INDUSTRIAL DIESEL ENGINE A-4JA1, A-4JB1 MODELS WORKSHOP MANUAL ©2003 ISUZU MOTORS LIMITED
FOREWORD This Workshop Manual is designed to help you perform necessary maintenance, service, and repair procedures on applicable Isuzu industrial engines. 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 1998 and later models.
TABLE OF CONTENTS SECTION 1. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SECTION 2. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SECTION 3. ENGINE ASSEMBLY (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (DISASSEMBLY) 29 SECTION 4. ENGINE ASSEMBLY (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (INSPECTION AND REPAIR) 47 SECTION 5.
GENERAL INFORMATION SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS ITEM PAGE General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Notes on the format of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Main data and specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION GENERAL REPAIR INSTRUCTIONS 1. Before performing any service operation with the engine mounted, disconnect the grounding cable from the battery. This will reduce the chance of cable damage and burning due to short circuiting. 2. Always use the proper tool or tools for the job at hand. Where specified, use the specially designed tool or tools. 3. Use genuine ISUZU parts. 4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove them.
GENERAL INFORMATION 4. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page. 5. For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex procedures are covered in detail. 6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area. A brief explanation of the notation used follows.
GENERAL INFORMATION 7. Below is a sample of the text of the Workshop Manual. This is the item shown in the illustration. It is marked with a triangle (▲) on the Major Components page. 4. Camshaft Timing Gear 1) Install the thrust plate 1 . 2) Apply engine oil to the bolt threads 2 . 3) Install the camshaft timing gear with the timing mark stamped side facing out. 2 Camshaft Timing Gear Bolt Torque kgf·m(lb.ft/N·m) Letters and numbers contained in a circle refer to the illustration. 11.0 ± 1.0 (79.
GENERAL INFORMATION 9. 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. "Limit" should be thought of as an absolute value. A measurement which is outside the "limit" indicates that the applicable part or parts must be either repaired or replaced. 10. Components and parts are listed in the singular form throughout the Manual. 11.
GENERAL INFORMATION MAIN DATA AND SPECIFICATIONS Engine Model A-4JA1 A-4JB1 4JB1T Item Engine type Water cooled, four-cycle, in-line, overhead valve Combustion chamber type Direct injection Cylinder liner type Dry No. of cylinders - Bore x Stroke Total piston displacement mm(in.) 4 - 93.0 x 92.0 (3.66 x 3.62) 4 - 93.0 x 102.0 (3.66 x 4.02) 4 - 93.0 x 102.0 (3.66 x 4.02) lit(cid) 2.449 (152.4) 2.771 (169.0) 2.771 (169.0) 18.4 18.2 18.
GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified. STANDARD BOLT Strength Class kgf·m (lb.ft/N·m) 4.8 (4T) 8.8 Refined Bolt Identification Bolt Diameter × pitch (mm) (7T) 9.8 (9T) Non-Refined No mark M 6 × 1.0 0.4 – 0.8 (2.9 – 5.8/3.9 – 7.8) 0.5 – 1.0 (3.6 – 7.2/4.9 – 9.8) M 8 × 1.25 0.8 – 1.8 (5.8 – 13.0/7.8 – 17.7) 1.2 – 2.3 (8.7 – 16.6/11.8 – 22.6) 1.7 – 3.1 (12.3 – 22.4/16.
GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified. FLANGED HEAD BOLT kgf·m (lb.ft/N·m) Bolt head marking Nominal size (dia. x pitch) 0.5 – 0.9 (3.61 – 6.50/4.6 – 8.5 0.6 – 1.2 (4.33 – 8.67/5.88 – 11.76) M 8 × 1.25 1.1 – 2.0 (7.95 – 14.46/10.78 – 19.61) 1.4 – 2.9 (4.33 – 8.67/5.88 – 11.76) 1.9 – 3.4 (13.74 – 24.59/18.63 – 33.34) M10 × 1.25 2.3 – 3.9 (17.35 – 28.20/23.53 – 38.24) 3.
GENERAL INFORMATION SPECIAL PARTS FIXING NUTS AND BOLTS Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket kgf·m(lb.ft./N·m) 0.8 – 1.8 (5.8 – 13.0/7.8 – 17.6) 5.0 – 6.0 (36.2 – 43.4/49.0 – 58.8) 1.0 – 2.0 (7.2 – 14.4/9.8 – 19.6) 1st Step 2nd Step New bolt 3.0 – 5.0 8.2 – 9.2 (21.7 – 36.1/29.4 – 49.0) (59.4 – 66.5/80.4 – 90.2) Reused bolt 8.0 – 9.0 10.0 – 11.0 (57.9 – 65.1/78.4 – 88.2) (72.4 – 79.6/98.1 – 107.
GENERAL INFORMATION Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley, Flywheel, and Oil Pan kgf·m(lb.ft./N·m) 11.5 – 12.5 (83.2 – 90.4/112.8 – 122.6) 8.0 – 9.0 (57.9 – 65.1/78.4 – 88.2) 16.0 – 18.0 (115.7 – 130.2/159.6 – 176.5) 20.1 – 24.5 (145.4 – 177.2/197.1 – 240.3) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 14 – 24 (1.4 – 2.4/4.4 – 7.
