . . . . . . . .1A-159
1A-2 ENGINE MECHANICAL (4HK1, 6HK1)
Function Check . . . . . . . . . . . . . . . . . . . . . . . 1A-160
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-161
Oil Port Cover ASM. . . . . . . . . . . . . . . . . . . . . . 1A-162
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-162
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-164
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-165
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-166
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-166
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-167
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-170
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-171
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173
Components. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-173
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 1A-174
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-174
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-175
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-176
Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . 1A-180
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-180
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-3

ISUZU DIESEL ENGINE (4HK1, 6HK1)

Precautions on Service Work Matters that require attention in specifically dealing
with this engine.
Matters that require attention in terms of
maintenance Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
To prevent damage to the engine and ensure reliability
are made with extreme precision. For this reason, they
of its performance, pay attention to the following in
are highly sensitive to foreign matter and if it gets in, it
maintaining the engine: When taking down the engine
can lead to an accident on the road, for instance; thus,
on the ground, do not make the bearing surface of the
make sure that foreign matter will be prevented from
oil pan touch directly the ground. Use a wood frame, for
getting in.
example, to support the engine with the engine foot and
When servicing the fuel system, every precaution must
the flywheel housing.
be taken to prevent the entry of foreign material into the
Because there is only a small clearance between the
system.
oil pan and the oil pump strainer, it can damage the
oil pan and the oil strainer. • Before beginning the service procedure, wash the
fuel line and the surrounding area.
• When the air duct or air cleaner is removed, cover
the air intake opening to prevent foreign matter • Perform the service procedures with clean hands.
from getting into the cylinder. If it gets into it, it can Do not wear work gloves.
considerably damage the cylinder and others while • Immediately after removing the fuel hose and/or
the engine is operating. fuel pipe, carefully tape vinyl bags over the
• When maintaining the engine, never fail to remove exposed ends of the hose or pipe.
the battery ground cable. If not, it may damage the • Always replace the high-pressure pipe in fuel
wire harness or electrical parts. If you need system with new one if it has been removed.
electricity on for the purpose of inspection, for Reuse of it causes damage the seal surface,
instance, watch out for short circuits and others. resulting in fuel leakage.
• Apply engine oil to the sliding contact surfaces of • If parts are to be replaced (fuel hose, fuel pipe,
the engine before reassembling it. This ensures etc.) do not open the new part packaging until
adequate lubrication when the engine is first installation.
started.
• When valve train parts, pistons, piston rings, Work procedure
connecting rods, connecting rod bearings or • The fuel opening must be quickly sealed when
crankshaft journal bearings are removed, put them removing the fuel pipe, injection pipe, fuel injector,
in order and keep them. fuel supply pump, and common rail.
• When installing them, put them back to the same • The eyebolts and gasket must be stored in a clean
location as they were removed. parts box with a lid to prevent adhesion of foreign
• Gaskets, oil seals, O-rings, etc. must be replaced matter.
with new ones when the engine is reassembled. • Fuel leakage could cause fires. Therefore, after
• As for parts where a liquid gasket is used, remove finishing the work, wipe off the fuel that has leaked
an old liquid gasket completely and clean it up out and make sure there is no fuel leakage after
thoroughly so that no oil, water or dust may be starting the engine.
clung to them. Then, apply the designated liquid
gasket to each place anew before assembly.
• Surfaces covered with liquid gasket must be
assembled within 7 minutes of gasket application.
If more than 7 minutes have elapsed, remove the
existing liquid gasket and apply new liquid gasket.
• When assembling or installing parts, fasten them
with the specified tightening torque so that they
may be installed properly.
1A-4 ENGINE MECHANICAL (4HK1, 6HK1)
How to read the model
4HK1

Name
1. Cast The Engine Model 2. Stamp An Engine Number
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-5
6HK1

