Mitsubishi 4M4 Service Manual

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Pub.No.TWDE0911, NOVEMBER 2009

Shop Manual

diesel engine

Pub.No.TWDE0911

NOVEMBER 2009

Shop Manual

Pub.No.TWDE0911, NOVEMBER 2009

GROUP INDEX

FOREWORD

This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso 4M4 series diesel engine, and includes procedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage.

GENERAL..........................................

ENGINE .............................................

LUBRICATION...................................

FUEL AND ENGINE CONTROL .......

COOLING ..........................................

INTAKE AND EXHAUST ...................

EMISSION CONTROL.......................

HYBRID ELECTRIC VEHICLE

SYSTEM ............................................

00 11 12 13 14 15 17 18

For more details, please consult your nearest authorized Mitsubishi dealer or distributors. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future.

NOVEMBER 2009

Applicable models 4M42T3

This Shop Manual contains the information classified into the following groups. If any system or equipment has two or more variations with significantly different construction, the variations are handled as different groups. These groups are identified by different alphabets preceded by the same number.

1. ENGINE volume

Group No. Group subject

11 ENGINE

12 LUBRICATION

13 FUEL AND ENGINE CONTROL

14 COOLING

15 INTAKE AND EXHAUST

17 EMISSION CONTROL

18 HYBRID ELECTRIC VEHICLE SYSTEM

2. CHASSIS volume

Group No. Group subject

21 CLUTCH

22 MANUAL TRANSMISSION

22E INOMAT-II

25 PROPELLER SHAFT

26 FRONT AXLE

27 REAR AXLE

31 WHEEL, TIRE

33 FRONT SUSPENSION

34 REAR SUSPENSION

35 BRAKE

35EA POWER ANTI-LOCK BRAKE SYSTEM

35EB HILL START ASSIST SYSTEM

36 PARKING BRAKE

37 STEERING

41 BUMPER, FRAME

42 CAB MOUNTING, TILT

43 DOOR

51 EXTERIOR

52 INTERIOR

55 HEATER, AIR-CONDITIONER

3. ELECTRICAL volume

Group No. Group subject

54 ELECTRICAL

GROUP 00 GENERAL

MODIFICATION SUMMARY ............................................................. 00-2

VEHICLE MODEL CODING SYSTEM .............................................. 00-4

EQUIPMENT TYPE CODING SYSTEM ............................................ 00-6

POWER TRAIN TABLE .................................................................... 00-7

HOW TO READ THIS MANUAL ....................................................... 00-8

CHASSIS NUMBER, ENGINE NUMBER, MOTOR NUMBER

AND NAME PLATE ......................................................................... 00-16

PRECAUTIONS FOR MAINTENANCE OPERATION .................... 00-18

JACKING UP THE VEHICLE .......................................................... 00-28

DIAGNOSIS CODES

1. Diagnosis Codes ...................................................................... 00-30

2. Reading and Erasing the Diagnosis Code ................................. 00-31

TABLE OF STANDARD TIGHTENING TORQUES ........................ 00-36

13A 13E

00-1

MODIFICATION SUMMARY

1. Characteristics of and Precautions for the ECO HYBRID Model

• The following are added to the characteristics of the CANTER ECO HYBRID.

• The CANTER ECO HYBRID is equipped with a dedicated high voltage battery (350 V) for the hybrid electric ve-

hicle system aside from the 24 V battery.

• High voltage is cut off when the starter switch is OFF and the vehicle is stationary.

• High voltage is generated in the high voltage circuit when the starter switch is ON or when the gear is engaged

and the wheels are rotating.

• High voltage in the high voltage circuit may be generated irrespective of the vehicle condition during the hybrid electric vehicle system abnormalities (the hybrid electric vehicle warning lamp illuminates).

• Be sure to observe the regulations of your country or region regarding the qualifications or trainings required for servicing the high-voltage equipment.

• The following are added to the precautions concerning high voltage cable and high voltage devices.

DANGER

• High voltage (350 V) may be generated in the high voltage circuit that consists of various high voltage devices (motor generator, motor electronic control unit and high voltage battery box) and cable (orange). Utmost care is required in handling these parts. When servicing, see Gr18 HYBRID ELECTRIC VEHICLE SYSTEM.

• Improper use of the high voltage battery may cause electric shock, overheating or fire though it is safe when properly handled. It may explode in the worst case.

• The following are added to the remedies against vehicle damage by collision or the like.

WARNING

• When the vehicle is on fire, use the ABC fire extinguisher to put out the fire. Since it is dangerous to fight a fire with a small quantity of water, spray a large amount of water from a fire hydrant or wait for the arrival of the fire brigade.

• When the vehicle is soaked in water, do not touch the high voltage devices and high voltage cable including the safety plug of the high voltage battery box to prevent electric shock. Work on the vehicle after pulling it out of water.

• Insulate any high voltage terminal that is exposed by damage with vinyl tape or the like to prevent electric shock.

CAUTION

• The electrolyte in the high voltage battery is as flammable as kerosene. If there is any fluid leakage near the high voltage box, wipe up the fluid while keeping fire away from it.

• Turn the starter switch to OFF to cut off the high voltage system. If it cannot be confirmed that the starter switch is OFF, disconnect the negative side battery cable from the 24 V battery. Then, remove the safety plug of the high voltage battery box with insulated gloves on while referring to Gr18 HYBRID ELECTRIC VEHICLE SYSTEM.

• In the case of the abnormality described above, replace the defective part referring to Gr18 HYBRID ELECTRIC VEHICLE SYSTEM.

00-2

M E M O

00-3

VEHICLE MODEL CODING SYSTEM

1 743 52 986

FE84BE

1 Basic vehicle type F Cab-over engine truck

2 Load capacity, drive system E 2 ton class and over, 4 × 2

3 Cab type 8 Wide cab

4 Suspension 4 Independent axle

5 Engine B 4M42T

6 Wheelbase E 3350 mm

7 Chassis arrangement for use V Van use

8 Rear tire arrangement, payload 3

9 Vehicle specification H Hybrid

10 Engine output variation 6 4M42T3 (96 kW {130 PS})

11 Export specification EX

V3H6

Low deck/rear double Payload 3000 to 4000 kg

00-4

1 743 52 986

FE84BE

1 Basic vehicle type F Cab-over engine truck

2 Load capacity, drive system E 2 ton class and over, 4 × 2

3 Cab type 8 Wide cab

4 Suspension 4 Independent axle

5 Engine B 4M42T

6 Wheelbase E 3350 mm

7 Chassis arrangement for use V Van use

8 Rear tire arrangement, payload 7

9 Steering position R Right-hand drive vehicle

10 Export specification FA

11 Vehicle specification H Hybrid

V7RFA

Rear double Payload 3000 to 4000 kg

00-5

EQUIPMENT TYPE CODING SYSTEM

Component Name plate marking Code description

Engine

4M42T3 4 M 4 2 T 3

Classification of turbocharger Turbocharged Order of development within same series Order of development among different series Diesel engine No. of cylinders (4)

Clutch

C3W28 C 3 W 28

Disc outside diameter Facing material (W: Woven) Load carrying capacity of truck class (ton nage) on which the clutch is primarily used Initial letter of the clutch

Transmission

M036S5 M 036 S 5

Forward speeds Type of mesh (S: Synchromesh) Load carrying capacity of truck class (ton nage) on which the clutch is primarily used Initial letter of the transmission

Propeller shaft

P3 P 3

Front axle

F200T F 200 T

Rear axle

R033T R 03 3 T

Reduction and differentioal

D033H D 03 3 H

Load carrying capacity of truck class (ton nage) on which the clutch is primarily used Initial letter of the propeller shaft

Vehicle type (T: Truck) Load carrying capacity of truck class (ton nage) on which the clutch is primarily used Initial letter of the front axle

Vehicle type (T: Truck) Order of development within same series Load carrying capacity of truck class (ton nage) on which the clutch is primarily used Initial letter of the rear axle

Tooth profile (H: Hypoid gear) Order of development within same series Load carrying capacity of truck class (ton nage) on which the clutch is primarily used Initial letter of the reduction & differentioal

00-6

POWER TRAIN TABLE

Vehicle model Engine Clutch Transmission Propeller shaft Rear axle

FE84BEV3H6EX 4M42T3 C3W28 M036S5 P3 R033T D033H

FE84BEV7RFAH 4M42T3 C3W28 M036S5 P3 R033T D033H

Reduction and

differential

00-7

HOW TO READ THIS MANUAL

This manual consists of the following parts:

• Specifications

• Structure and Operation

• Troubleshooting

• On-vehicle Inspection and Adjustment

• Service procedures

On-vehicle Inspection and Adjustment

• Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de-

scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc.

Service procedures

• Procedures for servicing components and parts off the vehicle are described centering on key points in their re-

moval, installation, disassembly, reassembly, inspection, etc.

Inspection

• Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given.

• Some routine visual checks and cleaning of some reused parts are not described but must always be included in

actual service work.

Caution

• This service manual contains important cautionary instructions and supplementary information under the following

four headings which identify the nature of the instructions and information:

DANGER

WARNING

CAUTION

NOTE

Terms and Units

• Front and rear

The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred to as the rear.

• Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right.

Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives.

Precautionary instructions, which, if not observed, could result in serious injury or death.

Precautionary instructions, which, if not observed, could result in damage to or destruction of equipment or parts.

Suggestions or supplementary information for more efficient use of equipment or better understandings.

Standard value

• Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-

ance between two parts when assembled, and the standard value for an assembly part, as the case may be.

Limit

• When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must

be replaced or repaired.

00-8

Tightening torque

• Values are directly specified for out-of-standard tightening torques for bolts and nuts.

• Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.

(Values for standard tightening torques are based on thread size and material.)

• When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.

Units

• Tightening torques and other parameters are given in SI* units with metric units added in brackets { }.

*SI: Le Système International d’Unités

Example: 390 N·m {40 kgf·m}

Metric unit SI unit

Item SI unit {metric unit} Conversion factor

Force N {kgf} 9.80665 N {1 kgf}

Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}

Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}

Pressure

Volume dm

Heat quantity J {kcal} 4186.05 J {1 kcal}

Heat flow W {kcal/h} 1.16279 W {1 kcal/h}

Power kW {PS} 0.7355 kW {1 PS}

Vacuum pressure

kPa {mmHg} 0.133322 kPa {1 mmHg}

Pa {mmH

O} 9.80665 Pa {1 mmH2O}

{L} 1 dm3 {1 L}

00-9

HOW TO READ THIS MANUAL

1. Illustrated Parts Breakdown and Service Procedures

Symbol Denotation Application Remarks

Tightening torque

Locating pin Parts to be positioned for installation

Non-reusable parts Parts not to be reused

Lubricant and/or sealant

Special tool

*a Associated part

Parts not tightened to standard torques (standard torques specified where necessary for servicing)

Parts to be coated with lubricant or sealant for assembly or installation

Parts for which special tools are required for service operation

Parts associated with those removed/disassembled for servicing

Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are specified.

Necessary lubricant and/or sealant, quantity required, etc. are specified in table.

Tool name/shape and part number are shown in table.

00-10

00-11

HOW TO READ THIS MANUAL

2. How to Use Diagnosis Codes <Electronic Control System>

There are the diagnosis code and message displayed on Multi-Use Tester. Numerical values in parenthesis are added only when a diagnostic code indicated in the Multi-Use Tester display differs from the code indicated by the number of warning lamp flashes.