GENERAL INFORMATION Timing Gear Case, Flywheel Housing, Camshaft, and Timing Gear kgf·m(lb.ft./N·m) M10 x 1.25 (0.39 x 0.05) 4.6 – 6.6 (33.3 – 47.7/45.1 – 64.7) M12 x 1.25 (0.47 x 0.05) 9.6 – 11.6 (69.4 – 83.9/94.1 – 113.8) M12 x 1.75 (0.47 x 0.07) 8.8 – 10.8 (63.7 – 78.1/86.3 – 105.9) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 10.0 – 12.0 (72.4 – 86.8/98.1 – 117.7) 1.0 – 1.5 (7.2 – 10.9/9.8 – 14.7) 1.4 – 2.4 (10.1 – 17.3/13.
GENERAL INFORMATION Cooling and Lubricating System kgf·m(lb.ft./N·m) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.
GENERAL INFORMATION Intake and Exhaust Manifold kgf·m(lb.ft./N·m) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.
GENERAL INFORMATION Engine Electrical kgf·m(lb.ft./N·m) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 2.0 – 2.5 (14.4 – 18.1/19.6 – 24.5) 3.6 – 4.6 (26.0 – 33.3/35.3 – 45.1) 6.0 – 8.0 (43.4 – 57.9/58.8 – 78.
GENERAL INFORMATION Fuel Injection System kgf·m(lb.ft./N·m) 20 – 4.0 (14.4 – 28.9/19.6 – 39.2) 3.2 – 4.4 (23.1 – 31.8/31.4 – 43.2) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.
MEMO 16
MAINTENANCE SECTION 2 MAINTENANCE TABLE OF CONTENTS ITEM PAGE Model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Injection pump identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fuel system .
MAINTENANCE MAINTENANCE Servicing refers to general maintenance procedures to be performed by qualified service personnel. Maintenance interval such as fuel or oil filter changes should be refered to “INSTRUCTION MANUAL”. MODEL IDENTIFICATION Engine Serial Number The engine number is stamped on the rear left hand side of the cylinder body. INJECTION PUMP IDENTIFICATION A Pump No. .............. NP - PE ......................
MAINTENANCE 4. Clean the oil cooler fitting face. This will allow the new oil filter to seat properly. 5. Apply a light coat of engine oil to the O-ring. 6. Turn in the new oil filter until the filter O-ring is fitted against the sealing face. 7. Use a filter wrench to turn in the filter an additional 1 and 1/4 of a turn. Filter Wrench 8. Check the engine oil level and replenish to the specified level if required. 9. Start the engine and check for oil leakage from the main oil filter.
MAINTENANCE Water Separator (Water Sedimentor) (Optional Equipment) Check the water separator float 1 level. 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. Drain Plug Torque kgf·m(lb.ft./N·m) 0.9 – 1.5 (6.5 – 10.9/8.8 – 14.7) Air Bleeding 1. For the engine equipped with in-line type injection pump 1) Loosen the priming pump cap 1 on the injection pump. 2) Loosen the fuel return eye bolt 2 on the fuel filter.
MAINTENANCE Injection Nozzle Injection Nozzle Inspection Use a nozzle tester to check the injection nozzle opening pressure and the spray condition. If the opening pressure is above or below the specified value, the injection nozzle must be replaced or reconditioned. If the spray condition is bad, the injection nozzle must be replaced or reconditioned. Injection Nozzle Opening Pressure kgf/cm2(psi/MPa) 185 (2,630/18.
MAINTENANCE COOLING SYSTEM D Cooling Fan Drive Belt C B Fan belt tension is adjusted by moving the alternator. A Crankshaft damper pulley B Alternator pulley A C Cooling fan drive pulley D Depress the drive belt mid-portion with a 10 kgf (22 lb/98 N) force. Drive Belt Deflection mm(in.) 10.0 (0.39) Thermostat Operating Test 1. Completely submerge the thermostat in water. 2. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat. 3.
MAINTENANCE VALVE CLEARANCE ADJUSTMENT 1. Retighten the rocker arm shaft bracket bolts in sequence as shown in the illustration. Rocker Arm Shaft Bracket Bolt Torque 3 1 2 4 TDC kgf·m(lb.ft/N·m) 5.0 – 6.0 (36.2 – 43.4/49.0 – 58.8) 2. Bring the piston in either the No. 1 cylinder or the No. 4 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft damper pulley TDC line is aligned with the timing pointer. 3. Check for play in the No.
MAINTENANCE Rotate the crankshaft 360°. 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. 4 stroke) INJECTION TIMING Injection Timing Confirmation Procedure 1. In-line type injection pump 1) Rotate the crankshaft clockwise to align the camshaft gear timing mark “O” with the timing gear case cover pointer. The No.
