Isuzu 4ja1 workshop manual free download -
Looking for:
Isuzu Repair and Service PDF Manuals - Workshopautomanuals |
Isuzu 4ja1 workshop manual free download.Isuzu 4JA1 Engine Factory Service Repair Manual
Engine Isuzu c turbo Workshop Manual Supplement 36 pages. Page 2 Information contained in this Workshop Manual is the latest available at the time of publication.
Isuzu reserves the right to make changes at any time without prior notice. This Workshop Manual is applicable to and later models. Notes on the format of this manual. Page 5: General Repair Instructions Always check and recheck your work. No service operation is complete until you have done this. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page.
For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex procedures are covered in detail. Page 7: General Information Important operation requiring extra care..
Specified torque tighten Special tool use required or.. Alignment marks.. Directional indication.. Lubrication oil.. Measurement criteria are defined by the terms "standard" and "limit". A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable. A measurement which is outside the "limit" indicates that the applicable part or parts must be either repaired or replaced. Page 19 MEMO Page Model Identification Use of the wrong service data will result in reduced engine performance and engine damage.
Clean the oil cooler fitting face. This will allow the new oil filter to seat properly. Apply a light coat of engine oil to the O-ring. Turn in the new oil filter until the filter O-ring is fitted against the sealing face.
If the float 1 has reached level 2 , loosen the drain plug 3 at the bottom side of the water separator to drain the water. If the opening pressure is above or below the specified value, the injection nozzle must be replaced or recondi- tioned.
Drive Belt Deflection mm in. Retighten the rocker arm shaft bracket bolts in sequence as shown in the illustration. Bring the piston in either the No. Realign the crankshaft damper pulley TDC line with the timing pointer. Adjust the clearances for the remaining valves as shown in the illustration. At TDC on the compression stroke of the No. The No. Start the engine and allow it to run for several minutes to warm it up. Stop the engine and cut the fuel supply.
Remove all of the glow plugs from the engine. Compression Gauge Adapter 4. Cylinder head gasket Water pump gasket 2. This design provides superior fuel economy for a wide range. Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold. Cooling fan and spacer Fuel leak off pipe 2. Cooling fan drive belt Fuel injection pipe with clip 3. Fuel Injection Pipe with Clip Loosen the injection pipe sleeve nuts at the delivery valve side.
Do not apply excessive force to the injection pipes. Loosen the injection pipe clips. Remove the injection pipes. Water by-pass hose Cylinder head gasket 2. Thermostat housing Crankshaft damper pulley with 3. Water pump dust seal 4. Injection nozzle holder Oil pan 9. Piston and connecting rod with 1a.
Oil pan If so crankcase equipped upper bearing 2. Crankcase If so equipped Crankshaft bearing cap with 3. Injection Nozzle Holder Remove the nozzle holder bracket nuts. Use the nozzle holder remover and the sliding hammer to remove the nozzle holder together with the holder bracket.
Nozzle Holder Remover: Sliding Humme: 7. Crankshaft Damper Pulley with Dust Seal Block the flywheel with a piece of wood to pre- vent it from turning. Use the damper pulley remover to remove the damper pulley.
Damper Pulley Remover Flywheel Block the flywheel with a piece of wood to pre- vent it from turning. Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration. Crankshaft Bearing Cap with Lower Bearing 1 Measure the crankshaft end play at the center journal of the crankshaft. Do this before removing the crankshaft bearing caps. If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced.
Rocker arm shaft snap ring 5. Rocker arm shaft spring 2. Rocker arm 6. Rocker arm shaft snap ring 3. Rocker arm shaft bracket 7. Rocker Arm Shaft Snap Ring 2. Rocker Arm 3. Rocker Arm Shaft Bracket Use a pair of snap ring pliers to remove the snap rings. Remove the rocker arms. Remove the rocker arm shaft bracket.