P0475: Exhaust Brake PWR (Open) (warning lamp flashes: 93)

Generation condition Exhaust shutter 3-Way magnetic valve circuit is open

System recovers if any valid signal is input when starter switch is turned

Recoverability

Control effected by electronic control unit

Service data C2: Auxiliary brake M/V1

Actuator test AA: Auxiliary brake M/V1

Inspection

Electronic control unit : Exhaust shutter 3-Way magnetic valve

Electrical equipment #565: Exhaust shutter 3-Way magnetic valve

Electric circuit diagram Exhaust shutter 3-Way magnetic valve circuit

from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid signals are input).

Control of auxiliary brake function is deactivated. White smoke reduction control is deactivated if idling condition is held

 for an extended period of time.

Refer to

Inspections Performed At Electronic Control Unit Connectors.

Refer to

Actuator Tests Performed Using Multi-Use Tester.

Refer to

Multi-Use Tester Service Data.

Refer to

Inspection of Electrical Equipment.

Electric Circuit Diagram.

00-12

3. How to Read Circuits

00-13

HOW TO READ THIS MANUAL

3.1 Index number: to

• Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its

own index number.

100 999

3.2 Key number: A01 to Z99

• Key numbers indicate electrical equipment installation locations. The installation location of a part can be easily

found using its key number shown in a circuit diagram. All of the electrical equipment installation locations are listed in Gr54-10.

3.3 Part name

3.4 Connector type (type indication)

• A list of the connectors used is included in Gr54-14.

3.5 Connector terminal number

3.6 Major harness division

• Major harness divisions are shown.

3.7 Wiring variations between different specifications

• Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown.

3.8 Code number: #001 to #999

• Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspec-

tion procedure for a electrical equipment can be found using its code number shown in a circuit diagram.

3.9 Grounding point: [1] to [99]

• Locations where wires are grounded to the vehicle. All of the grounding points are listed in .

130

3.10 Harness connection

• The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity.

3.11 Circuit number, wire diameter, wire color

00-14

(1) Wire color

Wire color Base color + tracer

BBlackBW

Br Brown BrW

GGreenGW

Gr, Gy

LBlueLW

O Orange OL

PPinkPB

Pu Purple

RRedRW

Sb Sky blue

VVioletVY

WWhiteWR

YYellow

green

Gray

Light

GrL, GyL

LgR

Black/

white

Brown/

white

Green/

white

Gray/

blue

Blue/ white

Light

green/

Orange/

blue

Pink/

black

Red/

white

Violet/ yellow

White/

Yell ow /

pink

BrB

GrR, GyR

LR Blue/red LY

LgY

red

Black/ yellow

Brown/

black

Green/

red

Gray/

red

Light green/ yellow

Orange/

black

Pink/

green

Red/

black

Violet/

white

White/

black

Yell ow /

black

Yell ow /

violet

BR Black/red BG

BrY

LgB

VR Violet/red VG

Brown/

yellow

Green/

yellow

Blue/

yellow

Light

green/

black

Orange/

green

Pink/

blue

Red/

yellow

White/

blue

Yell ow /

green

BrR

LgW

Black/

green

Brown/

red

Green/

black

Blue/ black

Light

green/

white

Pink/

white

Red/

green

Violet/

green

White/

green

Yell ow /

blue

BrG

RL Red/blue RO

Black/

blue

Brown/

green

Green/

blue

Blue/

orange

White/

orange

Yellow/

white

Green/ orange

Blue/

green

Red/

orange

Yellow/ orange

00-15

CHASSIS NUMBER, ENGINE NUMBER, MOTOR NUMBER AND NAME PLATE

• Serial chassis and engine numbers are assigned to the vehicles and engines in manufacturing sequence. Every

vehicle and engine has its own number. These numbers are required for registration and related inspection of the vehicle.

Chassis number

• The chassis number is indicated on the left frame, near the left front wheel.

Example: FE84BE – A

Chassis number Vehicle number

• The chassis number is included in the vehicle identification number (V.I.N), which is stamped on the left-hand frame near the left front wheel.

Example: JLF FE84BE0K J

Chassis number Vehicle number

Engine number

• The engine number is indicated on the right side of the crank-

case.

Example: 4M42 –

Engine number Engine model

Motor number

• The motor number is indicated on the left below part of the

clutch housing.

Example: S10B12345

00-16

Name plate

• Name plate contains the following information.

• MODEL

• Chassis number

• Engine number

• Wheel base

• Vehicle compliance and date plate are attached to the assistant driver’s side door opening. The compliance plate certifies that your vehicle complied with Australian Design Rules at the time of manufacture. In all correspondence related to your vehicle the following information should be quoted.

• The engine number.

• The vehicle identification number (V.I.N.) – shown on compli-

ance plate.

• The S.O.A. No. (where applicable), option code, paint and

trim codes located on date plate.

00-17

PRECAUTIONS FOR MAINTENANCE OPERATION

• Before performing service operations, inquire into the customer’s complaints and ascertain the conditions by

checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors about the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently.

• Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or disassembled. Then, follow the service procedure given in this manual.

• Perform service operations on a level surface. Before starting, take the following preparatory steps:

• To prevent soiling and damage, place covers over the seats,

trim and floor in the cab and over the paintwork of the body.

• Prepare all the general and special tools necessary for the job.

WARNING

• Special tools must be used wherever specified in this manual. Do not attempt to use other tools since they could cause injuries and/or vehicle damage.

• After manually tilting the cab, be sure to engage the stopper with

the lock lever to secure the cab stay in a rigid state.

• Take extreme care when removing/installing heavy items such as engine, transmission and axle. When lifting heavy items using a cable etc., observe the following precautions.

00-18

• Identify the mass of the item being lifted. Use a cable that is

strong enough to support the mass.

• When lifting the engine, always use the engine hanger.

• If lifting eyes are not provided on the item being lifted, tie a ca-

ble around the item taking into account the item’s center of gravity.

• Do not allow anyone to pass or stay under a lifted item that

may fall.

• Never work in shoes that have oily soles. When working with a partner or in a group, use pre-arranged signals and pay constant attention to safety. Be careful not to touch switches and levers unintentionally.

• Inspect for oil leakage etc. before washing the vehicle. If the order is reversed, any oil leakage or fault that may exist could go unnoticed during inspection.

• Prepare replacement parts ready for installation.

00-19

PRECAUTIONS FOR MAINTENANCE OPERATION

• Oil seals, packings, O-rings and other rubber parts, gaskets, and

split pins must be replaced with new ones after removal. Use only genuine MITSUBISHI replacement parts.

• When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective rotation, fatigue, clogging and any other possible defect.

• To facilitate correct reassembly of parts, make alignment marks on them before disassembly and arrange disassembled parts neatly. Make punch marks and other alignment marks where they will not detract from parts’ functionality and appearance.

• After removing parts from the vehicle, cover the area to keep it free of dust.

CAUTION

• Be careful not to mix up identical parts, similar parts and parts that have left/right alignments.

• Keep new replacement parts and original (removed) parts separately.

• Apply the specified oil or grease to U-seals, oil seals, dust seals

and bearings before reassembly.

• Always use the specified oils and greases when performing inspection or replacement. Immediately wipe away any excess oil or grease with a rag.

00-20

• Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and watch out for sharp edges and other items that might wound your hands.

• Before working on the electrical system, disconnect the (–) bat-

tery cable to prevent short circuits.

CAUTION

• Make sure the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. Semiconductor components may otherwise be damaged.

• Carefully handle sensors relays, and other items that are sensi-

tive to shock and heat. Do not remove or paint the cover of any control unit.

• When applying a voltage to a part for inspection purposes, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily operate on the battery voltage.

• When separating connectors, grasp the connectors themselves rather than the harnesses.

• To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them together until they click.

• Before washing the vehicle, cover electrical parts to keep them dry. (Use plastic sheets or the like.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them.

00-21

PRECAUTIONS FOR MAINTENANCE OPERATION

1. Handling Precautions for Electric Circuits

CAUTION

• Do not pierce wire insulation with test probes or alligator clips when performing electrical inspections. Doing so can, particularly with the chassis harness, hasten corrosion.

1.1 Inspection of harnesses

(2) Inspections with connectors fitted together

(2.1) Waterproof connectors

• Connect an inspection harness and connector A between the

connectors B of the circuit to be inspected. Perform the inspection by applying a test probe C to the connectors of the inspection harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust.

(2.2) Non-waterproof connectors

• Perform the inspection by inserting a test probe C into the wire-

entry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage.

(3) Inspections with connectors separated

(3.1) Inspections on female terminals

• Perform the inspection by carefully inserting a test probe into the

terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections.

00-22

(3.2) Inspections on male terminals

• Perform the inspection by applying test probes directly to the

pins.

CAUTION

• Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit’s internal circuitry.

• When using a multimeter to check continuity, do not allow the

test probes to touch the wrong terminals.

1.2 Inspection of connectors

(1) Visual inspection

• Check that the connectors are fitted together securely.

• Check whether wires have been separated from their terminals

due to pulling of the harness.

• Check that male and female terminals fit together tightly.

• Check for defective connections caused by loose terminals, by

rust on terminals, or by contamination of terminals by foreign substances.

(2) Checking for loose terminals

• If connector terminal retainers become damaged, male and fe-

male terminals may not mate with each other when the connector bodies are fitted together. To check for such terminals, gently pull each wire and see whether any terminals slip out of their connector housings.

00-23

PRECAUTIONS FOR MAINTENANCE OPERATION

1.3 Inspections when a fuse blows

• Remove the fuse, then measure the resistance between ground

and the fuse’s load side. Next, close the switch of each circuit connected to the fuse. If the resistance measurement between any switch and ground is zero, there is a short circuit between the switch and the load. If the resistance measurement is not zero, the circuit is not currently short-circuited; the fuse probably blew due to a momentary short circuit.

• The main causes of short circuits are as follows:

• Harnesses trapped between chassis parts

• Harness insulation damage due to friction or heat

• Moisture in connectors or circuitry

• Human error (accidental short-circuiting of components)

1.4 Inspection of chassis ground

• A special ground bolt is used to tighten a ground terminal. When

servicing the ground point, be sure to follow the procedures described below:

• When reinstalling the ground bolt

• When relocating the ground point

2. Service Precautions for Alternators

• When servicing alternators, observe the following precautions:

• Never reverse the polarity of battery connections.

Tighten the ground bolt to the specified torque.

A special ground bolt must be used. Spot-weld a nut to a frame and tighten the ground bolt to the specified torque. Be sure to apply touch-up paint to the welded point.

If the polarity of the battery connections were to be reversed, a large current would flow from the battery to the alternator, damaging the diodes and regulator.

00-24

• Never disconnect the battery cables with the engine running. Disconnection of the battery cables during engine operation would cause a surge voltage, leading to deterioration of the diodes and regulator.

• Never perform inspections using a high-voltage multimeter.

The use of a high-voltage multimeter could damage the diodes and regulator.

• Keep alternators dry. Water on alternators can cause internal short circuits and damage.

• Never operate an alternator with the B and L terminals short-circuited. Operation with the B and L terminals connected together would damage the diode trio.

• Disconnect the battery cables before quick-charging the battery with a quick charger. Unless the battery cables are disconnected, quick-charging can damage the diodes and regulator.