MAINTENANCE 2. Distributor type injection pump 1) Rotate the crankshaft clockwise to align the camshaft gear timing mark “O” with the timing gear case cover pointer. The No. 1 cylinder will now be at the point where nearly injection timing. 2) Remove injector pump distributor head plug. 3) Fit a dial gauge and set lift to 1 mm (0.039 in). 4) Set crankshaft damper pulley Top Dead Center mark about 45° before Top Dead Center from the pointer. 5) Set dial gauge in the “0” position.
MAINTENANCE COMPRESSION PRESSURE MEASUREMENT 1. Start the engine and allow it to run for several minutes to warm it up. 2. Stop the engine and cut the fuel supply. 3. Remove all of the glow plugs from the engine. Compression Gauge :5-8840-2675-0 Adapter :5-8840-9029-0 4. Set a compression gauge to the No. 1 cylinder glow plug hole. 5. Turn the engine over with the starter motor and take the compression gauge reading. Compression Pressure 26 kgf/cm2(psi/MPa) at 200 rpm Standard Limit 31 (441/3.
MAINTENANCE RECOMMENDED LUBRICANTS ENGINE TYPE TYPES OF LUBRICANTS Without turbocharger Diesel engine oil CC or CD grade With turbocharger Diesel engine oil CD grade ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE [Single grade] ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 20, 20W ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 40 ;;;;;;
MAINTENANCE ENGINE REPAIR KIT All of the numbered parts listed below are included in the Engine Repair Kit. The gaskets marked with an asterisk (*) are also included in the Top Overhaul Kit. 20 3 19 2 17 18 14 15 13 19 10 5 11 12 1 6 19 4 7 9 8 16 * * * 28 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
ENGINE ASSEMBLY ( 1 ) SECTION 3 ENGINE ASSEMBLY ( 1 ) TABLE OF CONTENTS ITEM PAGE General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY ( 1 ) ENGINE ASSEMBLY GENERAL DESCRIPTION This illustration is based on the A-4JA1 engine. The A-4J Series of industrial engines features the unique ISUZU troidal square combustion chamber. 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. Chrome plated dry type cylinder liners provide the highest durability.
ENGINE ASSEMBLY ( 1 ) DISASSEMBLY These disassembly steps are based on the A-4JA1 engine. 21 20 18 3 7 8 5 13 14 12 11 10 16 17 19 4 2 1 6 9 15 Disassembly Steps - 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cooling fan and spacer Cooling fan drive belt Cooling fan drive pulley Alternator and adjusting plate Fuel pipe (Fuel filter to injection pump) Fuel pipe (Fuel filter to feed pump) Fuel pipe (Fuel filter leak off) Fuel filter Oil pipe (Injection pump to cylinder body) Rear engine hanger 11.
ENGINE ASSEMBLY ( 1 ) Important Operations (Disassembly Steps - 1) 12. Fuel Injection Pipe with Clip 1) Loosen the injection pipe sleeve nuts at the delivery valve side. Do not apply excessive force to the injection pipes. 2) Loosen the injection pipe clips. 3) Remove the injection pipes. 13. Injection Pump 1) Remove the six injection pump bracket bolts from the cylinder body timing gear case. 2) Remove the injection pump rear bracket bolts from the rear bracket.
ENGINE ASSEMBLY ( 1 ) 6 1 7 2 8 3 9 13 10 12 5 11 4 16 17 14 Repair kit 15 Disassembly Steps - 2 1. 2. 3. ▲ 4. 5. 6. ▲ 7. 8. ▲ 9. Water by-pass hose Thermostat housing Water pump Injection nozzle holder Glow plug and glow plug connector Cylinder head cover Rocker arm shaft and rocker arm Push rod Cylinder head 10. Cylinder head gasket ▲ 11. Crankshaft damper pulley with 12. 13. 14. 15. ▲ 16. 17.
ENGINE ASSEMBLY ( 1 ) 16 15 7 6 14 4 3 11 13 12 3a 9 8 10 2 5 1a 1 Repair kit Disassembly Steps - 3 1. 1a. 2. ▲ 3. 3a. 4. 5. ▲ 6. Oil pan Oil pan (If so crankcase equipped) Crankcase (If so equipped) Flywheel Rear flywheel (If so equipped) Flywheel housing Oil pump with oil pipe Camshaft with camshaft timing gear and thrust plate 7. Timing gear case ▲ 8. Connecting rod cap with lower bearing 34 ▲ 9. Piston and connecting rod with upper bearing ▲ 10.
ENGINE ASSEMBLY ( 1 ) Important Operations (Disassembly Steps - 2) 4. Injection Nozzle Holder 1) Remove the nozzle holder bracket nuts. 2) Use the nozzle holder remover and the sliding hammer to remove the nozzle holder together with the holder bracket. Nozzle Holder Remover: 5-8840-2034-0 Sliding Humme: 5-8840-0019-0 7. Rocker Arm Shaft and Rocker Arm Loosen the rocker arm shaft bracket bolts in numerical order a little at a time.