WSHK0001

Name
1. Stamp An Engine Number

Explanations on functions and operation Cylinder liner

The cylinder liner is selected to match an internal
Electronic engine control
diameter of a bore of the cylinder block and built, which
With the control unit, the range from injection to air
is imprinted on the left side of the cylinder.
intake/exhaust, including fuel injection quantity,
injection timing, intake air restriction, EGR, and idling Piston
rpm, is controlled. The piston is aluminum-alloy and an autothermatic
piston with a strut cast, while the combustion chamber
Cylinder block
is a round reentrant type.
The cylinder block is cast-iron with the center distance
of each bore being equal and is of the highly rigid, Cylinder head
symmetrical structure with the crankshaft center being The cylinder head is cast-iron and there are 4 valves
the center. The bearing cap is of the ladder frame per cylinder. The angular tightening method of the
structure and tightened up under the plastic range cylinder head bolt further increases reliability and
rotation angle method. durability.
1A-6 ENGINE MECHANICAL (4HK1, 6HK1)
Crankshaft • Rotate the crankshaft to make the No.1 cylinder
Tuftriding is given, while on the No. 1 balance weight meet the compression top dead center (TDC).
imprinted is the grade of each journal diameter. 4HK1
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.
Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.
Common rail-type electronic control injection
system
The common rail-type electronic control injection
system is composed of a fuel supply pump that sets the
target pressure of high-pressure fuel and supply it, a
common rail that measures such high-pressure fuel
and a fuel injector that turns it into a fine spray and
injects it. Each is controlled via ECM based upon
various signals, while injection timing or fuel injection 6HK1
quantity is controlled under every possible driving
condition.
Fuel injector
The fuel injector is a 7-hole nozzle that adjusts fuel
injection quantity or injection timing by opening or
closing an electromagnetic valve on the head of the
fuel injector.
ECM corrects the dispersion of fuel injection quantity
between fuel injectors according to ID code data in
memory. At the replacement of fuel injectors, ID code
data should be stored in ECM.
Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.
Preheating system
The preheating system consists the ECM, the glow • Insert a 0.4 mm (0.016 in) thickness gauge into a
relay, glow plugs and the glow indicator lamp. The clearance between the rocker arm and the bridge
preheating system is operated when the engine coolant to check it and adjust it if needed.
temperature is low, and make the engine easy to start.
Valve clearance mm (in)
Lubrication system
It is an oil filter with full-flow bypass, which uses a Intake valve 0.4 (0.016)
water-cool oil cooler and oil jet to cool the piston. Exhaust valve 0.4 (0.016)

Function check Caution:

Inspection/adjustment of valve clearance Adjust while being cold.
1. Inspection of valve clearance 2. Adjustment of valve clearance
• Remove the cylinder head cover.
Caution:
• Remove the fuel injector harness ASM. Adjust valve clearance carefully so that the bridge may
• Loosen the terminal nuts alternately to remove. become level (hit the end of the 2 valve axes).
• Remove the leak off pipe.
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-7
a. Completely loosen all of the bridge and rocker • With a thickness gauge kept inserted, tighten
arm adjusting nuts and adjusting screws an adjusting screw of the bridge lightly and
(4HK1: 8 nuts and 8 screws, 6HK1: 12 nuts and make sure that the tip of the adjusting screw
12 screws). touches the end of valve axis and the
b. Place a 0.4 mm (0.016 in) thickness gauge movement of the thickness gauge has become
between the No. 1 cylinder rocker arm end and tight.
the bridge cap. • Then, check if the end of the valve axis on the
c. Tighten the rocker arm adjusting screw until the opposite side is unstable or hits diagonally. If
thickness gauge is snug (not tight) between the so, loosen the bridge adjusting screw a little so
rocker arm end and the bridge cap. that the end of the valves on both sides may
touch properly.
d. Tighten the rocker arm lock nut.
Valve bridge clearance: 0.1 mm (0.0039 in) or
e. Tighten the bridge adjusting screw until the less
bridge contacts the valve head.
• After making an adjustment so that the end of
f. Tighten the bridge lock nut. the valves on both sides may touch properly,
g. Check that the thickness gauge is still held tighten up an adjusting screw nut of the bridge
snugly between the rocker arm end and the with a flathead screwdriver so that the bridge
bridge cap. If it is too tight, slightly loosen the adjusting screw may not rotate.
bridge adjusting screw and lock nut to restore Tightening torque: 22 N m (2.2 kg m/16 lb ft)
snugness.
h. Remove the thickness gauge. Caution:
i. Repeat the above procedure for the remaining If the adjusting screw of the bridge is poorly adjusted,
cylinders. the bridge would tilt and be pushed down and seized,
which may damage the bridge guide, for example.
Tightening torque: 22 N m (2.2 kg m/16 lb ft)
Thus, adjust it accurately.