00-25

PRECAUTIONS FOR MAINTENANCE OPERATION

3. Intermittent Faults

• An intermittent fault typically occurs only under certain operating

conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs. Also ask about the frequency with which the fault occurs and about the fault symptoms. Then, reproduce the fault based on this information. In accordance with the conditions under which the fault occurs, determine whether the fault is caused by vibration, heat or other factors. if vibration is a possible factor, see if the fault can be reproduced by performing the following checks on individual connectors and other parts:

• Gently move connectors up and down and to left and right.

• Gently move wiring harnesses up and down and to left and

right.

• Gently wiggle sensors and other devices by hand.

• Gently wiggle wiring harnesses on suspension systems and

other moving parts.

• Connectors and other parts to be checked are those included or given as likely fault locations in inspection procedures corresponding to diagnosis codes and/or fault symptoms.

00-26

4. Precautions for Arc Welding

• When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless ap-

propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be largely damaged.

• Current flows backward as shown below.

4.1 From battery (–) cable

To prevent damage to the battery and to electrical devices that are connected directly to the battery, it is essential to disconnect the battery’s (–) cable.

4.2 Procedure

• Turn the starter switch to the LOCK position.

• Disconnect the battery’s (–) cable.

• Remove the safety plug of the high voltage battery box referring

to Gr18 HYBRID ELECTRIC VEHICLE SYSTEM.

• Cover all parts of the vehicle that may be damaged by welding sparks.

• Connect the welder’s (–) cable to the vehicle as close as possible to the area being welded. Do not connect the welder’s (–) cable to the cab if the frame is being welded, and vice versa.

• Set the welding current in accordance with the part being welded.

5. Maintenance for Trucks with Airbags

• For maintenance of SRS airbags and seat belts with pretensioners, work should be conducted safely by following

the work procedure and precautions.

6. Precautions When Starting the Engine

• The engine warning lamp may illuminate if the starter switch is kept turned to the START position for a while with

the gear engaged. (Diagnosis code P0016 “No SNSR Offset/Backup Mode” of the engine electronic control unit occurs.)

• If the engine warning lamp illuminated, place the transmission in neutral and turn the starter switch from OFF to ON four times to turn off the warning lamp.

00-27

JACKING UP THE VEHICLE

Jacking up procedure

1 Apply chocks to the rear wheels. 2 Raise the front of the vehicle using a bottle jack or garage jack. 3 Place rigid racks to support the frame on the front side of the vehicle.

WARNING

• Apply chocks to the rear wheels to hold the vehicle in place.

• Do not remove the chocks until service operations are finished.

• It is extremely dangerous to support the vehicle with a bottle jack or garage jack alone. Use rigid racks additionally to support the frame on the front side of the vehicle.

• Leave the bottle jack or garage jack and rigid racks in place until all service operations are completed. Be sure not to remove them during work.

00-28

Jacking up procedure

1 Apply chocks to the front wheels. 2 Raise the rear of the vehicle using a bottle jack or garage jack. 3 Place rigid racks to support the frame on both sides of the vehicle.

WARNING

• Apply chocks to the front wheels to hold the vehicle in place.

• Do not remove the chocks until service operations are finished.

• It is extremely dangerous to support the vehicle with a bottle jack or garage jack alone. Use rigid racks additionally to support the frame on both sides of the vehicle.

• Leave the bottle jack or garage jack and rigid racks in place until all service operations are completed. Be sure not to remove them during work.

00-29

DIAGNOSIS CODES

1. Diagnosis Codes

• Diagnosis codes indicate the faulty sections of the vehicle.

• A fault can be repaired by reading out the diagnosis code(s) stored in the control unit and performing the remedy

for that code(s).

• Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to be diagnosed.

• Using a Multi-Use Tester

• Using flashing of a warning lamp on meter cluster

• The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in-

dividual systems.

1.1 Systems and diagnosis code displaying methods

Diagnosis codes

Warning

lamp

System

Common rail

Turbo charger

Diesel particulate filter

Exhaust gas recirculation 17

Starter continuous energizing preventing function

Pre-heat control

displaying methods

Multi-Use

Te st e r

Flashing of

warning lamp

Reference

Hybrid electric vehicle system O O 18

(ORANGE)

INOMAT-II

Power anti-lock brake system O O 35EA

Hill start assist system O O 35EB

SRS airbag O – 52

(Gear shift

indicator indi-

cation)

O 22E

1.2 Types of diagnosis codes

(1) Present diagnosis code

• Fault developed in the vehicle after the starter switch is set to ON is indicated by corresponding diagnosis code.

• The fault warning lamp is lit at the same time.

(2) Past diagnosis code

• Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec-

tronic control unit.

• With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or repair against present diagnosis codes, the present diagnosis code is stored as past diagnosis codes in the memory of the electronic control unit.

• When reading out the past diagnosis codes, the warning lamp does not illuminate as such codes do not indicate the current fault.

00-30

2. Reading and Erasing the Diagnosis Code

2.1 Using a Multi-Use Tester

(1) Connecting a Multi-Use Tester

Special tools

Mark Tool name and shape Part No. Application

SOFTWARE DISC

Multi-Use Tester-III SOFTWARE DISC

V.C.I. MH062927

Multi-Use Tester test Harness E A: Harness for inspection and drive recorder B: Harness for drive recorder C: Drive recorder harness D: Cigarette lighter plug harness

FMS-E09-2* (Multi-Use Tester-III version)

MH063659 A: MH063661 B: MH063663 C: MH063665 D: MH063666

*Installation of the Multi-Use Tester-III or version-up of the current version into Multi-Use Tester-III SOFTWARE DISC (Pub. No. SG0901A)

Data transmission between electronic control unit and PC

Power supply to V.C.I. and communication with electronic control unit

Multi-Use Tester test harness D (used for extension)

USB cable MH063668

MH062951

Multi-Use Tester test harness B extension

Communication between V.C.I. and PC

00-31

DIAGNOSIS CODES

(1.1) To perform system inspection

• Move the starter switch to the LOCK position.

• Connect PC installed , , -A and as shown.

• Connect -A connector to the Multi-Use Tester connector on

the vehicle.

(1.2) To use drive recorder function

• Move the starter switch to the LOCK position.

• Connect PC installed , , -A, -C, -D and

as shown.

• Connect -C connector to the Multi-Use Tester connector on the vehicle.

• Connect the cigarette lighter plug of -D to the cigarette light- er socket on the vehicle.

(1.3) To extend the Multi-Use Tester test harness

• Connect to -A to extend the test harness to use the

Multi-Use Tester outside the vehicle.

00-32

(2) Access of diagnosis code

• Set the starter switch to ON.

• Operate the Multi-Use Tester for a display of necessary diagnosis code stored in the memory of the electronic

control unit and identify the location of the fault.

(3) Clearing of diagnosis code

• Set the starter switch to ON (the engine not to be started).

• Operate the Multi-Use Tester to delete all the diagnosis codes stored in the memory of the electronic control unit.

2.2 Using flashing of a warning lamp on meter cluster

(1) Engine control, Power anti-lock brake system, Hill start assist system, Hybrid electric vehicle system

• Using the diagnosis and memory clear

switches, display diagnosis codes.

• Diagnosis codes of the battery electronic control unit are sent to the motor electronic control unit and are displayed along with those of the motor electronic control unit by the diagnosis switch operation. However, some diagnosis codes (minor faults) can be checked only with the Multi-Use Tester.

CAUTION

• Opening the memory clear switch followed by its reconnection will erase the stored diagnosis codes from the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure described below before handling diagnosis codes.

00-33

DIAGNOSIS CODES

(1.1) Reading diagnosis codes

• To read a diagnosis code, observe how may times the warning

lamp flashes and how long each illumination lasts.

• The duration of illumination differs between the first and second digits.

• Second digit: 1.2 sec.

• First digit: 0.4 sec.

• A diagnosis code consists of the flashing of second digit and the

flashing of first digit in that order. If a diagnosis code has “0” in the second digit, only the first digit will be displayed.

• The diagnosis code 01 will be displayed if the system is normal.

• The same diagnosis code will be displayed 3 times in a row be-

fore moving to the display of the next code.

• After the last diagnosis code is displayed, the first code will be displayed again 3 times in a row and then the subsequent codes. This will be repeated.

(1.2) Present diagnosis codes

• Turn the starter switch ON.

• Remove the diagnosis switch.

• Present diagnosis codes will be displayed by flashing of the

warning lamp.

• When the diagnosis switch is connected, electronic control unit will stop (terminate) displaying diagnosis codes.

(1.3) Present and past diagnosis codes

• Turn the starter switch to the ON position.

• Open the diagnosis switch.

• Present diagnosis codes will be displayed by flashing of the

warning lamp.

• Open the memory clear switch.

• Present and past diagnosis codes will be displayed by flashing

of the warning lamp.

• Turn the starter switch to the OFF position and connect the memory clear switch and diagnosis switch to terminate the diagnosis code displaying mode.

00-34

(1.4) Erasing diagnosis codes

• Turn the starter switch to the ON position (do not start the en-

gine).

• Open the memory clear switch and reconnect it; all diagnosis codes stored in electronic control unit memory will be erased. To cancel diagnosis code erasure after opening the memory clear switch, turn the starter switch to the OFF position and then reconnect the memory clear switch.

• Erase the diagnosis codes stored in the battery electronic control unit using the Multi-Use Tester.

(2) INOMAT-II

• Display diagnosis codes using the di-

agnosis switch and memory clear switch.

NOTE

• Diagnosis codes are erased by disconnecting and connecting operation of the memory clear switch. Fully understand the procedures before working.

(2.1) Reading diagnosis codes

• To read a diagnosis code, check the indication of the gear shift

indicator. Example:If the codes are 12 and 34, they will be displayed as

shown in the drawing.

• If the system is normal, the diagnosis code 01 will be displayed.

• Diagnosis codes will be displayed each code once in the reverse

chronological order.

• After the last diagnosis code is displayed, the first code will be displayed again and then the subsequent codes. This will be repeated.

(2.2) Present diagnosis codes

• Turn the starter switch to ON.

• Disconnect the diagnosis switch.

• The present diagnosis codes will be displayed on the gear shift

indicator.

• When the diagnosis switch is connected, ECU will stop (terminate) displaying diagnosis codes.

(2.3) Present and past diagnosis codes

• Turn the starter switch to ON.

• Disconnect the diagnosis switch.

• The present diagnosis codes will be displayed on the gear shift

indicator.

• Disconnect the memory clear switch.

• The present and past diagnosis codes will be displayed on the

gear shift indicator.

• After the starter switch is turned to OFF, connect the memory clear switch and diagnosis switch to terminate the operation.

(2.4) Erasing diagnosis codes

• Turn the starter switch to ON. (Do not start the engine.)

• All diagnosis codes stored in the electronic control unit can be

erased by disconnecting the memory clear switch and then connecting it again. If you discontinue the operation after the memory clear switch is disconnected, turn the starter switch to OFF and then connect the memory clear switch.

00-35

TABLE OF STANDARD TIGHTENING TORQUES

• Use specified bolts and nuts. Tighten them to the torques shown below as appropriate, unless otherwise speci-

fied.

• Threads and bearing surfaces shall be dry.

• If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the

bolt.