ENGINE ASSEMBLY ( 1 ) 11. Crankshaft Damper Pulley with Dust Seal 1) Block the flywheel with a piece of wood to prevent it from turning. 2) Use the damper pulley remover to remove the damper pulley. Damper Pulley Remover 16. Idler Gear “A” Measure the camshaft timing gear backlash, the crankshaft timing gear backlash, and the idler gear “A” end play before removing the idler gear “A” and shaft. Timing Gear Backlash Measurement 1) Set a dial indicator to the timing gear to be measured.
ENGINE ASSEMBLY ( 1 ) Important Operations (Disassembly Steps - 3) 3. Flywheel 1 4 5 3 2 1) Block the flywheel with a piece of wood to prevent it from turning. 2) Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration. 6 6. Camshaft with Camshaft Timing Gear and Thrust Plate 1) Remove the thrust plate bolts. 2) Pull the camshaft free along with the camshaft timing gear and the thrust plate.
ENGINE ASSEMBLY ( 1 ) 10. 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. Crankshaft End Play 2) 3 4 10 7 8 9 6 5 2 1 mm(in.) Standard Limit 0.10 (0.0039) 0.30 (0.0118) Loosen the crankshaft bearing cap bolts in numerical order a little at a time.
ENGINE ASSEMBLY ( 1 ) DISASSEMBLY SINGLE UNIT ROCKER ARM SHAFT AND ROCKER ARM 6 2 7 5 1 4 3 Disassembly Steps ▲ 1. Rocker arm shaft snap ring ▲ 2. Rocker arm ▲ 3. Rocker arm shaft bracket 5. Rocker arm shaft spring 6. Rocker arm shaft snap ring 7. Rocker arm shaft 4.
ENGINE ASSEMBLY ( 1 ) Important Operations 1. Rocker Arm Shaft Snap Ring 2. Rocker Arm 3. Rocker Arm Shaft Bracket 1) Use a pair of snap ring pliers to remove the snap rings. 2) Remove the rocker arms. 3) 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 arm shaft bracket with the cylinder number from which it was removed.
ENGINE ASSEMBLY ( 1 ) CYLINDER HEAD 1 2 3 5 6 7 4 Disassembly Steps ▲ 1. Split collar 2. Valve spring upper seat 3. Valve spring ▲ 4. Intake and exhaust valves 5. Valve stem oil seal 6. Valve spring lower washer 7.
ENGINE ASSEMBLY ( 1 ) Important Operations 1. Split Collar 1) Place the cylinder head on a flat wooden surface. 2) Use the spring compressor to remove the split collar. Do not allow the valve to fall from the cylinder head. Spring Compressor: 9-8523-1423-0 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.
ENGINE ASSEMBLY ( 1 ) PISTON AND CONNECTING ROD 2 6 7 4 3 5 1 Disassembly Steps ▲ ▲ ▲ ▲ 1. 2. 3. 4. Connecting rod bearing Piston ring Piston pin snap ring Piston pin ▲ ▲ 5. Connecting rod 6. Piston pin snap ring 7.
ENGINE ASSEMBLY ( 1 ) Important Operations 1. 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. 2. Piston Ring 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use a piston pin replacer to remove the piston rings. Piston Ring Replacer Do not attempt to use some other tool to remove the piston rings.
ENGINE ASSEMBLY ( 1 ) CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE 4 3 2 1 Disassembly Steps ▲ 1. Camshaft timing gear ▲ 2. Thrust plate 3. Feather key 4.
ENGINE ASSEMBLY ( 1 ) Important Operations 1. Camshaft Timing Gear 2. Thrust Plate 3 2 1) Clamp the camshaft in a vise. Take care not to damage the camshaft. 2) Use the universal puller 1 to pull out the camshaft timing gear 2 . Universal Puller: 5-8840-0086-0 3) 1 46 Remove the thrust plate 3 .
ENGINE ASSEMBLY ( 2 ) SECTION 4 ENGINE ASSEMBLY ( 2 ) TABLE OF CONTENTS ITEM PAGE Inspection and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY ( 2 ) INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. CYLINDER HEAD Cylinder Head Lower Face Warpage 1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face. 2. Regrind the cylinder head lower face if the measured values are greater than the specified limit but less than the maximum grinding allowance.
ENGINE ASSEMBLY ( 2 ) Manifold Fitting Face Warpage mm (in) Standard Limit Maximum Grinding Allwance 0.05 (0.002) or less 0.2 (0.008) 0.4 (0.016) VALVE GUIDE Valve Stem and Valve Guide Clearance Measuring Method - I 1. With the valve stem inserted in the valve guide, set the dial indicator needle to “0”. 2. Move the valve head from side to side. Read the dial indicator. Note the highest dial indication.
ENGINE ASSEMBLY ( 2 ) Valve Guide Installation 1. Apply engine oil to the valve guide outer circumference. 2. Attach the valve guide replacer to the valve guide. 3. Use a hammer to drive the valve guide into position from the cylinder head upper face. Valve Guide Replacer: 9-8523-1212-0 4. Measure the height of the valve guide upper end from the upper face of the cylinder head. Valve Guide Upper End Height (H) (Reference) mm(in) 13.0 (0.
