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ENGINE : Click On The Applicable Bookmark To Selected The Required Model Year
ENGINE : Click On The Applicable Bookmark To Selected The Required Model Year
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ENGINE <4D5>
Click on the applicable bookmark to selected the required model year.
ENGINE <4D5>
CONTENTS
GENERAL INFORMATION
Items 4D56
Compression ratio 21
Exhaust 4
SEALANTS
Items Specified sealant Remarks
SPECIAL TOOLS
Tools Number Name Use
MB991502 MUT-II Drive belt tension measurements
sub-assembly
MB991802 Pin B
MD998382 Crankshaft front oil Installing the crankshaft front oil seal
seal installer
MD998051 Cylinder head bolt Removal and installation of the cylinder head
wrench bolt
ON-VEHICLE SERVICE
A
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
Indicator mark ALTERNATOR AND POWER STEERING OIL PUMP
DRIVE BELT TENSION CHECK
Caution
Perform the check after rotating the engine to the normal
direction (one revolution and over).
1. Check that the indicator mark of the auto-tensioner is
located within the scope shown as “A” on the tensioner
bracket.
2. If the mark is located out of the scope “A,” replace the
drive belt.
NOTE
Since the auto-tensioner is used, it is not necessary to
adjust the tension of the belt.
Deflec-
tion
AUTO-TENSIONER CHECK
1. Run the engine at idling speed and then stop it to check
whether the drive belt is forced out from the width of
the auto-tensioner pulley.
2. Remove the alternator and power steering oil pump drive
belt. (Refer P.11B-19.)
3. Locate a ring spanner onto the auto-tensioner pulley
mounting bolt, and move the tensioner back and forth
to confirm there is no stiffness.
4. If some abnormality is found during the above mentioned
check (1) and (3), replace the auto-tensioner.
5. Install the alternator and power steering oil pump drive
belt. (Refer P.11B-19.)
NOTE
Insert the thickness gauge from the centre of the cylinder
Adjusting head towards the outside so that it doesn’t touch the
screw
pad.
Pad
Thickness gauge
10 mm
Timing marks Timing marks 4. Align the timing marks of the camshaft sprocket and set
the No. 1 cylinder to the top dead centre position.
Camshaft Crankshaft
sprocket pulley
10 mm
MD998384
Set to 9_ ATDC
1 ± 0.03 mm or more (3) Tilt the injection pump to the left and right and adjust
the needle on the dial gauge so that the display value
is uniform.
(4) Provisionally tighten the mounting nut and bolt of
the injection pump.
(5) Repeat steps 9 - 13 to check if the adjustment has
been made correctly.
1 ± 0.03 mm of less
Front
view
Injection pipe (6) Tighten the mounting nuts and bolts to the specified
union nuts torque.
(30 ± 6 N×m) (7) Tighten the injection pump union nuts to the specified
torque.
Caution
When tightening the nuts, hold the delivery valve
Nuts holders with a spanner so that they don’t turn
(19 ± 3 N×m) Bolts
(23 ± 3 N×m) at the same time.
Timing
check plug
(17 ± 2N×m)
Locking
nut
Idle speed ad-
justing screw
Vehicles with immobilizer 3. Disconnect the fuel cut solenoid valve connector.
<Vehicles without immobilizer> Disconnect the fuel cut
Fuel cut valve valve controller connector. <Vehicles with immobilizer>
controller
NOTE
Doing this will prevent carrying out fuel injection.
4. Cover the glow plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
(1) Keep away from the glow plug hole when cranking
(2) If compression is measured with water, oil, fuel,
etc., that has come from cracks inside the cylinder,
these materials will become heated and will gush
out from glow plug hole, which is dangerous.
Compression gauge 5. Set compression gauge to one of the glow plug holes.
6. Crank the engine and measure the compression pressure.
Standard value (at engine speed of 280 r/min):
3,040 kPa
Limit (at engine speed of 280 r/min): min. 2,256 kPa
7. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: max 294 kPa
8. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the glow plug hole, and repeat the
operations in steps (6) and (7).
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
9. Connect the fuel cut solenoid valve connector or fuel
cut valve controller connector.
10. Install the glow plugs.
Tightening torque: 18 ± 2 N×m
Bolt B
Bolt B
Access cover
Access cover 7. Install the access cover while sliding the front lower cover
Guide down along the two guides.
8. Install the timing belt upper cover.
1
10
12 ± 1 N×m
11
19 ± 3 N×m
19 ± 3 N×m
5 6
(Engine oil)
4
9
3
7.0 ± 1.0 N×m
2
39 ± 5 N×m
Removal steps
1. Engine oil level gauge and guide 6. Oil level sensor
assembly 7. Space rubber
2. Drain plug 8. Bell housing cover
"BA 3. Drain plug gasket AA" "AA 9. Oil pan
4. Alternator vacuum pump oil return 10. Oil screen
hose connection 11. Oil screen gasket
5. Oil level sensor connector
INSPECTION
D Check oil pan for cracks.
D Check oil pan sealant-coated surface for damage and
deformation.