Hexagon Head Bolts and Stud Bolts (Unit: N·m {kgf·m})

Strength

Identification

symbol

Nominal diameter (stud) (stud) (stud)

M10

M12

M14

M16

M18

M20

M22

M24

2 to 3

{0.2 to 0.3}

4 to 6

{0.4 to 0.6}

9 to 13

{0.9 to 1.3}

18 to 27

{1.8 to 2.7}

34 to 50

{3.4 to 5.1}

60 to 80

{6.0 to 8.0}

90 to 120

{9 to 12}

130 to 170

{14 to 18}

180 to 240

{19 to 25}

250 to 330

{25 to 33}

320 to 430

{33 to 44}

4T 7T 8T

–

17 to 25

{1.8 to 2.6}

31 to 45

{3.1 to 4.6}

55 to 75

{5.5 to 7.5}

90 to 110

{9 to 11}

120 to 150

{12 to 16}

170 to 220

{17 to 22}

230 to 300

{23 to 30}

290 to 380

{29 to 39}

4 to 6

{0.4 to 0.6}

7 to 10

{0.7 to 1.0}

16 to 24

{1.7 to 2.5}

34 to 50

{3.5 to 5.1}

70 to 90

{7.0 to 9.5}

110 to 150

{11 to 15}

170 to 220

{17 to 23}

250 to 330

{25 to 33}

340 to 460

{35 to 47}

460 to 620

{47 to 63}

600 to 810

{62 to 83}

–

32 to 48

{3.3 to 4.9}

65 to 85

{6.5 to 8.5}

100 to 140

{11 to 14}

160 to 210

{16 to 21}

220 to 290

{23 to 30}

310 to 410

{32 to 42}

420 to 560

{43 to 57}

540 to 720

{55 to 73}

5 to 7

{0.5 to 0.7}

8 to 12

{0.8 to 1.2}

19 to 28

{2.0 to 2.9}

45 to 60

{4.5 to 6.0}

80 to 105

{8.5 to 11}

130 to 170

{13 to 17}

200 to 260

{20 to 27}

290 to 380

{30 to 39}

400 to 530

{41 to 55}

540 to 720

{55 to 73}

700 to 940

{72 to 96}

–

37 to 55

{3.8 to 5.7}

75 to 95

{7.5 to 10}

120 to 160

{12 to 16}

190 to 240

{19 to 25}

250 to 340

{26 to 35}

360 to 480

{37 to 49}

490 to 650

{50 to 67}

620 to 830

{63 to 85}

Hexagon Head Flange Bolts (Unit: N·m {kgf·m})

Strength

Identification

Nominal diameter

M10

M12

symbol

4 to 6

{0.4 to 0.6}

10 to 15

{1.0 to 1.5}

21 to 31

{2.1 to 3.1}

38 to 56

{3.8 to 5.5}

4T 7T 8T

–

20 to 29

{2.0 to 3.0}

35 to 51

{3.5 to 5.2}

8 to 12

{0.8 to 1.2}

19 to 28

{2.0 to 2.9}

45 to 55

{4.5 to 5.5}

80 to 105

{8.0 to 10.5}

–

37 to 54

{3.8 to 5.6}

70 to 95

{7.5 to 9.5}

10 to 14

{1.0 to 1.4}

22 to 33

{2.3 to 3.3}

50 to 65

{5.0 to 6.5}

90 to 120

{9 to 12}

–

50 to 60

{5.0 to 6.0}

85 to 110

{8.5 to 11}

00-36

Hexagon Nuts (Unit: N·m {kgf·m})

Strength

Identification

Nominal diameter

M10

M12

M14

M16

M18

M20

M22

M24

symbol

Standard screw

thread

2 to 3

{0.2 to 0.3}

4 to 6

{0.4 to 0.6}

9 to 13

{0.9 to 1.3}

18 to 27

{1.8 to 2.7}

34 to 50

{3.4 to 5.1}

60 to 80

{6.0 to 8.0}

90 to 120

{9 to 12}

130 to 170

{14 to 18}

180 to 240

{19 to 25}

250 to 330

{25 to 33}

320 to 430

{33 to 44}

4T 6T

Coarse screw

thread

–

17 to 25

{1.8 to 2.6}

31 to 45

{3.1 to 4.6}

55 to 75

{5.5 to 7.5}

90 to 110

{9 to 11}

120 to 150

{12 to 16}

170 to 220

{17 to 22}

230 to 300

{23 to 30}

290 to 380

{29 to 39}

Standard screw thread Coarse screw thread

4 to 6

{0.4 to 0.6}

7 to 10

{0.7 to 1.0}

16 to 24

{1.7 to 2.5}

34 to 50

{3.5 to 5.1}

70 to 90

{7.0 to 9.5}

110 to 150

{11 to 15}

170 to 220

{17 to 23}

250 to 330

{25 to 33}

340 to 460

{35 to 47}

460 to 620

{47 to 63}

600 to 810

{62 to 83}

–

32 to 48

{3.3 to 4.9}

65 to 85

{6.5 to 8.5}

100 to 140

{11 to 14}

160 to 210

{16 to 21}

220 to 290

{23 to 30}

310 to 410

{32 to 42}

420 to 560

{43 to 57}

540 to 720

{55 to 73}

Hexagon Flange Nuts (Unit: N·m {kgf·m})

Strength

Identification

Nominal diameter

M10

M12

symbol

Standard screw

thread

4 to 6

{0.4 to 0.6}

10 to 15

{1.0 to 1.5}

21 to 31

{2.1 to 3.1}

38 to 56

{3.8 to 5.6}

Coarse screw

thread

–

20 to 29

{2.0 to 3.0}

35 to 51

{3.5 to 5.2}

00-37

TABLE OF STANDARD TIGHTENING TORQUES

Tightening Torque for General-Purpose Flare Nut (Unit: N·m {kgf·m})

Pipe diameter φ4.76 mm φ6.35 mm φ8 mm φ10 mm φ12 mm φ15 mm

Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10}

Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type) (Unit: N·m {kgf·m})

Nominal diameter × wall thickness

Tightening torque 20 {2.0 } 34 {3.5 } 49 {5.0 } 54 {5.5 }

Tightening Torque for General-Purpose Air Piping Nylon Tube (SAE Type) (Unit: N·m {kgf·m})

Nominal diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in.

Tightening torque 13 {1.3 } 29 {3.0 } 49 {5.0 } 64 {6.5 }

6 × 1 mm 10 × 1.25 mm 12 × 1.5 mm 15 × 1.5 mm

+60+0.6

+40+0.4

+10

+1.0

+0.5

+100+1.0

+50+0.5

00-38

GROUP 11 ENGINE

SPECIFICATIONS .............................................................................. 11-2

STRUCTURE AND OPERATION

1. Exploded View ............................................................................. 11-3

2. Cylinder Head and Cylinder Head Gasket .................................... 11-4

3. Valve Mechanism ......................................................................... 11-5

4. Timing Chain ............................................................................... 11-6

5. Timing Gears ............................................................................... 11-7

6. Connecting Rod ........................................................................... 11-8

7. Piston .......................................................................................... 11-8

8. Flywheel .............................................................................................. 11-9

9. Crankcase, Crankshaft and Main Bearing ..................................... 11-10

10.Oil Seal ............................................................................................. 11-13

TROUBLESHOOTING ..................................................................... 11-14

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Measuring Compression Pressure ............................................. 11-16

2. Inspection and Adjustment of Valve Clearance .......................... 11-18

3. Inspection and Replacement of Timing Chain ............................ 11-19

4. Protrusion of Timing Chain Tensioner’s Plunger ........................ 11-25

5. Damage to the Starter Pinion Contact Surface of Ring Gear ....... 11-26

ENGINE REMOVAL AND INSTALLATION........................................11-28

ROCKER COVER ............................................................................ 11-30

CAMSHAFT HOLDER AND CAMSHAFT

....................................... 11-32

CYLINDER HEAD AND VALVE MECHANISM..................................11-38

PISTON AND CONNECTING ROD ...................................................11-54

FLYWHEEL ........................................................................................11-66

TIMING GEAR CASE.........................................................................11-70

TIMING GEAR....................................................................................11-74

CRANKSHAFT AND CRANKCASE ..................................................11-80

11-1

SPECIFICATIONS

Item Specifications

Engine model 4M42T3

Type 4-cylinder, in-line, water-cooled, 4-cycle diesel engine

Combustion chamber Direction injection type

Valve mechanism Double overhead camshaft (DOHC)

Maximum output kW {PS} /rpm 96 {130} /3200

Maximum torque N·m {kgf·m} /rpm 294 {30} /1700

Bore × stroke mm φ95 × 105

Total displacement cm

Compression ratio 17.0

{L} 2977 {2.977}

11-2

STRUCTURE AND OPERATION

1. Exploded View

11-3

STRUCTURE AND OPERATION

2. Cylinder Head and Cylinder Head Gasket

2.1 Cylinder head

• The arrangement of the intake ports

and exhaust ports is of a cross-flow type. The exhaust ports are provided on the right side and the intake ports are provided on the left side of the cylinder head.

• Cylinder head bolt (M12) is fastened to the upper crankcase and cylinder head bolt (M10) is fastened to the timing gear case.

• The cylinder head bolts must be tightened according to the specified procedure.

11-4

2.2 Cylinder head gasket

• Select and use a cylinder head gasket

of a thickness that can accommodate the piston projection.

• The size (thickness) class of the gasket can be identified by the shape of the notches cut on the edge of each gasket.

3. Valve Mechanism

• The camshaft is driven by the timing chain. The exhaust camshaft and the intake camshaft are supported by cam-

shaft holders at the journals and are retained by camshaft caps from above.

• There are two types of rocker arms: long rocker arm and short rocker arm. They are alternately provided by the valve position.

11-5

STRUCTURE AND OPERATION

4. Timing Chain

• The timing chain is an endless chain with 110 links that connects the exhaust cam sprocket, intake cam sprocket

and the idler sprocket.

• The timing chain has mark link plates at three locations that indicate the position at which the crankshaft and the camshaft should take when the chain is installed. There are two plates at the first location and one plate at the second location. The first location (two-mark-link location) must be aligned with the mating mark “ ” on the exhaust cam sprocket and the intake cam sprocket, and the second location (one-mark-link location) must be aligned with the mating mark “ ” on the idler sprocket.

• The chain tensioner gives tension to the timing chain. The chain tensioner has a plunger with a built-in spring.

• When the chain tensioner is installed in position, the plunger directly pushes the tension lever, and the timing

chain is tensioned automatically by a force determined by the tension of the plunger spring.

• After the plunger is installed, it is locked in place by a cam provided in the chain tensioner, which prevents accidental deflection of the timing chain while it is driven. Do not crank the engine in the reverse direction after installing the chain tensioner, as this will apply undue forces to the plunger and may cause such undesirable consequences as cam being over ridden by the plunger.

11-6

5. Timing Gears

• Each timing gear has mating mark(s) “1” or “5” to ensure that it is engaged correctly with another gear during in-

stallation.

5.1 Idler gear

• The idler gear is press fitted into the

idler sprocket, which drives the timing chain, and rotates on the idler shaft.

• The idler shaft is anchored to the crankcase using the idler washer and bolt. The idler sprocket is fitted with the idler bushing, which is lubricated by engine oil supplied through the oil holes drilled in the idler shaft.

11-7

STRUCTURE AND OPERATION

6. Connecting Rod

• The “F” mark indicates the assembly direction onto the piston and engine front side.

• The color mark indicates the diameter class of the large end.

7. Piston

• For selective fit of the pistons with the

upper crankcase, match corresponding size marks on the pistons and upper crankcase. The size marks of the pistons are “A” through “C” and the “C” marked piston has the largest outside diameter.

• Install the pistons with the front marks facing forward of the engine.

11-8

8. Flywheel

• The bearing is fitted into the flywheel and held in place by the washers.