ENGINE ASSEMBLY ( 2 ) Valve Depression 2 1. Install the valve 1 to the cylinder head 2 . 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. 1 Valve Depression mm(in) Standard Limit Intake 0.73 (0.029) 1.28 (0.050) Exhaust 0.70 (0.028) 1.20 (0.047) Valve Contact Width 1. Check the valve contact faces for roughness and unevenness.
ENGINE ASSEMBLY ( 2 ) 3. Use a screwdriver 3 to pry the valve seat insert free. Take care not to damage the cylinder head 4 . 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. 2.
ENGINE ASSEMBLY ( 2 ) 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while tapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. VALVE SPRING Valve Spring Free Height Use a vernier caliper to measure the valve spring free height.
ENGINE ASSEMBLY ( 2 ) ROCKER ARM SHAFT AND ROCKER ARM Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on a V-block. 2. 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. Rocker Arm Shaft Run-Out mm(in) Standard Limit 0.2 (0.008) 0.
ENGINE ASSEMBLY ( 2 ) 3. 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. 1 If the step wear or scoring is severe, the rocker arm must be replaced. CYLINDER BODY Cylinder Body Upper Face Warpage 1.
ENGINE ASSEMBLY ( 2 ) Cylinder Body Height (Reference) mm(in) Standard 247.945 – 248.105 (9.7616 – 9.7679) 4. Reinstall the cylinder liner. Refer to “Cylinder Body Bore Measurement”. 5. Reinstall the cylinder body dowel. X Y Y X 1 Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder bore at measuring point 1 in the thrust X – X and axial Y – Y directions of the crankshaft. Measuring Point 1 : Maximum wear portion [11 – 15 mm (0.43 – 0.
ENGINE ASSEMBLY ( 2 ) Cylinder Liner Replacement 2 Cylinder Liner Removal 1. 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. Cylinder Liner Remover: 5-8840-2039-0 (A-4JA1, A-4JB1) 1 2. Use a bench press 2 to slowly force the cylinder liner from the cylinder body. 3. Discard the cylinder liner. Note: Take care not to damage the cylinder body upper face during the cylinder liner removal procedure. 4.
ENGINE ASSEMBLY ( 2 ) Cylinder Liner Installation 1. Cylinder Liner Installation Using The Special Tool. 1) Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores. 2) Use compressed air to blow-dry the cylinder liner and bore surfaces. Note: All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation. 3) Insert the cylinder liner 1 into the cylinder body 2 from the top of the cylinder body.
ENGINE ASSEMBLY ( 2 ) WARNING: DRY ICE MUST BE USED WITH GREAT CARE. CARELESS HANDLING OF DRY ICE CAN RESULT IN SEVERE FROSTBITE. Piston Selection Select the same grade number as the one for the cylinder liner inside diameter.
ENGINE ASSEMBLY ( 2 ) W Piston Grade Selection X Z Y Z Y W X 1 Measure the cylinder liner bore. Then select the appropriate piston grade for the installed cylinder liner. 1. Measure the cylinder liner bore. There are two measuring points ( 1 and 2 ). Measure the cylinder liner bore in four different direction (W – W, X – X, and Z – Z) at both measuring points. 2 Calculate the average value of the eight measurements to determine the correct cylinder liner bore. Measuring Points 1 : 20 mm (0.
ENGINE ASSEMBLY ( 2 ) TAPPET AND PUSH ROD 1 2 3 Visually inspect the tappet camshaft contact surfaces for pitting, cracking, and other abnormal conditions. The tappet must be replaced if any of these conditions are present. Refer to the illustration at the left. 4 5 1 2 3 4 5 Pitting Cracking Normal contact Irregular contact Irregular contact Note: The tappet surfaces are spherical. Do not attempt to grind them with an oil stone or similar tool in an effort to repair the tappet.
ENGINE ASSEMBLY ( 2 ) Tappet and Cylinder Body Clearance mm(in) Standard Limit 0.03 (0.0012) 0.1 (0.0039) Push Rod Curvature 1. Lay the push rod on a surface plate. 2. 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 0.3 (0.012) 3. Visually inspect both ends of the push rod for excessive wear and damage.
ENGINE ASSEMBLY ( 2 ) Cam Height Measure the cam height (H) with a micrometer. If the measured value is less than the specified limit, the camshaft must be replaced. H Cam Height H mm(in) Standard Limit 42.08 (1.65) 41.65 (1.64) Camshaft Run-Out 1. Mount the camshaft on V-blocks. 2. 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 0.02 (0.0008) 0.10 (0.
ENGINE ASSEMBLY ( 2 ) Camshaft Bearing Installation 1. Align the bearing oil holes with the cylinder body oil holes. 2. Use the camshaft bearing replacer installer to install the camshaft bearing. Bearing Replacer: 5-8840-2038-0 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. 1 3 2 3 2. Use a feeler gauge to measure the clearance between the thrust plate and the camshaft journal.
ENGINE ASSEMBLY ( 2 ) CRANKSHAFT AND BEARING Inspect the surface of the crankshaft journals and crankpins for excessive wear and damage. 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.