If the rocker arms and rocker arm shaft brackets are to be reinstalled, mark their installation positions by tagging each rocker arm and rocker Split collar 5. Valve stem oil seal 2. Valve spring upper seat 6. Valve spring lower washer 3. Valve spring 7. Cylinder head 4. Intake and exhaust valves Split Collar Place the cylinder head on a flat wooden surface.
Use the spring compressor to remove the split collar. Do not allow the valve to fall from the cylinder head. Spring Compressor: 4. Connecting rod bearing 5. Connecting rod 2. Piston ring 6. Piston pin snap ring 3. Piston pin snap ring 7. Piston 4. Piston pin Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. Piston Ring Clamp the connecting rod in a vise.
Camshaft timing gear 3. Feather key 2. Thrust plate 4. Camshaft Timing Gear 2. Thrust Plate Clamp the camshaft in a vise. Take care not to damage the camshaft.
Use the universal puller 1 to pull out the camshaft timing gear 2. Universal Puller: Remove the thrust plate 3. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face. Apply engine oil to the valve guide outer circumfer- ence.
Attach the valve guide replacer to the valve guide. Use a hammer to drive the valve guide into position from the cylinder head upper face. Install the valve 1 to the cylinder head 2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert must be replaced. Use a screwdriver 3 to pry the valve seat insert free.
Take care not to damage the cylinder head 4. Carefully remove carbon and other foreign material from the cylinder head insert bore. Valve Seat Insert Installation 1. Apply abrasive compound to the valve seat insert surface. Insert the valve into the valve guide.
Turn the valve while tapping it to fit the valve seat insert. Check that the valve contact width is correct. Place the rocker arm shaft on a V-block. Use a dial indicator to measure the rocker arm shaft central portion run-out. If the run-out is very slight, correct the rocker arm shaft run-out with a bench press.
Check that the rocker arm oil port is free of obstruc- tions. If necessary, use compressed air to clean the rocker arm oil port. Rocker Arm Correction Inspect the rocker arm valve stem contact surfaces for step wear 1 and scoring 2.
Reinstall the cylinder liner. Reinstall the cylinder body dowel. Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder bore at measuring point 1 in the thrust X — Page 60 from the lower side of the cylinder body unit it makes firm contact with the cylinder liner. Use a bench press 2 to slowly force the cylinder liner from the cylinder body. Note: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation.
Piston Selection Select the same grade number as the one for the cylinder liner inside diameter. Grade of cylinder Grade of piston Combination Page 63 Calculate the average value of the eight measure- ments to determine the correct cylinder liner bore. Measuring Points 1 : 20 mm 0. The tappet must be replaced if any of these conditions are present. Refer to the illustration at the left. Lay the push rod on a surface plate. Roll the push rod along the surface plate and mea- sure the push rod curvature with a thickness gauge.
If the measured value is less than the specified limit, the camshaft must be replaced. Cam Height H mm in Standard Limit Align the bearing oil holes with the cylinder body oil holes. By , a joint venture with another Japanese brand, Subaru, was opened, and the export of cars to the United States of America began. In , the company experienced another crisis, after which it completely ceased production of cars under its own brand, focusing only on the production of a Fronter model for the German brand Opel, another division of General Motors.
In and , the first generation of power units was released, meeting the most stringent requirements of the Japanese government, which should have come into force in Isuzu again receives many awards, and also begins production of engines for the Toyota concern.
The company unveiled the Giga heavy-duty truck, whose engine fully met the new eco-standards set by the Japanese government. By , the company had already produced more than 21 million diesel engines, both for its own production equipment and for other automotive companies. For example, Isuzu engines were installed in cars of the Renault-Nissan Alliance or General Motors in different years.
In , a joint venture between Isuzu and CBC-Group was opened, which began assembling buses and trucks for the Kazakhstan market. At the same time, the company significantly expanded its sales market by opening branches in several countries around the world. In addition, the company's specialists develop and produce high-tech diesel engines including for GM cars. Isuzu 4jg Engine Service Manual. Adobe Acrobat Document 3. Valve spring lower washer 7. Split Collar 1 Place the cylinder head on a flat wooden surface.