• The peripheral edge on one side of the ring gear is chamfered for easy engagement of the gear with the starter

pinion.

11-9

STRUCTURE AND OPERATION

9. Crankcase, Crankshaft and Main Bearing

9.1 Crankcase

• The crankcase is a bi-block type con-

sisting of an upper crankcase and a lower crankcase that are assembled to grip the crankshaft in between.

• The upper crankcase has cylinders whose surfaces are machined for direct contact with sliding pistons. The walls of the cylinders have water jackets for cooling the cylinders.

• The main cap bolts that hold the upper crankcase and the lower crankcase together must be tightened according to the specified procedure.

11-10

• The upper crankcase is provided with

piston size marks “A”, “B” and “C” stamped to help to select appropriate pistons.

9.2 Crankshaft

• The crankshaft has two sets of color

marks. Color mark A indicates the outside diameter of the journals (at five locations), and color mark B indicates the outside diameter of the pins (at four locations).

9.3 Main bearing

• Each upper main bearing has an oil

hole, which provides a passage for engine oil to the corresponding crankshaft journal.

• Main bearings of different thickness are available so that the most appropriate ones can be selected to ensure proper clearance between them and journals. Bearing thickness classes are identified by color marks (red, blue and yellow) painted on the sides of the bearings.

• All the upper and lower main bearings are identical except for the No. 3 upper bearing and the No. 3 lower bearing.

11-11

STRUCTURE AND OPERATION

9.4 Thrust plates

• Two upper and lower thrust plate pairs

are installed on both sides of the upper and lower main bearings at the rear most journal of the crankshaft.

• The thrust plates must be of a thickness that corresponds to the end play of the crankshaft. Each thrust plate has two oil grooves to ensure its minimum friction against the crankshaft journal.

11-12

10.Oil Seal

10.1 Front oil seal

• The front oil seal is fitted in the timing

gear case, and prevents oil from leaking by contact of its lip with the crankshaft pulley.

10.2 Rear oil seal

• The rear oil seal is fitted in the rear oil

seal case, and prevents oil from leaking by contact of its lip with the crankshaft.

11-1 3

TROUBLESHOOTING

Symptoms

Reference Gr

Possible causes

Incorrect valve clearance O O

Cylinder head and valve mechanism

Defective timing chain-related parts O

Timing gears

Camshaft

Pistons and connecting rods

Crankshaft

Fuel system

Cooling system

Intake and exhaust system

Incorrect oil viscosity O

Incorrectly fitted piping and hoses O

Defective/incorrectly fitted alternator and other auxiliaries O

Defective cylinder head gasket O O

Worn valve and valve seat; carbon deposits O O

Weakened valve spring O O

Worn lifter shim O

Incorrect backlash in timing gears O

Poor lubrication of timing gears and idler shaft O

Excessive end play in camshaft O

Worn camshaft O

Worn/damaged piston ring groove(s) O O

Worn/damaged piston ring(s) O O

Worn piston pin and connecting rod small end O

Excessive end play in crankshaft O

Incorrectly fitted crankshaft O

Worn/damaged crankshaft pins and connecting rod bearings

Worn/damaged crankshaft journals and main bearings O

Defective supply pump O O

Faulty fuel spray from injector O O

Air or water trapped in fuel system components O

Irregular fuel (kerosene, heavy oil, bio-fuel, etc.) is used O

Malfunctioning cooling system O

Loose/damaged belts O

Clogged air cleaner O

Clogged muffler O

Low power output

Abnormal engine noise

Gr13

Gr14

Gr15Malfunctioning turbocharger O O

11-14

M E M O

11-1 5

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Measuring Compression Pressure

Service standards

Location Maintenance item Standard value Limit Remedy

Each cylinder (at 220 rpm)

– Compression pressure

Cylinder-to-cylinder pressure difference

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Compression gauge adaptor

2840 kPa

{29 kgf/cm2}

–

2260 kPa

{23 kgf/cm2}

295 kPa

{3 kgf/cm

or less

Inspect

}

Inspect

M16 × 1.5 M10 × 1.25

MH063494 Measuring compression pressure

• For the hybrid electric vehicle system, there are two methods of cranking the engine, a conventional method using the starter and a method using the motor of the hybrid electric vehicle system.

• If the engine is cranked with the motor of the hybrid electric vehicle system, measurement of compression pressure may become inaccurate since the engine speed is slightly higher than when the starter is used for cranking. For this reason, engine cranking should be performed using the starter following the procedure below.

• Turn the starter switch quickly up to the START position before the READY indicator lamp in the meter cluster

illuminates. Though the indicator lamp illuminates in several seconds, the starter will keep running.

• If the starter switch is turned to the START position after the READY indicator lamp in the meter cluster illumi-

nates, the starter will not run and the engine is cranked with the motor of the hybrid electric vehicle system. In this case, turn the starter switch to OFF and try again.

• A drop in compression pressure can be used as a guide to determine when the engine should be overhauled.

• Measure the compression pressure at regular intervals. Keeping track of its transmission can provide a useful tool

for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to normal as the parts wear down.

• Before the compression measurement, check that the engine oil, starter, and battery are in normal condition.

• Place the vehicle in the following conditions.

• Warm up the engine until the coolant temperature reaches approximately 80 to 90°C.

• Turn off the lights and auxiliaries.

• Place the transmission shift lever into the N position.

• Place the steering wheel in the straight-ahead position.

11-16

• Remove the fuse (M9) to prevent fuel from being injected when the engine is cranked by the starter.

CAUTION

• When cranking the engine, never shut off the power to the engine electronic control unit by disconnecting the engine electronic control unit connector or the like. If the engine is cranked while shutting off the power to the engine electronic control unit, the electronic control unit cannot control the supply pump and this may cause failure to the pump.

• Remove all glow plugs.

• Cover the glow plug mounting holes with shop towels. After

cranking the engine with the starter, check that no foreign substances are deposited on the shop towels.

• If there are deposits (such as engine oil or coolant) on the shop towels, the following may be the cause:

• Deposits of engine oil alone can mean a defective piston ring

seal; the piston rings must be inspected.

• Deposits of both engine oil and coolant can mean cracks in

the cylinders or cylinder head; the crankcase or cylinder head must be replaced.

WARNING

• When coolant and engine oil deposits are evident, crank-

ing the engine could be dangerous as these substances, heated to high temperatures, will blow out from the glow plug mounting holes. Make sure to stay away from the glow plug mounting holes when the engine is being cranked.

• Attach to one of the glow plug mounting holes and then at-

tach a compression gauge.

• Crank the engine and measure the compression pressure for all the cylinders one after another. Determine the compression pressure difference between the cylinders.

• If the compression pressure and the cylinder-to-cylinder pressure difference are not within the limit, pour a small amount of engine oil into the corresponding glow plug mounting hole and remeasure the compression pressure.

• If the compression pressure increases, the piston rings and

cylinder surfaces may be badly worn or otherwise damaged.

• If the compression pressure remains unchanged, there may

be seizure in the valves, the valves may be incorrectly seated or the cylinder head gasket may be defective.

• Install the glow plugs. (See later sections.)

11-1 7

ON-VEHICLE INSPECTION AND ADJUSTMENT

2. Inspection and Adjustment of Valve Clearance

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy

Valve clearance (when en-

–

gine is cold)

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks

– Lock nut (adjusting screw mounting) 9 to 10 {0.9 to 1.1} –

Special tools

Mark Tool name and shape Part No. Application

Intake valve 0.1 – Adjust

Exhaust valve 0.15 – Adjust

Front hub and flange yoke holder

MB990767 For cranking the engine

• Valve clearance should be checked and adjusted as follows while the engine is still cold.

[Inspection]

• Remove the rocker cover.

• Bring the No. 1 or No. 4 cylinder piston to the top dead center

(TDC) on the compression stroke according to the following procedure:

• Rotate the crankshaft pulley in the illustrated direction so that

the notch on the crankshaft pulley is aligned with the “0” mark on the timing gear case.

CAUTION

• Do not turn the crankshaft pulley in the opposite direction to the illustrated one (counterclockwise), as this may cause damage to the tensioner that is adjusting the tension of the timing chain on the timing gear. If you turn the crankshaft pulley in the wrong direction by mistake, remove and reinstall the chain tensioner.

11-18

• This will place either the No. 1 or No. 4 cylinder piston at TDC

on the compression stroke. When the protrusion on the camshaft is facing upward the No.1 piston is at TDC. Rotate the engine by one full turn to switch the TDCs of the No. 1 and No. 4 cylinder pistons.

• With the No. 1 or No. 4 cylinder piston at TDC, measure the

clearance of the valves marked with a circle in the table below.

Cylinder No. 1 2 3 4

Valve INEXINEXINEXINEX

No. 1 cylinder piston at TDC on compression stroke

No. 4 cylinder piston at TDC on compression stroke

• The feeler gauge must have a slight drag when taking measurements.

• If the feeler gauge can be moved without any resistance, the measurement will be incorrect.

• If the measurements are not within the standard value range, adjust the valve clearance via the following procedures.

[Adjustment]

• For valve clearance adjustment, loosen the lock nut and turn the

adjusting screw so that the feeler gauge moves with some resistance.

• After the adjustment, hold the adjusting screw in place with a screwdriver and tighten the lock nut to the specified torque. Inspect the valve clearance again with the feeler gauge.

• After the inspection, install the rocker cover and the gasket. (See later sections.)

OOO – –O – –

–––OO–OO

3. Inspection and Replacement of Timing Chain

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy

– Protrusion of chain tensioner’s plunger – 20

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Front hub and flange yoke holder

MB990767 Cranking the engine

Replace timing

chain

11-1 9

ON-VEHICLE INSPECTION AND ADJUSTMENT

Mark Tool name and shape Part No. Application

Fixture tool *MH063678

Dummy tensioner *MH063554

Chain disassembly tool

A: Body B: Slider

13.5

Riveting tool

A: Set bolt B: Punch C: Die D: Holder

18 9.6

*MH063555 A: MH063556 B: MH063558

*MH063559 A: MH063563 B: MH063565 C: MH063564 D: MH063560

Tools marked with * are components of the timing chain tool set (MH063679).

[Inspection]

• Perform the following inspections. If there is any abnormality, re-

place the timing chain.

(1) Noise

• Run the engine and check for any abnormal noise caused by in-

terference between piston and valve.

• If abnormal noise is heard, check the pistons and valves for possible interference. (See “CYLINDER HEAD AND MECHANISM” and “PISTON AND CONNECTING ROD”.)

(2) Protrusion of chain tensioner’s plunger

• Measure the protrusion of the chain tensioner’s plunger to deter-

mine the elongation of the timing chain.

• Remove the chain tensioner from the cylinder head. The plunger is bounced a little out of the chain tensioner by the spring inside. Prevent the plunger from falling.

• Measure the distance from the forward end of the plunger to the farthest wear mark. If the measured value exceeds the specified limit, replace the timing chain.

Replacement of timing chain

11-20

[Replacement]

• Remove the fan coupling, front engine hanger and rocker cover.

• To check the timing position, rotate the crankshaft pulley clock-

wise with and align the timing mark “0” on the timing gear case with the notch on the crankshaft pulley to bring the No. 1 cylinder piston to the top dead center (TDC) on the compression stroke. The No. 1 cylinder piston is at TDC if the protrusion on the camshaft is facing upward.

• With the No. 1 cylinder piston at TDC, check that the two mating marks “ ” on the cam sprocket are at the illustrated positions.