ENGINE ASSEMBLY ( 2 ) Note: The ammonium cuprous chloride solution is highly corrosive. 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. 2. 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.
ENGINE ASSEMBLY ( 2 ) Crankshaft Journal Diameter mm(in) Standard Limit A-4JA1 59.917 – 59.932 (2.3589 – 2.3595) 59.910 (2.3587) A-4JB1 69.917 – 69.932 (2.7526 – 2.7531) 69.910 (2.7524) Crankpin Diameter mm(in) Standard Limit 52.915 – 52.930 (2.0833 – 2.0839) 52.906 (2.0829) Crankshaft Journal and Crankpin Uneven Wear mm(in) Standard Limit 0.05 (0.002) or less 0.08 (0.
ENGINE ASSEMBLY ( 2 ) Crankpin and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or the crankshaft must be replaced. Crankpin and Bearing Clearance mm(in) Standard Limit 0.029 – 0.066 (0.0011 – 0.0026) 0.10 (0.0039) Clearance Measurements (With Plastigage) Crankshaft Journal and Bearing Clearance 1. Clean the cylinder body, the journal bearing fitting surface, the bearing caps, and the bearings. 2.
ENGINE ASSEMBLY ( 2 ) 9. 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. 1) Use a micrometer to measure the crankshaft outside diameter. 2) Use an inside dial indicator to measure the bearing inside diameter. If the crankshaft journal and bearing clearance exceeds the limit, the crankshaft and/or the bearing must be replaced.
ENGINE ASSEMBLY ( 2 ) 5. 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. Connecting Rod Bearing Cap Bolt Torque kgf·m(lb.ft/N·m) 8.0 – 9.0 (57.9 – 65.1/78.4 – 88.2) 6. Remove the bearing cap. 7. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container.
ENGINE ASSEMBLY ( 2 ) CRANKSHAFT PILOT BEARING Check the crankshaft pilot bearing for excessive wear and damage and replace it if necessary. Crankshaft Pilot Bearing Replacement Crankshaft Pilot Bearing Removal Use the pilot bearing remover to remove the pilot bearing. Pilot Bearing Remover: 5-8840-2000-0 Sliding Hammer: 5-8840-0019-0 Crankshaft Pilot Bearing Installation 1. Place the crankshaft pilot bearing horizontally across the crankshaft bearing installation hole. 2.
ENGINE ASSEMBLY ( 2 ) FLYWHEEL AND RING GEAR Flywheel 1. Inspect the flywheel friction surface for excessive wear and heat cracks. 2. 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.
ENGINE ASSEMBLY ( 2 ) Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200°C (390°F). 2. Install the ring gear when it is sufficiently heated. The ring gear must be installed with the chamfer facing the clutch.
ENGINE ASSEMBLY ( 2 ) Piston Ring Gap mm(in) Standard 1 s t Compression Ring 2nd Compression Ring Oil Ring 0.20 – 0.40 (0.008 – 0.016) 0.10 – 0.30 (0.004 – 0.012) Limit 1.5 (0.059) Piston Ring and Piston Ring Groove Clearance Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston. If the clearance between the piston ring and the piston ring groove exceeds the specified limit, the piston ring must be replaced.
ENGINE ASSEMBLY ( 2 ) PISTON PIN Piston Pin Diameter Use a micrometer to measure the piston pin outside diameter at several points. If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin Diameter mm(in) Standard Limit 31.0 (1.220) 30.97 (1.219) Piston Pin and Piston Clearance Use an inside dial indicator to measure the piston pin hole (in the piston). Piston Pin Hole mm(in) Standard 29.002 – 29.007 Piston Pin and Piston Pin Hole Clearance mm(in) 0.
ENGINE ASSEMBLY ( 2 ) Connecting Rod Bushing Installation 1. Clamp the connecting rod in a vice. 2. 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. 1 2 CONNECTING ROD Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole.
ENGINE ASSEMBLY ( 2 ) Connecting Rod Side Face Clearance 1. Install the connecting rod to the crankpin. 2. 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. Connecting Rod and Crankpin Side Face Clearance mm(in) Standard Limit 0.23 (0.009) 0.35 (0.
ENGINE ASSEMBLY ( 2 ) Idler Gear “A” Inside Diameter 1. Use an inside dial indic ator to measure the idler gear Idler Gear Inside Diameter mm(in) Standard Limit 45.0 – 45.03 (1.7717 – 1.7728) 45.10 (1.7756) If the clearance between the idler gear shaft outside diameter and the idler gear inside diameter exceeds the limit, the idler gear must be replaced. Idler Gear Shaft and Idler Gear Clearance mm(in) Standard Limit 0.025 – 0.085 (0.0010 – 0.0033) 0.2 (0.
ENGINE ASSEMBLY ( 2 ) Oil Seal Installation 1. Apply a coat of engine oil to the oil seal lip circumference. 2. Use the oil seal installer and the installer grip to insert the oil seal 1 mm (0.039 in) into the front portion of the timing gear case.