Do not allow the valve to fall from the cylinder head. Spring Compressor: 4. Intake and Exhaust Valve If the intake and exhaust valves are to be reinstalled, mark their installation positions by tagging each valve with the cylinder number from which it was removed. Connecting rod 6. Piston pin snap ring 7. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
Piston Ring 1 Clamp the connecting rod in a vise. Take care not to damage the connecting rod. Piston Ring Replacer Do not attempt to use some other tool to remove the piston rings. Thrust plate 3. Feather key 4. Camshaft Timing Gear 2. Thrust Plate 3 2 1 Clamp the camshaft in a vise. Take care not to damage the camshaft. Universal Puller: 3 1 46 Remove the thrust plate 3. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face.
Regrind the cylinder head lower face if the measured values are greater than the specified limit but less than the maximum grinding allowance.
Move the valve head from side to side. Read the dial indicator. Note the highest dial indication. Apply engine oil to the valve guide outer circumference. Attach the valve guide replacer to the valve guide. Use a hammer to drive the valve guide into position from the cylinder head upper face.
Valve Guide Replacer: 4. Measure the height of the valve guide upper end from the upper face of the cylinder head.
Install the valve 1 to the cylinder head 2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert must be replaced. Check the valve contact faces for roughness and unevenness.
Use a screwdriver 3 to pry the valve seat insert free. Take care not to damage the cylinder head 4. Carefully remove carbon and other foreign material from the cylinder head insert bore.
Valve Seat Insert Installation 3 1 1. Carefully place the attachment 1 having a smaller outside diameter than the valve seat insert on the valve seat insert 2. Note: 2 The smooth side of the attachment must contact the valve seat insert. Apply abrasive compound to the valve seat insert surface. Insert the valve into the valve guide. Turn the valve while tapping it to fit the valve seat insert.
Check that the valve contact width is correct. Check that the valve seat insert surface is in contact with the entire circumference of the valve. Place the rocker arm shaft on a V-block. Use a dial indicator to measure the rocker arm shaft central portion run-out.
If the run-out is very slight, correct the rocker arm shaft run-out with a bench press. The rocker arm must be at cold condition. If the measured rocker arm shaft run-out exceeds the specified limit, the rocker arm shaft must be replaced. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm oil port.
Rocker Arm Correction 2 Inspect the rocker arm valve stem contact surfaces for step wear 1 and scoring 2. If the contact surfaces have light step wear or scoring, they may be honed with an oil stone.
Reinstall the cylinder liner. Reinstall the cylinder body dowel. Measuring Point 1 : Maximum wear portion [11 — 15 mm 0. Insert the cylinder liner remover 1 into the cylinder body from the lower side of the cylinder body unit it makes firm contact with the cylinder liner. Use a bench press 2 to slowly force the cylinder liner from the cylinder body. Discard the cylinder liner. Note: Take care not to damage the cylinder body upper face during the cylinder liner removal procedure.
Note: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation. Piston Selection Select the same grade number as the one for the cylinder liner inside diameter. Then select the appropriate piston grade for the installed cylinder liner.
Measure the cylinder liner bore. There are two measuring points 1 and 2. Measuring Points 1 : 20 mm 0. The tappet must be replaced if any of these conditions are present.
Refer to the illustration at the left. Do not attempt to grind them with an oil stone or similar tool in an effort to repair the tappet. Lay the push rod on a surface plate. Roll the push rod along the surface plate and measure the push rod curvature with a thickness gauge. If the measured value exceeds the specified limit, the push rod must be replaced. Push Rod Curvature mm in Limit 0. Visually inspect both ends of the push rod for excessive wear and damage. If the measured value is less than the specified limit, the camshaft must be replaced.