• Install on the cylinder head and tighten the bolts (M8 × 20 mm) firmly.

• Crank the engine by hand and bring the mark link plate (one plate) of the timing chain to the illustrated position of the cam sprocket.

11-2 1

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Remove the chain tensioner and its gasket from the cylinder

head.

• Install on the cylinder head.

CAUTION

• Fill the space around the timing chain with shop towels to prevent parts from falling into the timing gear case.

• Using , remove the pins of the mark link plate (one plate)

from the timing chain. Then, remove the mark link plate and the plate from the timing chain.

• If the pins are difficult to remove, press them out by inserting the temporary link of the timing chain kit into the pin holes from the front side of the engine.

CAUTION

• Do not mix up the mark link plate, pins and plates of the timing gear with those of the timing chain kit.

11-22

• With the mark link plate (two plates) of the new timing chain fac-

ing the front of the engine, connect the new timing chain with the unlinked end of the old timing chain using a temporary link and clip.

• Remove the shop towels from the timing chain.

• Slowly crank the engine by hand in the normal direction to rotate

the timing chain so that the new timing chain takes the place of the old one.

• Stop cranking when the old timing chain is completely delivered and the temporary link comes to the illustrated position of the cam sprocket.

• Fill the space around the timing chain with shop towels again. Remove the temporary link and the timing chain.

CAUTION

• When the temporary link and clip are removed, discard them so as not to mix them with the timing chain kit.

• Remove from the cylinder head.

• Install a permanent link from the rear of the engine to connect

the two ends of the new timing chain.

• Remove .

11-2 3

ON-VEHICLE INSPECTION AND ADJUSTMENT

• Crank the engine by hand until the permanent link comes to the

illustrated position of the intake cam sprocket.

• Attach a mark link plate onto the punch of .

• Align the pins of the permanent link with the holes on the mark

link plate to set .

• Tighten the bolt of until it cannot be tightened any further.

• Check that the pins of the permanent link project by the amount

indicated in the illustration.

• Turn around 180 degrees and mount it so that the die is aligned with the mark link plate.

• Tighten the bolt of to approximately 64 N flatten the end of each pin of the permanent link.

• Check that the pin ends are flattened to the width indicated in the illustration.

• Remove the shop towels from the timing chain.

·m {6.5 kgf·m} and

11-24

• Check that the new chain tensioner’s plunger is locked in place

by the hook, then install it to the cylinder head with the new gasket. Make sure the sealant application surface of the gasket.

• Crank the engine in the normal direction (clockwise as viewed from the front of the engine). This unhooks the plunger, allowing the tension of the timing chain to be adjusted by the internal ratchet mechanism.

CAUTION

• After the chain tension is installed, if the engine is reversed (counterclockwise as viewed from the front of the engine), an excessive thrust is imparted to the plunger, possibly causing damage to the cam. In case the engine is reversed, remove and check the chain tensioner. Reinstall it if there is no abnormality.

• With the No. 1 cylinder piston at TDC, check that the mating

marks “ ” on the cam sprocket are at the same place as before.

• Install the rocker cover and fan coupling.

4. Protrusion of Timing Chain Tensioner’s Plunger

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy

– Protrusion of timing chain tensioner’s plunger – 20 Replace

• Measure the protrusion of the chain tensioner’s plunger to deter-

mine the elongation of the timing chain.

• Remove the chain tensioner from the cylinder head. The plunger is bounced a little out of the chain tensioner by the spring inside. Prevent the plunger from falling.

• Measure the distance from the forward end of the plunger to the farthest wear mark.

• If the measured value exceeds the specified limit, replace the timing chain. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”, “3. Inspection and Replacement of Timing Chain”.)

11-2 5

ON-VEHICLE INSPECTION AND ADJUSTMENT

5. Damage to the Starter Pinion Contact Surface of Ring Gear

• Remove the starter from the engine. (See Gr54.)

• Visually examine the starter pinion contact surface of the ring

gear for crack and other damage from the starter mounting hole.

• If there is any cracks or damages, replace the ring gear. (See “FLYWHEEL”.)

11-26

M E M O

11-2 7

ENGINE REMOVAL AND INSTALLATION

CAUTION

• Hoist the engine using care not to strike it against the cab and rear body.

• Only use hoisting equipment appropriate for the engine and transmission mass (approximately 510 kg).

Disassembly sequence

1 Transmission mounting support 2 Engine and transmission

Assembly sequence

Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks

Bolt (front mounting installation) 50 to 65 {5.1 to 6.6} –

Nut (transmission mounting support installation) 130 to 170 {13 to 17} –

Nut (transmission mounting support installation) 220 to 300 {22.4 to 30.6} –

11-28

Removal procedure

Removal: Engine and transmission

• Hook the wire rope and lifting mechanism each onto the three

hangers on the engine and lift the engine with a crane until they are tight.

• Support the transmission with the transmission jack.

• Check that all wiring and piping have been disconnected from

the engine.

• Remove the engine rear support.

• Push down the transmission part of the assembly, and then

move the engine and transmission assembly forward.

• Once the transmission is out of the front end of the rear body, turn the engine and transmission assembly 90 degrees to the right so as to prevent the assembly from hitting the frame and cab, and lower it to the right side of the vehicle. Make fine adjustments to the hoisting equipment as necessary.

11-2 9

ROCKER COVER

11-30

Disassembly sequence

1 Oil filler cap 2 Grommet 3 Cover 4 Spacer 5 Insulator 6 Rocker cover rubber 7 Snap ring 8 Fuel return hose 9 Injection pipe (See Gr13.)

10 Bolt (with hexagonal hole)

WARNING

• Fuel is highly flammable. Keep it away from flames and sources of heat.

• Thoroughly wipe up any spilled fuel. Otherwise, it may catch fire.

CAUTION

• When removing the injectors, be careful not to hit them with the tools etc.

• To help prevent fuel injection problems, keep the injector and injection pipe free from contamination.

11 Injector (See Gr13.) 12 O-ring 13 Tip gasket 14 Rocker cover 15 O-ring 16 Rocker cover gasket A 17 Rocker cover gasket B

: Locating pin : Non-reusable parts

• Before removing the injectors, check that the injector mounting holes are clear of trapped water, oil and any other substances.

Assembly sequence

Follow the disassembly sequence in reverse.

CAUTION

• Be sure to tighten the injector mounting bolts to the specified torque. Overtightening the bolts can deform the injectors, resulting in incorrect fuel injection.

Tightening torques (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks

Injection pipe 30.4 to 35 {3.1 to 3.6} –

Bolt (injector mounting) 5.2 to 7.2 {0.53 to 0.73} –

Bolt (rocker cover mounting) 5 ± 1 {0.5 ± 0.1} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity

O-ring Engine oil As required

11-3 1

CAMSHAFT HOLDER AND CAMSHAFT

Disassembly sequence

1 Upper guide plate 2 Bolt 3 No. 1 camshaft cap 4 Camshaft cap 5 Chain tensioner 6 Gasket 7 Exhaust camshaft

11-32

8 Intake camshaft

9 Camshaft holder 10 Adjusting screw 11 Short rocker 12 Adjusting screw 13 Long rocker 14 Pivot bolt

a: Cam sprocket

b: Timing chain

: Locating pin : Non-reusable parts

CAUTION

• Each camshaft cap and camshaft holder are processed as a pair. Do not replace only one of the two. Never change the combination.

Assembly sequence

Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy

– End play of camshaft 0.10 to 0.18 0.3 Inspect

Short

Difference between ma-

Exhaust cam-

shaft

8 Intake camshaft

11, 13 Clearance at rocker roller in radial direction 0.024 to 0.058 – Replace

jor axis and minor axis

Bend 0.015 0.03 Replace

Oil clearance at journals 0.05 to 0.086 0.15 Replace

Difference between major axis and minor axis

Bend 0.015 0.03 Replace

Oil clearance at journals 0.05 to 0.086 0.15 Replace

rocker side

Long rocker side

Short rocker side

Major axis:

39.913

Minor axis:

Major axis:

39.163

Minor axis:

Major axis:

40.160

Minor axis:

Major axis:

39.102

Minor axis:

5.913 5.86 Replace

6.163 6.11 Replace

6.160 6.11 Replace

6.102 6.05 Replace

Tightening torques (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks

Bolt (cam sprocket mounting) 88 {9.0}

Bolt (camshaft cap mounting) 18.6 to 20.6 {1.9 to 2.1} –

Lock nut (adjusting screw mounting) 9 to 10 {0.9 to 1.1} –

Pivot bolt 30 to 46 {3.1 to 4.7} –

(left hand thread)

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity

Threads and seating surfaces of bolt (cam sprocket mounting)

Cam, journals and thrust surface of No. 1 journal of camshaft

Rocker roller

Sphere of adjusting screw

Concave of pivot bolt

Engine oil As required

Wet

11-3 3

CAMSHAFT HOLDER AND CAMSHAFT

Removal procedure

Removal: Cam sprocket

• Bring the No. 1 cylinder piston to the top dead center (TDC) on

the compression stroke. Make sure that the camshaft cam faces up in this position.

• After holding on the hexagonal portion of the camshaft to prevent it from turning, loosen the bolt to remove the cam sprocket.

CAUTION

• When removing the bolt, do not use the timing chain for the stopper.

• The bolt has a left-hand thread and has an arrow on its top that indicates the direction for tightening the bolt. To remove the bolt, turn it in the direction opposite to the arrow.

• The cam sprocket and the timing chain have the positional relation for installation. Keep the cam sprocket attached to the timing chain unless absolutely necessary.

Inspection: End play of camshaft

• Attach a dial gauge to the rear of the engine and measure end

play of the camshaft.

• If the measurement exceeds the limit, replace the defective part(s).

Inspection procedure

Inspection: Camshaft

(1) Difference between major axis and minor axis

• If the measured value is below the specified limit, replace the

camshaft.

(2) Bend

• Support the camshaft at its No. 1 journal and No. 5 journal. Mea-

sure the extent of bend in the camshaft at the center of the No. 3 journal.

• Turn the camshaft through one revolution. One-half of the dial indicator reading represents the extent of bend.

• If the measurement exceeds the specified limit, replace the camshaft.

11-34

(3) Oil clearance at the journals

• Measure the oil clearance, and if the measured value is higher

than the limit, replace the faulty parts.

CAUTION

• Each camshaft cap and camshaft holder are processed as a pair. Do not replace only one of the two. Never change the combination.

Inspection: Clearance at the rocker (roller) in the radial direction

• If the measured value is not within the standard value range, re-

place the rocker.

11-3 5

CAMSHAFT HOLDER AND CAMSHAFT

Installation procedure

Installation: Chain tensioner and gasket

• Turn the cam of the chain tensioner, push in the plunger by hand

and hold it in the retracted position with the hook.

• Install the gasket on the cylinder head so that the sealant will be on the chain tensioner side.

CAUTION

• Installing the chain tensioner without holding the plunger in the retracted position will apply an excessive load on the timing chain and cause damage. Always push in the plunger and hold it in the retracted position before installing the tensioner.

Installation: Chain tensioner

• Install the chain tensioner, then crank the engine in the normal

direction (to clockwise as seen from the front of the engine). This will undo the hook, and the ratchet mechanism inside the chain tensioner will start adjusting the tension of the timing chain.

CAUTION

• Do not crank the engine in the reverse direction (counterclockwise as seen from the front of the engine) after installing the chain tensioner, as this will apply an excessive load on the plunger and may cause damage to the cam. If you crank the engine in the reverse direction by mistake, remove the chain tensioner and inspect it for damage. The tensioner may be reinstalled if it is intact.