D Check oil screen for cracked, clogged or damaged wire
net and pipe.
8
6 7
44 ± 10 N×m
5 11
11 ± 1 N×m
11 ± 1 N×m
(Engine oil)
11 ± 1 N×m
11 ± 1 N×m
10
177 ± 9 N×m
4
3
2
1
Removal steps
D Radiator upper shroud D Cooling fan (Refer to GROUP 14.)
(Refer to GROUP 14.) AC" 5. Alternator and power steering oil
AA" 1. A/C compressor drive belt pump drive belt
<Vehicles with A/C> 6. Auto-tensioner
2. A/C compressor connector 7. Fan Clutch
<Vehicles with A/C> 8. Water pump pulley
AB" 3. A/C compressor <Vehicles with A/C> "CA 9. Timing belt front upper cover
4. Tension pulley and tension pulley AD" 10. Crankshaft pulley
bracket assembly <Vehicles with A/C> "CA 11. Timing belt front lower cover
15
12 26 ± 3 N×m
14
13
26 ± 3 N×m
23
22
20
21
26 ± 3 N×m
26 ± 3 N×m
19
18
17
16
MB991802
Belt deflection
Crankshaft
sprocket B
Tension
side
Amount of belt 9. Press on the center of the bolt with an index finger to check
deflection the amount of deflection.
Standard value: 4 - 5 mm
C B 6×50
C 6×60
d=Nominal diameter
l=Nominal length
A
A
B
A A
5 6
3
7
8
10
9
1 (Engine oil)
2
(Engine oil)
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
D Timing belt and timing belt B removal D Transmission assembly
and installation (Refer to P.11B-19.) (Refer to GROUP 22.)
1. Crankshaft sprocket B 3. Adapter plate
"DA 2. Crankshaft front oil seal AA" "CA 4. Flywheel assembly
5. Crankshaft adaptor
6. Ball bearing
7. Oil seal case
8. Gasket
"BA 9. Oil separator
"AA 10. Crankshaft rear oil seal
MD998781
MD998376
MD998382 MD998383
(Apply oil to outer
surface)
10 mm 10 mm
5
7 37 ± 2 N×m
7
8
Sealant: 4
11 20 ± 1 N×m
3M ATD Part No. 8660 or
equivalent 37 ± 2 N×m 12 12
20 ± 1 N×m
12
13
12
10
9
69 ± 5 N×m
11 ± 1 N×m
Cable tie wrap 2. Tie the camshaft sprocket and timing belt together with
a cable tie wrap so that timing mark is not maladjusted.
Timing belt
Camshaft
sprocket
MD998719
Front of engine
C 6×60
d=Nominal diameter
l=Nominal length
11
22 ± 4 N×m 8
30 ± 6 N×m
22 ± 4 N×m
9
7
10
13 6
24 ± 4 N×m 2
12 12 ± 1 N×m
14 1
(Engine oil)
Removal steps
1. Oil level gauge guide and oil level 7. Earth cable connection
gauge assembly AB" "CA 8. Fuel injection pipe
AA" "DA 2. Radiator upper hose 9. Heater hose connection
D Rocker cover (Refer to P.11B-27.) 10. Fuel hose connection
3. Engine coolant temperature switch D Water pipe assembly C
connector (for A/C compressor (Refer to GROUP 14.)
control.) AC" 11. Power steering oil pump assembly
4. Engine coolant temperature switch 12. Power steering oil pump bracket
connector (for condenser fan con- bolt
trol.) AD" "BA 13. Cylinder head assembly
5. Glow plug connector "AA 14. Cylinder head gasket
6. Engine coolant temperature gauge
unit and sensor connector
6 14 16 8
2 10 18 12 4
1 5 13 17 15 11 7
9 3
Front of engine
Identification code
INSTALLATION SERVICE POINTS
"AA CYLINDER HEAD GASKET INSTALLATION
To replace the cylinder head gasket only, select a gasket
of correct specification according to the table below.
Identification holes Identification code Part number
specification specification
C (Thickness after tightening 145 MD302891
the bolts 1.45 mm)
Identification holes
D (Thickness after tightening 150 MD302892
the bolts 1.50 mm)
E (Thickness after tightening 155 MD302893
Detail of the Identification holes
the bolts 1.55 mm)
Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.
Therefore, if the piston or the connecting rod is replaced,
the protrusion amount may be changed. Always select
a correct gasket by measuring the protrusion amount.
(For details, refer to the Engine Workshop Manual.)
Cylinder head
bolt washer
MD998051
17 13 9 5 1 3 7 11 15
14 10 6 4 12
18 2 8 16
Front of engine
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Hood Removal and Installation (Refer to GROUP 42.) D Accelerator Cable Adjustment
D Under Cover and Skid Plate Removal and Installation (Refer to GROUP 17 - On-vehicle Service.)
D Engine Oil Draining and Refilling <Post-installation operation>
(Refer to GROUP 12 - On-vehicle Service.) D Fuel Line Air-bleeding
D Battery and Battery Tray Removal and Installation (Refer to GROUP 13B - On-vehicle Service.)