Mount the camshaft on V-blocks. Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the camshaft must be replaced. Camshaft Run-Out mm in Standard Limit 0. Align the bearing oil holes with the cylinder body oil holes. Use the camshaft bearing replacer installer to install the camshaft bearing.
Bearing Replacer: Camshaft End Play 1. Before removing the camshaft gear 1, push the thrust plate 2 as far as it will go toward the camshaft gear 3. Use a feeler gauge to measure the clearance between the thrust plate and the camshaft journal. Inspect the oil seal fitting surfaces for excessive wear and damage.
Inspect the oil ports for obstructions. Note: To increase crankshaft strength, tufftriding Nitrizing Treatment has been applied. Because of this, it is not possible to regrind the crankshaft surfaces. Because of this, it is imperative that the surfaces being tested be cleaned immediately after completing the test. Crankshaft Run-Out 1. Set a dial indicator to the center of the crankshaft journal.
Gently turn the crankshaft in the normal direction of rotation. Read the dial indicator as you turn the crankshaft. If the measured value exceeds the specified limit, the crankshaft must be replaced. Crankpin and Bearing Clearance mm in Standard Limit 0. Clean the cylinder body, the journal bearing fitting surface, the bearing caps, and the bearings. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container.
If the measured value exceeds the limit, perform the following additional steps. Install the bearing cap and tighten it to the specified torque. Do not allow the connecting rod to move when installing and tightening the bearing cap. Remove the bearing cap. Place the crankshaft pilot bearing horizontally across the crankshaft bearing installation hole.
Inspect the flywheel friction surface for excessive wear and heat cracks. Measure the flywheel friction surface wear amount depth The flywheel friction surface area actually making contact with the clutch driven plate the shaded area in the illustration will be smaller than the original machined surface area. There will be a ridge on the flywheel surface area. Be sure to measure the surface wear in the area inside the ridge. Heat the ring gear evenly with a gas burner to invite thermal expansion.
Install the ring gear when it is sufficiently heated. The ring gear must be installed with the chamfer facing the clutch. If the clearance between the piston ring and the piston ring groove exceeds the specified limit, the piston ring must be replaced.
If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin Diameter mm in Standard Limit Piston Pin Hole mm in Standard Clamp the connecting rod in a vice. Use the connecting rod bushing installer to install the connecting rod bushing. Connecting Rod Bushing Replacer: 3. Use a piston pin hole grinder 1 fitted with a reamer 2 to ream the piston pin hole. Install the connecting rod to the crankpin.
Use a feeler gauge to measure the clearance between the connecting rod big end side face and the crankpin side face. If the measured value exceeds the specified limit, the connecting rod must be replaced. Apply a coat of engine oil to the oil seal lip circumference. Use the oil seal installer and the installer grip to insert the oil seal 1 mm 0.
Rocker arm shaft 2. Rocker arm shaft snap ring 3. Rocker arm 4. Rocker arm shaft bracket 82 5. Rocker arm 6. Rocker arm shaft spring 7. Rocker Arm Shaft 1 Position the rocker arm shaft with the large oil hole Dia.
Valve spring 6. Valve spring upper seat 7. Valve Stem Oil Seal 1 Apply a coat engine oil to the oil seal inner face. Oil Seal Installer: 4. Intake and Exhaust Valve 1 Apply a coat of engine oil to valve stem.
Take care not to allow the installed valves to fall free. Piston pin snap ring 6. Piston ring 7. Piston 2. Piston pin snap ring 3. Connecting rod 1 Clamp the connecting rod in a vise.
Piston Ring 3 1 Use a piston ring replacer to install the three piston rings.
Isuzu 4ja1 workshop manual free download. MANUAL ISUZU 4JA1-4JH1.pdf
Quick Links. Table of Contents. Previous Page. Next Page. Engine Isuzu c turbo Workshop Manual Supplement 35 pages. Page 2 Information contained in this Workshop Manual is the latest available at the time of publication. Isuzu reserves the right to make changes at any time without prior notice.
