Hitachi 4HK1 Interim Tier 4 Compatible Engine Workshop Manual PNEWDCA – PDF

1. Repair work safety information

1. Use an engine stand when demounting the engine from the equipment. Be sure not to place the engine directly on the ground or allow the oil pan to come into contact with the ground.

2. When performing a procedure with two or more people, make sure to ensure each other’s safety.

3. When repairing the electrical system, make sure to disconnect the cable from the negative (-) battery terminal before working. Keep fire away when removing the battery cover

IDE-2620H 1
0 Introduction (All) 5
Introduction 6
safety information 6
14A Service Information Guide (All) 7
Contents included in service information 8
Plastic gauge 10
Recommended liquid gasket 12
Thread locking adhesive agent 14
Term 15
Abbreviations 16
Standard bolts 20
1B Mechanical (4HK1) 27
Cylinder head cover 28
removal 28
installation 29
Cylinder head assembly 30
removal 30
disassembly 41
inspection 46
reassembly 53
installation 61
Idle gear 78
removal 78
inspection 92
installation 93
Inlet cover118
removal118
installation123
Cylinder block132
removal132
inspection151
installation152
Exhaust manifold189
removal189
inspection193
installation194
Crankshaft200
removal200
disassembly217
inspection218
reassembly222
installation223
Piston258
removal258
disassembly270
inspection271
reassembly278
installation280
Camshaft301
removal301
disassembly303
inspection304
reassembly306
installation307
Flywheel313
removal313
inspection315
installation316
Crankshaft rear oil seal318
removal318
installation320
Rocker arm shaft323
removal323
disassembly325
inspection326
reassembly328
installation329
Valve spring333
removal333
inspection336
installation337
Valve stem oil seal344
removal344
installation347
Crankshaft front oil seal354
removal354
installation356
CMP sensor359
removal359
inspection360
installation361
Front cover362
removal362
installation364
Intake throttle valve369
removal369
installation370
CKP sensor371
removal371
inspection372
installation373
Supplementary Information374
1C Fuel System (4HK1)401
Fuel supply pump402
removal402
installation404
Common rail assembly408
removal408
installation411
Injector416
removal416
installation420
Suction control valve425
removal425
installation426
Fuel filter428
removal428
installation429
Relief valve431
removal431
installation432
Fuel filter element434
removal434
installation435
Fuel filter pressure sensor437
removal437
installation438
Supplementary Information439
1D Cooling (4HK1)445
Water pump assembly446
removal446
inspection448
installation449
Thermostat452
removal452
inspection453
installation454
Cooling fan belt455
inspection455
Radiator456
inspection456
Engine coolant temperature sensor457
removal457
inspection458
installation459
Coolant460
inspection460
Overheat switch462
removal462
installation463
Supplementary Information464
1E Lubrication (4HK1)471
Oil pan472
removal472
installation473
Oil pump assembly474
removal474
disassembly488
inspection489
reassembly491
installation492
Oil level switch517
removal517
installation518
Oil cooler assembly519
removal519
disassembly524
reassembly525
installation526
Oil pressure sensor534
removal534
inspection535
installation536
Engine oil537
inspection537
Oil port cover538
removal538
installation539
Supplementary Information540
1F Induction (4HK1)547
Boost temperature sensor548
removal548
installation549
Turbocharger assembly550
removal550
inspection552
installation553
Intercooler556
inspection556
Air cleaner element557
inspection557
IMT sensor558
removal558
installation559
Boost sensor560
removal560
inspection561
installation562
Supplementary Information563
1G Exhaust (4HK1)565
DPD assembly566
disassembly566
inspection568
reassembly569
Exhaust differential pressure sensor572
removal572
inspection573
installation574
Exhaust gas temperature sensor575
removal575
inspection576
installation577
Supplementary Information578
1H AuxEmission Control Devices (4HK1)581
EGR valve582
removal582
inspection585
installation586
Supplementary Information590
1J Electrical (4HK1)595
Glow plug596
removal596
inspection597
installation598
Generator599
removal599
disassembly600
inspection601
reassembly605
installation606
ECM607
removal607
installation608
Starter assembly609
removal609
disassembly610
inspection612
reassembly616
installation618
Supplementary Information619
SERVICE MANUAL REVISION REQUEST FORM625