11-36

M E M O

11-3 7

CYLINDER HEAD AND VALVE MECHANISM

Disassembly sequence

1 Connecting plate 2 Glow plug 3 Cylinder head bolt (M10) 4 Cylinder head bolt (M12) 5 Cylinder head (See later sections.) 6 Cylinder head gasket

a: Cam sprocket

b: Timing chain

c: Timing gear case

d: Crankcase

e: Front plate

: Locating pin : Non-reusable parts

CAUTION

• Glow plugs are fitted protruding from the bottom of the cylinder head. Therefore, when placing the cylinder head on the work bench without glow plugs removed, be careful not to have the glow plugs damaged.

11-38

Assembly sequence

Follow the disassembly sequence in reverse.

CAUTION

• The cylinder head bolts (M12) are tightened using the torque-turn method. Any cylinder head bolt that has three marks indicating that the bolt has been tightened three times already must be replaced with a new one.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks

Nut (connecting plate mounting) 1.0 to 1.5 {0.1 to 0.15} –

Glow plug 18 {1.8} –

Cylinder head bolt (M10) 58 {5.8} –

Cylinder head bolt (M12) 49 {5} + 90°+ 90°

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity

Cylinder head bolt threads and seating surfaces of their heads

Top surfaces of areas where timing gear case, crankcase and front plate join together

Engine oil As required

ThreeBond 1217H As required

• Wet

• Reusable up

to three times

Special tools

Mark Tool name and shape Part No. Application

Cam sprocket holder kit MH063490 Supporting the cam sprocket

Removal procedure

Removal: Cylinder head

• Loosen the cylinder head bolts (M10: 1, 2), (M12: 3 to 20) by

turns in the order indicated in the illustration before they are removed in the same order.

11-3 9

CYLINDER HEAD AND VALVE MECHANISM

• With the timing chain kept attached to the cam sprocket, remove

the cylinder head by lifting it straight up.

• After removing the cylinder head, hold the cam sprocket using . Be careful not to drop the timing chain.

Installation procedure

Removal: Cylinder head gasket

CAUTION

• When removing the cylinder head gasket, be careful not to

scratch the cylinder head, upper crankcase and the timing gear case.

Installation: Cylinder head

CAUTION

• Before fitting the cylinder head bolts (M12), check the

punch marks on each bolt’s head. (Bolts with one or two punch marks can be reused.)

• The number of punch marks indicates the number of times

the bolt has been tightened using the torque-turn method. Any bolt that has three marks (indicating that the bolt has been tightened three times already) must be replaced with a new one.

11-40

• The cylinder head gasket is a selective use part. Choose the

gasket according to the following procedure.

• Measure the amount of piston projection for every cylinder. (See

the PISTON AND CONNECTING ROD section.)

• After the measurement, select a cylinder head gasket with the

thickness appropriate for the average amount of piston projection from the following table.

• If any cylinder has a piston that has the amount of projection

greater than the maximum value of the average piston projection amount by 0.05 mm or more, use a gasket a rank thicker (A→B, B→C, C→D).

Unit: mm

Piston projection Cylinder head gasket

Average piston

projection

-0.209 to -0.149 A (1) 0.70 ± 0.04

-0.148 to -0.088 B (2) 0.75 ± 0.04

-0.087 to -0.027 C (3) 0.80 ± 0.04

-0.026 to 0.035 D (4) 0.85 ± 0.04

• The size class of the cylinder head gasket can be determined

from the number of notches on the gasket edge.

( ): Number of notches

Size

Thickness when

tightened

CAUTION

• If pistons, connecting rods or other relevant parts are re-

placed, measure to check the pistons for any change in protrusion.

• Clean the sealant application surfaces of each part.

• Apply sealant to the top surfaces of the areas where the timing

gear case, the front plate and the upper crankcase join together (two locations).

• Install the cylinder head together with the cylinder head gasket

on the crankcase within three minutes of applying the sealant, being careful not to dislodge the sealant.

CAUTION

• Do not damage the cylinder head gasket. If damaged, ab-

normalities such as coolant or oil leakage, engine noise and output drop could be caused.

• Do not run the engine within one hour of installing the cylin-

der head. Reapply sealant to the surfaces indicated above if any cylinder head bolts are loosened or removed.

• Tighten the cylinder head bolts by following different tightening

procedures for bolts 1 to 18 (M12) and bolts 19 and 20 (M10). The bolts should be tightened in steps according to the following instructions.

• Install the cylinder head bolts with the shear droop (press

punched edge) side of the washer on each of them facing in the indicated direction.

11-4 1

CYLINDER HEAD AND VALVE MECHANISM

Tightening procedure for bolts 1 to 18

• Retighten the tightened cylinder head bolts (M12) to a torque of

49 N·m {5 kgf·m} in the order indicated in the illustration.

• After tightening, tighten the bolts further 90 degrees in the order

indicated in the illustration.

• Then, tighten the bolts further another 90 degrees in the order

indicated in the illustration.

• Finally, put a punch mark on the head of each bolt (M12) to indi-

cate the number of times the bolt has been used.

CAUTION

• Cylinder head bolts (M12) are tightened using the torque-

turn method, and must never be additionally tightened after the final tightening.

Tightening procedure for bolts 19 and 20

• After completing the tightening procedure for bolts 1 to 18 (M12),

tighten bolts 19 and 20 (M10) to 58 N·m {5.8 kgf·m}.

11-42

M E M O

11-4 3

CYLINDER HEAD AND VALVE MECHANISM

Cylinder Head

Disassembly sequence

1 Valve cap 2 Valv e cott er 3 Valve spring retainer 4 Exhaust valve spring 5 Intake valve spring 6 Valve spring seat 7 Valve stem seal

8 Exhaust valve

9 Intake valve 10 Exhaust valve guide 11 Intake valve guide 12 Exhaust valve seat 13 Intake valve seat 14 Sealing cap (φ28 mm)

15 Sealing cap (φ22 mm) 16 Sealing cap (φ14 mm) 17 Cylinder head

: Non-reusable parts

Assembly sequence

Follow the disassembly sequence in reverse.

CAUTION

• When exhaust or intake valves are removed, their valve stem seals must be replaced.

11-44

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy

Free length 64.95 61.70

Exhaust valve

spring

5 Intake valve spring

8 Exhaust valve

8, 10 Exhaust valve stem-to-exhaust valve guide clearance 0.05 to 0.09 0.15 Replace

9 Intake valve

9, 11 Intake valve stem-to-intake valve guide clearance 0.02 to 0.06 0.1 Replace

12 Exhaust valve seat width 2.2 ± 0.2 2.8 Replace

13 Intake valve seat width 2.2 ± 0.2 2.8 Replace

17 Cylinder head

Installed load (installed length: 39.5)

Tilt – 2°

Free length 49.61 47.13

Installed load (installed length: 39.5)

Tilt – 2°

Stem diameter φ6.6 φ6.45 Replace

Valve seat angle 45° ± 15’ – Reface

Valve margin 1.0 0.8 Replace

Sinkage from cylinder head bottom surface

Stem diameter φ6.6 φ6.45 Replace

Valve seat angle 45° ± 15’ – Reface

Valve margin 1.0 0.8 Replace

Sinkage from cylinder head bottom surface

Distortion of bottom surface 0.05 0.2 Replace

Height from top to bottom 116 ± 0.2 115.8 Replace

Valve seat hole diameters

Intake side φ31.5 –

Exhaust side φ29.5 –

356.0 N ± 18 N {36.3 ± 1.8 kgf}

243.2 N ± 12 N {24.8 ± 1.2 kgf}

–0.05 –0.07

0.3 ± 0.25 0.8 Replace

–0.025 –0.040

0.3 ± 0.25 0.8 Replace

+0.025 0

+0.021 0

–

Replace

Reface or replace

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity

Valve cap top surface

Valve stem seal lip

Valve stem and tip

Valve guide outer surface

Sealing cap holes in cylinder head entire inner surfaces

Engine oil As required

ThreeBond 1386D or

Loctite 962T

As required

11-4 5

CYLINDER HEAD AND VALVE MECHANISM

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Valve spring compressor adapter plate

Valve spring compressor (use one of the types shown on the right)

Valve stem seal installer

ABC

φ18 φ15.4 φ6.6

MD998784

MD998772

MD999597

MH063609 Installation of valve stem seal

Removal and installation of valve cotter

Valve guide remover

φ6.6 φ11. 5

Valve guide installer

ABC

φ24.5 φ12 16.5

Caulking tool, body

φ6.6

Caulking ring, intake valve guide

φ31.5

Caulking ring, exhaust valve guide

φ29.5

MD998665 Removal of valve guide

MH063610 Installation of valve guide

MH063613

MH062807

MH062808

Installation of valve seat

11-46

Removal procedure

Removal: Valve cotter

• Using and , remove and install the valve cotters ac-

cording to the following procedure.

• Install on the cylinder head using any bolts (M8 × 1.25 mm).

• Install

on using any washers and nuts (M6 × 1.0 mm).

11-4 7

CYLINDER HEAD AND VALVE MECHANISM

• Set the stay to a level position.

• Adjust the retainer and the mobile nut so that the retainer holder

presses down on the valve spring retainer from directly above, and fix them in place with the wing bolt. Adjust the vertical position of the retainer holder by raising or lowering the stay using the nuts.

• Turn the handle clockwise to press down on the valve spring retainer, thus removing the valve cotter.

Inspection procedure

• Place a wood piece between the valve and to protect the

valve from damage.

• Using , press down on the upper retainer to remove the valve cotter.

Inspection: Valve

• If the valve is replaced after performing the following inspection,

make sure to lap the valve and valve seat.

(1) Stem outside diameter

• Replace the valve if the measured value is below the limit or is

severely worn.

11-48

(2) Valve seat angle

• Reface the valve if the measured value is not within the standard

value range.

(3) Valve margin

• Reface or replace the valve if the measured value is below the

limit.

Refacing of valve

• Limit grinding to a necessary minimum.

• If the valve margin is below the limit after grinding, replace the

valve.

• After grinding, make sure to lap the valve and valve seat.

Inspection: Valve stem-to-valve guide clearance

• If the clearance exceeds the specified limit, replace the defective

part(s).

Replacement of valve guide [Removal]

[Installation]

• Measure the diameter of the valve guide mounting hole in the

cylinder head.

• If the measurement exceeds the specified value, select an oversized valve guide from the table below.

• Recondition the valve guide mounting hole to the diameter corresponding to the diameter of the selected oversized valve guide.

Unit: mm Available oversize 0.05 0.25 0.50 Valve guide inside

diameter

+0.018

φ12.05 φ12.25 φ12.50

+0.018

11-4 9

CYLINDER HEAD AND VALVE MECHANISM

• Temporarily place the lower retainer on the cylinder head. Then,

install the valve guide until contacts the lower retainer closely.

CAUTION

• The valve guides have a specified amount of depth. Make sure to use to achieve the specified depth.

• Intake valve guides are longer than exhaust valve guides. Make sure to install the correct type of guide in each location.

Inspection: Contact between valve and valve seat

• Before starting inspection, check that the valve and valve guide

are intact.

• Apply an even coat of red lead to the valve contact surface of the valve seat.

• Strike the valve once against the valve seat. Do not rotate the valve during this operation.

• If the red lead deposited on the valve indicates a poor contact pattern, take either of the following corrective actions.