MEMO 80
ENGINE ASSEMBLY ( 3 ) SECTION 5 ENGINE ASSEMBLY ( 3 ) TABLE OF CONTENTS ITEM PAGE Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY ( 3 ) REASSEMBLY SINGLE UNIT ROCKER ARM SHAFT AND ROCKER ARM 3 2 4 5 6 1 7 Reassembly Steps ▲ 1. 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.
ENGINE ASSEMBLY ( 3 ) Important Operations 1. Rocker Arm Shaft 1) Position the rocker arm shaft with the large oil hole (Dia. 4 mm (0.157 in)) facing the front of the engine. 2) Install the rocker arm shaft together with the rocker arm, the rocker arm shaft bracket, and the spring.
ENGINE ASSEMBLY ( 3 ) CYLINDER HEAD 7 6 5 3 2 1 4 Reassembly Steps 1. 2. ▲ 3. ▲ 4. 84 Cylinder head Valve spring lower washer Valve stem oil seal Intake and exhaust valve ▲ ▲ 5. Valve spring 6. Valve spring upper seat 7.
ENGINE ASSEMBLY ( 3 ) Important Operations 3. Valve Stem Oil Seal 1) Apply a coat engine oil to the oil seal inner face. 2) Use an oil seal installer to install the oil seal to the valve guide. Oil Seal Installer: 5-8840-2033-0 4. Intake and Exhaust Valve 1) Apply a coat of engine oil to valve stem. 2) Install the intake and exhaust valves. 3) Turn the cylinder head up to install the valve springs. Take care not to allow the installed valves to fall free. 5.
ENGINE ASSEMBLY ( 3 ) PISTON AND CONNECTING ROD 6 2 1 4 5 3 7 Reassembly Steps ▲ ▲ ▲ ▲ 86 1. 2. 3. 4. Piston Piston pin snap ring Connecting rod Piston pin ▲ ▲ 5. Piston pin snap ring 6. Piston ring 7.
ENGINE ASSEMBLY ( 3 ) Important Operations 1. Piston 2. Piston pin snap ring 3. Connecting rod 1) Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2) Use a pair of snap ring pliers to install the piston pin snap ring to the piston. 3) Install the piston to the connecting rod. 1 The piston head front mark 1 and the connecting rod “ISUZU” casting mark 2 must be facing the same direction. 2 4.
ENGINE ASSEMBLY ( 3 ) 6. Piston Ring 3 1) Use a piston ring replacer to install the three piston rings. Piston Ring Replacer: 2 Install the piston rings in the order shown in the illustration. 1 1 Oil ring (Coil expander type) 2 2nd compression ring (Taper undercut type) 3 1st compression ring (Barrel face type) Note: Install the compression rings with the stamped side facing up.
ENGINE ASSEMBLY ( 3 ) CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE 1 2 3 4 Reassembly Steps 1. Camshaft 2. Feather key ▲ 3. Thrust plate 4.
ENGINE ASSEMBLY ( 3 ) Important Operations 4. Camshaft Timing Gear 1) Install the thrust plate 1 . 2) Apply engine oil to the bolt threads 2 . 3) Install the camshaft timing gear with the timing mark stamped side facing out. 2 Camshaft Timing Gear Bolt Torque kgf·m(lb.ft/N·m) 10.0 – 12.0 (72.4 – 86.8/98.1 – 117.
ENGINE ASSEMBLY ( 3 ) MEMO 91
ENGINE ASSEMBLY ( 3 ) REASSEMBLY 1 13 7 8 2 14 15 5 3 4 15a 9 10 6 11 12 16a 16 Repair kit Reassembly Steps – 1 ▲ ▲ ▲ ▲ ▲ ▲ Cylinder body Tappet Crankshaft upper bearing Crankshaft with crankshaft timing gear Crankshaft thrust bearing Crankshaft bearing cap with lower bearing ▲ 7. Timing gear case ▲ 8. Camshaft with camshaft timing gear and thrust plate ▲ 9. Piston and connecting rod with upper bearing 92 1. 2. 3. 4. 5. 6. ▲ ▲ ▲ ▲ ▲ ▲ 10. 11. 12. 13. 14. 15. 15a ▲ 16.
ENGINE ASSEMBLY ( 3 ) 17 14 11 13 10 12 9 5 8 6 15 7 16 2 1 4 Repair kit 3 Reassembly Steps – 2 ▲ 1. Idler gear shaft ▲ 2. Idler gear “A” ▲ 3. Idler gear “B” 4. Timing gear oil pipe ▲ 5. Timing case cover 6. Timing gear case cover ▲ 7. Crankshaft damper pulley with dust seal ▲ 8. Cylinder head gasket ▲ 9. Cylinder head 10. Push rod ▲ 11. Rocker arm shaft and rocker arm ▲ 12. Water pump ▲ 13. Thermostat housing 14. Water by-pass hose ▲ 15. Glow plug and glow plug connector seal ▲ 16.