D Air Cleaner Removal and Installation <Post-installation operation>
(Refer to GROUP 15.) D Drive Belt Tension Check and Adjustment
D Radiator Removal and Installation <Vehicles with A/C> (Refer to P.11B-6.)
(Refer to GROUP 14.) <Post-installation operation>
2
3
5
11 ± 1 N×m 4
12
13 6
14 ± 3 N×m 11
12
7
8
10
9
Removal steps
1. Earth cable connection 8. Oil pressure switch connector
2. Glow plug connector 9. Engine oil level sensor connector
3. Engine coolant temperature switch 10. Free-wheeling hub engage switch
connector (for A/C compressor 11. A/C compressor connector
control) <Vehicles with A/C>
4. Engine coolant temperature switch 12. Starter connector
connector (for condenser fan control) D A/C compressor assembly <Vehicles
5. Fuel cut solenoid valve connector with A/C> (Refer to P.11B-19.)
6. Injection pump connector 13. Earth cable connection
7. Alternator connector
18
18
15 22 ± 4 N×m
19
17
22 ± 4 N×m 12 ± 2 N×m
20
16 21
44 ± 5 N×m
18
23
22
44 ± 10 N×m*
14
ENGINE <4D5>
CONTENTS
GENERAL INFORMATION
Items 4D56
Compression ratio 21
Exhaust 4
SERVICE SPECIFICATIONS
Items Standard value
Idle speed r/min 750 ± 30
Timing belt tension mm 4-5
Timing belt B tension mm 4-5
SEALANT
Items Specified sealant Remarks
MB991802 Pin B
MD998051 Cylinder head bolt Removal and installation of the cylinder head
wrench bolt
Tachometer
Injection
nozzle
12 ± 1 N·m
12
19 ± 3 N·m
19 ± 3 N·m
6
4
9
8
2 3
7.0 ± 1.0 N·m
39 ± 5 N·m
7
10
35 ± 6 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
Removal steps
1. Engine oil level gauge and guide 6. Oil level sensor
assembly 7. Space rubber
2. Drain plug 8. Bell housing cover
"BA 3. Drain plug gasket AA" "AA 9. Oil pan
4. Alternator vacuum pump oil return 10. Oil pan cover
hose connection 11. Oil screen
5. Oil level sensor connector 12. Oil screen gasket
INSPECTION
D Check oil pan for cracks.
D Check oil pan sealant-coated surface for damage and
deformation.
D Check oil screen for cracked, clogged or damaged wire
net and pipe.
6 7
44 ± 10 N·m
5 11
11 ± 1 N·m
11 ± 1 N·m
(Engine oil)
11 ± 1 N·m
11 ± 1 N·m
10
177 ± 9 N·m
4
3
2
1
Removal steps
D Radiator upper shroud AC" 5. Alternator and power steering oil
AA" 1. A/C compressor drive belt pump drive belt
<Vehicles with A/C> 6. Auto-tensioner
2. A/C compressor connector 7. Fan Clutch
<Vehicles with A/C> 8. Water pump pulley
AB" 3. A/C compressor <Vehicles with A/C> "CA 9. Timing belt front upper cover
4. Tension pulley and tension pulley AD" 10. Crankshaft pulley
bracket assembly <Vehicles with A/C> "CA 11. Timing belt front lower cover
D Cooling fan
26 ± 3 N·m
24
23
21
22 26 ± 3 N·m
19
18
17
26 ± 3 N·m
20
16
MB991802
Belt deflection
Crankshaft
sprocket B
Tension
side
C B 6×50
C 6×60
d=Nominal diameter
l=Nominal length
A
A
B
A
A
5
29 ± 2 N·m → +120° 4
(During cold engine)
3
(Engine oil) 4.9 ± 1.0 N·m
6
9
22 ± 4 N·m 30 ± 6 N·m
22 ± 4 N·m
7
8
24 ± 4 N·m
11 2
12 ± 1 N·m
10
1
12
(Engine oil)
Removal steps
1. Oil level gauge guide and oil level AB" "CA 6. Fuel injection pipe
gauge assembly 7. Heater hose connection
AA" "DA 2. Radiator upper hose 8. Fuel hose connection
D Rocker cover D Water pipe assembly C
3. Engine coolant temperature switch (Refer to GROUP 14.)
connector (for A/C compressor AC" 9. Power steering oil pump assembly
control) 10. Power steering oil pump bracket
4. Engine coolant temperature switch bolt
connector (for condenser fan con- AD" "BA 11. Cylinder head assembly
trol) "AA 12. Cylinder head gasket
5. Glow plug connector
6 14 16 8
2 10 18 12 4
1 5 9 13 17 15 11 7 3
Front of engine
B Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.
C Therefore, if the piston or the connecting rod is replaced,
the protrusion amount may be changed. Always select
a correct gasket by measuring the protrusion amount.
(For details, refer to the Engine Workshop Manual.)
MD998051
17 13 9 5 1 3 7 11 15
14 10 6 4 12
18 2 8 16
Front of engine
14 10 6 4 12
18 2 8 16
Front of engine