This Workshop Manual is applicable to and later models. Notes on the format of this manual. Page 5: General Repair Instructions Always check and recheck your work. No service operation is complete until you have done this. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail. Page 7: General Information Important operation requiring extra care.. Specified torque tighten Special tool use required or.. Alignment marks.. Directional indication.. Lubrication oil.. Measurement criteria are defined by the terms "standard" and "limit". A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable.
A measurement which is outside the "limit" indicates that the applicable part or parts must be either repaired or replaced. Page 19 MEMO Page Model Identification Use of the wrong service data will result in reduced engine performance and engine damage. Clean the oil cooler fitting face. This will allow the new oil filter to seat properly.
Apply a light coat of engine oil to the O-ring. Turn in the new oil filter until the filter O-ring is fitted against the sealing face. If the float 1 has reached level 2 , loosen the drain plug 3 at the bottom side of the water separator to drain the water. If the opening pressure is above or below the specified value, the injection nozzle must be replaced or recondi- tioned. Drive Belt Deflection mm in.
Retighten the rocker arm shaft bracket bolts in sequence as shown in the illustration. Bring the piston in either the No. Realign the crankshaft damper pulley TDC line with the timing pointer. Adjust the clearances for the remaining valves as shown in the illustration.
At TDC on the compression stroke of the No. The No. Start the engine and allow it to run for several minutes to warm it up.
Stop the engine and cut the fuel supply. Remove all of the glow plugs from the engine. Compression Gauge Adapter 4.
Cylinder head gasket Water pump gasket 2. This design provides superior fuel economy for a wide range. Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold. Cooling fan and spacer Fuel leak off pipe 2.
Cooling fan drive belt Fuel injection pipe with clip 3. Fuel Injection Pipe with Clip Loosen the injection pipe sleeve nuts at the delivery valve side. Do not apply excessive force to the injection pipes. Loosen the injection pipe clips. Remove the injection pipes. Water by-pass hose Cylinder head gasket 2. Thermostat housing Crankshaft damper pulley with 3. Water pump dust seal 4. Injection nozzle holder Oil pan 9. Piston and connecting rod with 1a. Oil pan If so crankcase equipped upper bearing 2.
Crankcase If so equipped Crankshaft bearing cap with 3. Injection Nozzle Holder Remove the nozzle holder bracket nuts. Use the nozzle holder remover and the sliding hammer to remove the nozzle holder together with the holder bracket.
Nozzle Holder Remover: Sliding Humme: 7. Crankshaft Damper Pulley with Dust Seal Block the flywheel with a piece of wood to pre- vent it from turning. Use the damper pulley remover to remove the damper pulley. Damper Pulley Remover Flywheel Block the flywheel with a piece of wood to pre- vent it from turning.
Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration. Crankshaft Bearing Cap with Lower Bearing 1 Measure the crankshaft end play at the center journal of the crankshaft. Do this before removing the crankshaft bearing caps. If the measured value exceeds the specified limit, the crankshaft thrust bearing must be replaced.
Rocker arm shaft snap ring 5. Rocker arm shaft spring 2. Rocker arm 6. Rocker arm shaft snap ring 3. Rocker arm shaft bracket 7. Rocker Arm Shaft Snap Ring 2. Rocker Arm 3. Rocker Arm Shaft Bracket Use a pair of snap ring pliers to remove the snap rings. Remove the rocker arms. Remove the rocker arm shaft bracket. If the rocker arms and rocker arm shaft brackets are to be reinstalled, mark their installation positions by tagging each rocker arm and rocker Split collar 5.
Valve stem oil seal 2. Valve spring upper seat 6. Valve spring lower washer 3. Valve spring 7. Cylinder head 4. Intake and exhaust valves Split Collar Place the cylinder head on a flat wooden surface. Use the spring compressor to remove the split collar. Do not allow the valve to fall from the cylinder head. Spring Compressor: 4. Connecting rod bearing 5.
Comments
Post a Comment