Tightening torque:
Name
1. Rocker Arm Rocker arm adjustment 22 N m (2.2 kg m/16 lb ft)
2. Bridge Cap screw nut
3. Bridge Bridge adjustment screw 22 N m (2.2 kg m/16 lb ft)
nut
1A-8 ENGINE MECHANICAL (4HK1, 6HK1)
Adjustment table (4HK1)
Cylinder No. 1 2 3 4
Valve arrangement IN EX IN EX IN EX IN EX
No. 1 cylinder
Compression top dead center position
No. 4 cylinder
Compression top dead center position

Adjustment table (6HK1)

Cylinder No. 1 2 3 4 5 6
Valve arrangement IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 cylinder
Compression top dead center position
No. 6 cylinder
Compression top dead center position

• If the No. 1 cylinder is the compression TDC,

adjust a valve clearance with mark given on
the table and if the No. 4 (4HK1) or No. 6
(6HK1) cylinder is the compression TDC, that
with mark.
4HK1

6HK1

WSHK0002
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-9
4HK1

WSHK0003

• Attach the harness ASM to the fuel injector.

Tighten the harness bracket with the
designated torque. Name
1. Fuel Injector Harness Connector
Tightening torque: 48 N m (4.9 kg m/35 lb ft)
6HK1
• Install the terminal nuts on the fuel injector.

Tightening torque: 2 N m (0.2 kg m/18 lb in)

Note:
• Tighten the terminal nuts alternately in order to
prevent imbalance in tightening because they are
unified.
• Do not tighten the nuts too tightly because it leads
to damage to the terminal stud.
• Install the cylinder head cover.
Refer to the “Cylinder Head Cover”.
Compression pressure inspection
• Warm-up the engine.
1
• Remove a negative terminal of the battery and
remove all the glow plugs.
• Remove the harness connector for the fuel injector
WSHK0004
built on the lower head cover (no fuel will be
injected). Name
1. Fuel Injection Harness Connector
Caution:
When the harness connector is removed, ECM judges
• Install the negative terminal of the battery.
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear memory • Turn on the starter to emit foreign matter within the
of ECM. cylinders.
(For how to clear memory of ECM, refer to the Engine • Install an adapter and a gauge of a compression
Control System Section) gauge of the special tool.
1A-10 ENGINE MECHANICAL (4HK1, 6HK1)

Compression gauge: 5-8840-2675-0 (J-26999-12)

Compression gauge adapter
4HK1: 5-8840-2815-0 (EN-46722)
6HK1: 5-8840-2622-0
• Turn on the starter to inspect compression
pressure.
4HK1
Compression pressure MPa (psi) / 200 rpm
Standard 2.84 – 3.24 (412 – 469)
Limit 1.96 (284)
Differences among
294 kPa (43)
the cylinders

6HK1
Compression pressure MPa (psi) / 200 rpm
Standard 3.24 (469)
Limit 2.26 (327)
Differences among
294 kPa (43)
the cylinders

• Measure each cylinder one by one.

Caution:
To keep engine speed at 200 rpm or more, use fully
charged batteries.
• Remove a compression gauge of the special tool.
• Remove a negative terminal of the batteries.
• Install a harness connector for the fuel injector built
on the lower head cover.
• Install all the glow plugs.
Tightening torque: 20 N m (2.0 kg m/15 lb ft)
• Install the negative terminal of the battery.
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-11
Main Data and Specifications

Item Engine model 4HK1

Type Diesel/4-cycle/water cooled-type, inline four-cylinder
OHC
Combustion chamber form Direct injection type
Cylinder liner type Dry type
Number of cylinders - cylinder bore mm (in) 4-115 (4.53) 125 (4.92)
strokes
Displacement cc (cu.in) 5193 (317)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3.23 (468)/200
Idle speed rpm 800
Valve clearance Intake 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold)
Ignition type Compressed ignition
Injection order 1-3-4-2
Lubricating system
Lubricating type Pressure type
Oil pump type Gear type
Volume of lubricating oil L (qts) 13.0 (13.7) — 20.5 (21.7)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in, water-cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax-type units
Thermostat valve-opening temperature C ( F) 85 (185)
Volume of coolant L (qts) 14 (14.8) (incl. radiator)
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Injection nozzle type Multi-hole type
7-hole and 0.16 mm (0.0063 in) inside diameter
Charging system
Generator type AC type
Power output V/A 24 - 50
Regulator type IC
1A-12 ENGINE MECHANICAL (4HK1, 6HK1)