Contact Corrective action

Minor defect Lapping

Serious defect

Lapping

• Perform lapping according to the following procedure.

• Apply a thin coat of lapping compound to the valve seat contact

surface of the valve.

• Adding a small amount of engine oil to the lapping compound can facilitate even application.

• Start with an intermediate-grit compound (120 to 150 grit) and finish with a fine-grit compound (200 grit or more).

Refacing or replacement of valve and valve seat

CAUTION

• Do not put any compound on the stem of the valve.

11-50

• Strike the valve several times against the valve seat while rotating the valve a little at a time.

• Wash away the compound with diesel fuel.

• Apply engine oil to the valve contact surface of the valve seat

and rub in the valve and valve seat well.

• Inspect the contact pattern of the valve and valve seat again.

• If the contact pattern is still defective, replace the valve seat.

Inspection: Valve seats

• If a valve is corrected or replaced with a new one as a result of

the following inspection, make sure to lap the valve and valve seat.

(1) Valve seat width

• If the measurement exceeds the limit, reface or replace the

valve seat.

(2) Valve sinkage from cylinder head bottom surface

• Measure the sinkage with the valve seat in intimate contact.

• If the measurement exceeds the limit, adjust or replace the de-

fective part(s).

Refacing the valve seat

• Grind the valve seat using a valve seat cutter or valve seat

grinder.

• After grinding, place a piece of sandpaper approximately #400 between the cutter and valve seat and grind the valve seat lightly.

• Use a 15° or 75° cutter to cut the valve seat to a width within the standard range. If the valve seat cannot be refaced, replace the valve seat.

CAUTION

• Make sure that the valve seat refacing does not cause the valve sinkage to exceed the specified limit.

• After refacing, lap the valve and valve seat.

Replacement of valve seat [Removal]

• The valve seats are installed by expansion fitting. To remove a

valve seat, grind inside the metal stock to reduce the wall thickness, then remove the valve seat at room temperature.

11-5 1

CYLINDER HEAD AND VALVE MECHANISM

[Installation]

• Measure the inside diameters of the intake and exhaust valve

seat holes A and B in the cylinder head.

• If the measurement exceeds the specified value, select an oversized valve seat from the table below.

• Reface valve seats A and B to the inside diameters of the selected oversizes.

Available oversize 0.30 0.60

Intake valve seat mounting hole

Exhaust valve seat mounting hole

• Replace the cylinder head if defects are evident.

• Chill the valve seats thoroughly by immersing them in liquid ni-

trogen.

• Install the valve seat until it contacts the cylinder head closely using and (for intake valve seat) or (for exhaust valve seat).

• After installing the valve seat, lap the valve seat and valve.

Diameter: A φ31.8 φ32.1

Diameter: B φ29.8 φ30.1

+0.025

+0.021

Unit: mm

+0.025

+0.021

Inspection: Distortion of cylinder head bottom surface

• If the distortion exceeds the specified limit, replace the cylinder

head.

CAUTION

• Make sure that height of the cylinder head from the top surface to the bottom surface is not reduced to a value below the specified limit.

11-52

Installation procedure

Installation: Sealing cap

• Apply sealant to the press fitting hole in the cylinder head.

• Install sealing caps and press them in to the depths respectively

specified.

Installation: Valve stem seal

• Apply engine oil to the valve stem seal lip.

• Install the valve stem seal until it contacts the lower retainer

closely using .

• After installing the valve stem seal, check that the spring of the valve stem seal is deformed or broken.

Installation: Valve cotter

• Install the valve cotter in the same manner as in removal. (See

“ Removal: Valve cotter”.)

11-5 3

PISTON AND CONNECTING ROD

Disassembly sequence

1 Lower connecting rod bearing 2 Connecting rod cap 3 Upper connecting rod bearing 4 Piston and connecting rod (See

later sections.)

a: Upper crankcase

b: Crankshaft

Assembly sequence

Follow the disassembly sequence in reverse.

CAUTION

• The connecting rod bolts are tightened using the torque-turn method. Any connecting rod bolt that has three marks indicating that it has been tightened three times already must be replaced with a new bolt together with its nut.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy

Piston projection from upper crankcase top surface

–

(average value)

– Connecting rod end play 0.15 to 0.45 0.5 Replace

1, 3 Connecting rod bearing span when free – 58.5 Replace

b Connecting rod bearing-to-crankshaft oil clearance 0.022 to 0.055 0.1 Replace

1, 3,

a Piston-to-crankcase cylinder clearance 0.105 to 0.125 –

Bore diameter φ95 to 95.03 φ95.25 Replace

a Cylinder (upper crankcase)

Out-of-roundness 0.005 or less –

Taper 0.015 or less –

-0.209 to 0.035 – Inspect

Correct or

replace

Correct or

replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks

• Wet

Nut (connecting rod cap installation) 49 {5.0} + 90°

• Reusable up to three times

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity

Nut threads

Connecting rod bearing inside surface

Engine oil As required

11-54

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Piston guide

φ95

MH062226

Installation of piston and connecting rod

Inspection before removal

Inspection: Piston projection from upper crankcase top surface

CAUTION

• The amount of piston projection affects engine performance and must therefore be inspected without fail.

• Set the piston at the top dead center.

• Mark reference points A (five points in total) on the top surface of

the upper crankcase as shown in the illustration. Using each of the marks as a zero point, measure the amount of piston projection relative to the zero point (height of measurement point B height of reference point A).

• Make the measurements at the two measurement points B for each cylinder (eight points in total) using the reference point A nearest to each measurement point, and calculate the average value of all the measurements.

• If the average value is out of the standard value range, check the clearance between all relevant parts.

• Select and use a cylinder head gasket that can accommodate the average piston projection (average value of the eight measurements). (See the CYLINDER HEAD AND VALVE MECHANISM section.)

Inspection: Connecting rod end play

• Measure the end play for every connecting rod.

• If any measurement exceeds the specified limit, replace the de-

fective part(s).

Inspection procedure

Inspection: Connecting rod bearing span when free

CAUTION

• Do not attempt to manually expand the bearings.

• If the span is less than the specified limit, replace both the upper

and lower bearings as a matched set.

11-5 5

PISTON AND CONNECTING ROD

Inspection: Connecting rod bearing-to-crankshaft oil clearance

• Fit the lower bearing to the connecting rod cap and the upper

bearing to the connecting rod, then tighten the nut to a torque of 49 N·m {5.0 kgf·m}.

• Measure the inside diameter of the bearing and the diameter of the crankshaft pin.

• If the clearance exceeds the limit, replace the defective part(s).

• If a bearing has to be replaced with an undersized one, machine

the crankshaft pin to the specified undersize diameter. (See the CRANKSHAFT AND CRANKCASE section.)

Inspection: Piston-to-crankcase cylinder clearance

• If the measurement is not within the standard value range, per-

form one of the steps below according to the condition.

A: Measure on cylinder bore in crankcase (in direction of

crankshaft axis)

B: Measure on cylinder bore in crankcase (in direction perpen-

dicular to crankshaft axis)

C: Measure on piston (in direction perpendicular to piston pin

hole)

• If the crankcase cylinder bore diameter exceeds the specified limit, rebore all the cylinders to an oversize diameter and replace the pistons and piston rings with the corresponding oversized ones.

CAUTION

• If any one cylinder is found to be defective and must be rebored, all the other cylinders must also be rebored to the same oversize.

• If the cylinder bore diameter is within the standard value range,

replace the piston and piston rings.

Selection of oversized piston

• Available oversizes: 0.50 mm and 1.00 mm (two sizes)

• Measure the bore diameter of each cylinder. Select the appropri-

ate oversized piston based on the largest of the measurements.

• Measure the outside diameter of the chosen oversized piston.

• Rebore each cylinder to a diameter at which the piston-to-cylin-

der clearance will be within the standard value range.

11-56

CAUTION

• Rebore the cylinder in the following order to prevent the generated heat from causing distortion in the crankcase. No. 2→No. 4→No. 1→No. 3

Installation procedure

Reboring diameter (tolerance ± 0.005) =

Oversized piston diameter (measured value) + Piston-to-cylinder clearance (median of service standard value range) – 0.02 mm (honing margin)

• After boring the cylinders, hone them to the finish dimension (tolerance ± 0.005). Finish dimension (tolerance ± 0.005) =

Oversized piston diameter (measured value) + Piston-to-cylinder clearance (median of service standard value range)

• Honing finish surface roughness: 1.2 to 3.5 µm

• Honing cross hatch angle: 20° ± 5° (semi angle)

• Cylinder bore out-of-squareness: 0.05 mm

• Measure the piston-to-cylinder clearance.

Installation: Connecting rod bearings

CAUTION

• Do not reverse the positions of the lower bearing and the upper bearing (with oil hole) when installing, as this may cause seizure in the engine.

• Select and use a bearing set of a thickness that can accommo-

date the inside diameter of the connecting rod’s large end and the diameter of the crankshaft pin. Use either of the following methods for the selection.

(1) Measurement based selection

• Install the connecting rod cap on the piston and connecting rod

assembly without fitting the lower and upper bearings.

• Tighten the nut to 49 N

·m {5.0 kgf·m}.

• Measure the inside diameter of the connecting rod’s large end (vertically from one point), and the outside diameter of the crankshaft pin (vertically or horizontally from one point).

• Select a bearing set that matches the measurements from the table below. If the color identification mark is indiscernible, measure the thickness of the bearing walls and use the measurements in its place.

Unit: mm

Diameter of

crankshaft pin

-0.012

φ54

-0.020

φ54

-0.029

Inside diameter

of connecting

rod large end

+0.019

φ58 Colorless 2

+0.010 +0.010

φ58 Blue 2

0 +0.019

φ58 Yellow 2

+0.010 +0.010

φ58 Colorless 2

Color identifica-

tion mark

Bearing

Thickness

-0.001

-0.005

-0.009 +

0.003

-0.001

-0.005

11-5 7

Mitsubishi 4M4 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

GROUP 00 GENERAL

MODIFICATION SUMMARY

VEHICLE MODEL CODING SYSTEM

EQUIPMENT TYPE CODING SYSTEM

POWER TRAIN TABLE

HOW TO READ THIS MANUAL

CHASSIS NUMBER, ENGINE NUMBER, MOTOR NUMBER AND NAME PLATE

PRECAUTIONS FOR MAINTENANCE OPERATION

JACKING UP THE VEHICLE

DIAGNOSIS CODES

1. Diagnosis Codes

2. Reading and Erasing the Diagnosis Code

TABLE OF STANDARD TIGHTENING TORQUES

GROUP 11 ENGINE

SPECIFICATIONS

STRUCTURE AND OPERATION

1. Exploded View

2. Cylinder Head and Cylinder Head Gasket

3. Valve Mechanism

4. Timing Chain

5. Timing Gears

6. Connecting Rod

7. Piston

8. Flywheel

9. Crankcase, Crankshaft and Main Bearing

10.Oil Seal

TROUBLESHOOTING

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Measuring Compression Pressure

2. Inspection and Adjustment of Valve Clearance

3. Inspection and Replacement of Timing Chain

4. Protrusion of Timing Chain Tensioner’s Plunger

5. Damage to the Starter Pinion Contact Surface of Ring Gear

ENGINE REMOVAL AND INSTALLATION

ROCKER COVER

CAMSHAFT HOLDER AND CAMSHAFT

CYLINDER HEAD AND VALVE MECHANISM

PISTON AND CONNECTING ROD