Item Engine model 4HK1

Starting system
Starter type Reduction type
Power output V-kw 24 - 5.0
Preheat system type Glow plug
Glow plug standard voltage/electric current V/A 23 - 3.5

Item Engine model 6HK1

Type Diesel/4-cycle/water cooled-type, inline four-cylinder
OHC
Combustion chamber form Direct injection type
Cylinder liner type Dry type
Number of cylinders - cylinder bore mm (in) 6-115 (4.53) 125 (4.92)
strokes
Displacement cc (cu.in) 7790 (475)
Compression ratio 17.5
Compression pressure MPa (psi)/rpm 3.04 (441)/200
Idle speed rpm For Hitachi products: 800, For JCB and Sumitomo
products: 900
Valve clearance Intake 0.4 (0.016) (cold)
mm (in) Exhaust 0.4 (0.016) (cold)
Ignition type Compressed ignition
Injection order 1-5-3-6-2-4
Lubricating system
Lubricating type Pressure type
Oil pump type Gear type
Volume of lubricating oil L (qts) 28 (29.6) — 38 (40.2)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in, water-cooling
Cooling system
Cooling type Water cooling type
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax-type units
Thermostat valve-opening temperature C ( F) 82 (180)
Volume of coolant L (qts) 14.5 (15.3)
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-13

Item Engine model 6HK1

Injection nozzle type Multi-hole type
7-hole and 0.16 mm (0.0063 in) inside diameter
Charging system
Generator type AC type
Power output V/A 24 - 90/50
Regulator type IC
Starting system
Starter type Reduction type
Power output V-kw 24 - 5.0
Preheat system type Glow plug
Glow plug standard voltage/electric current V/A 23 - 3.5

Special tool

Illustration Tool Number/Description

5-8840-26750-0
J-26999-12
Compression gauge

5-8840-2815-0
EN-46722
Compression gauge
adapter
(4HK1)


5-8840-2622-0
Compression gauge
adapter
(6HK1)
1A-14 ENGINE MECHANICAL (4HK1, 6HK1)

Cylinder Head Cover

Components
4HK1

Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-15
6HK1

WSHK0005

Name
1. Head Cover 3. Head Cover Case
2. Gasket 4. Gasket

Removal
1. Remove the head cover.
2. Remove the gasket.
1A-16 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1 4HK1

Name Name
1. Head Cover 1. Head Cover Case
2. Fuel Injector Harness Connector
6HK1
6HK1

WSHK0006

WSHK0007
Name
1. Head Cover Name
1. Head Cover Case
3. Remove the fuel injector harness connector. 2. Fuel Injector Harness Connector
4. Remove the head cover case.
6. Remove the rubber plug.
5. Remove the gasket.

Installation
1. Install the rubber plug to the cylinder head.
• Apply liquid gasket (ThreeBond 1207B or
equivalent) to the position shown in the illustration
forming beads with diameters of 3—4 mm (0.12—
0.16 in). (4HK1)
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-17
• Apply liquid gasket (ThreeBond 1207B or 4HK1
equivalent) to the position shown in the illustration.
(6HK1)

• Install within seven minutes after applying liquid

gasket.


Name
1. Head Cover Case
2. Fuel Injector Harness Connector

 6HK1
Name
1. Rubber Plug
2. Liquid Gasket
1
2. Install the gasket on the lower cover.
3. Install the head cover case.
Tightening torque: 4HK1: 18 N m (1.8 kg m/13 lb ft),
6HK1: 13 N m (1.3 kg m/9.6 lb ft)
4. Install the fuel injector harness connector.

Caution:
Push it in thoroughly until the claws of the lock raise.
2

WSHK0007

Name
1. Head Cover Case
2. Fuel Injector Harness Connector

5. Install the gasket on the head cover.

6. Install the head cover and tighten up according to
the orders given on the figure.
Tightening torque: 4HK1: 18 N m (1.8 kg m/13 lb ft),
6HK1: 13 N m (1.3 kg m/9.6 lb ft)
1A-18 ENGINE MECHANICAL (4HK1, 6HK1)
4HK1

6HK1

WSHK0008
 ENGINE MECHANICAL (4HK1, 6HK1) 1A-19
Torque Specifications
4HK1
1A-20 ENGINE MECHANICAL (4HK1, 6HK1)
6HK1

N m{kg m/lb ft}

13 {1.3 / 9.6}

13 {1.3 / 9.6}

WSHK0009
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.