ENGINE ASSEMBLY ( 3 ) Important Operations (Reassembly Steps-1) 1. Cylinder Body Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder body, the oil holes, and the water jackets. 2. Tappet 1) Apply a coat of engine oil to the tappet 1 and the cylinder body tappet insert holes 2 . 1 2) Locate the position mark applied at disassembly (if the tappet is to be reused). Note: The tappet must be installed before the camshaft. 2 3.
ENGINE ASSEMBLY ( 3 ) 5. Crankshaft Thrust Bearing 1) Apply an ample coat of engine oil to the crankshaft thrust bearings. 2) Install the crankshaft thrust bearings to the crankshaft center journal. The crankshaft thrust bearing oil groove must be facing the sliding face. 6. Crankshaft Bearing Cap with Lower Bearing 1) Apply silicon adhesive to the cylinder body No. 5 bearing cap fitting surface at the points shown in the illustration.
ENGINE ASSEMBLY ( 3 ) 8. Camshaft with Camshaft Timing Gear and Thrust Plate 1) Apply a coat of engine oil to the camshaft and the camshaft bearings. 2) Install the camshaft to the cylinder body. Take care not to damage the camshaft bearings. 3) Tighten the thrust plate to the specified torque. Thrust Plate Bolt Torque kgf·m(lb.ft/N·m) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 4) Check to see that the camshaft turns smoothly by rotating it manually. 9. Piston and Connecting Rod with Upper Bearing 3 10.
ENGINE ASSEMBLY ( 3 ) 6) Position the piston head front mark so that it is facing the front of the cylinder body. 7) Use a piston ring compressor to compress the piston rings. Piston Ring Compressor 8) Use a hammer grip to push the piston in until the connecting rod makes contact with the crankpin. At the same time, rotate the crankshaft until the crankpin is at BDC. 9) Install the connecting rod bearing caps. The bearing cap front marks must be facing the front of the engine.
ENGINE ASSEMBLY ( 3 ) 12. Oil Pump with Oil Pipe Install the oil pump with the oil pipe and tighten the bolts to the specified torque. Oil Pump Bolt Torque kgf·m(lb.ft/N·m) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) Note: Take care not to damage the O-rings when tightening the oil pipe bolts. 13. Crankshaft Rear Oil Seal 1) Apply engine oil to the oil seal lip circumference and the oil seal outer circumference. 2) Use the oil seal installer to install the oil seal to the cylinder body.
ENGINE ASSEMBLY ( 3 ) 15. Flywheel 1) Block the flywheel with a piece of wood to prevent it from turning. 1 7 2) Apply a coat of engine oil to the threads of the flywheel bolts. 6 3 4 5 3) Tighten the flywheel bolts in the numerical order shown in the illustration. 8 2 Flywheel Bolt Torque kgf·m(lb.ft/N·m) 11.5 – 12.5 (83.2 – 90.4/112.8 – 122.6) 16. Oil Pan 1) Apply sealant to the No.
ENGINE ASSEMBLY ( 3 ) Important Operations (Reassembly Steps-2) 1. Idler Gear Shaft The idler gear shaft oil hole must be facing up. 2. Idler Gear “A” 1) Apply engine oil to the idler gear 1 and the idler gear shaft 2 . 2 1 2) Position the idler gear setting marks “X” and “Y” so that they are facing the front of the engine. 3) Align the idler gear “X” setting mark with the crankshaft timing gear 3 “X – X” setting mark.
ENGINE ASSEMBLY ( 3 ) 5. Timing Case Cover 1) Before installing the timing gear case, apply a 3 mm x 5 mm (0.12 in x 0.20 in) strip of liquid gasket to the portion of the feather key indicated by the arrow in the illustration. 2) Check that the timing case cover O-ring is firmly inserted into the gear case groove. 3) Tighten the timing case cover bolts to the specified torque. Timing Case Cover Bolt Torque kgf·m(lb.ft/N·m) M 8x1.25 (0.31x0.05) Bolt 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) M12x1.25 (0.47x0.
ENGINE ASSEMBLY ( 3 ) 9. Cylinder Head 1) Align the cylinder body dowels and the cylinder head dowel holes. Carefully set the cylinder head to the cylinder head gasket. 2) Apply engine oil to the cylinder head fixing bolt threads and setting faces. 13 4 5 17 1 9 3) Tighten the cylinder head bolts to the specified torque in two steps following the numerical order shown in the illustration. 12 8 16 Cylinder Head Bolt Torque 1st Step 18 14 2 6 15 7 10 3 11 New Bolt kgf·m(lb.
ENGINE ASSEMBLY ( 3 ) 15. Glow Plug and Glow Plug Connector 1) Tighten the glow plugs to the specified torque. Glow Plug Torque kgf·m(lb.ft/N·m) 2.0 – 2.5 (14.4 – 18.1/19.6 – 24.5) 2) Install the glow plug connectors. 16. Injection Nozzle Holder 3 5 4 2 1 1) Install the injection nozzle gasket 1 and the Oring 2 to the injection nozzle holder 3 . 2) Install the nozzle holder 3 together with the nozzle holder bracket 4 to the cylinder head.
ENGINE ASSEMBLY ( 3 ) 12 18 14 19 7 6 9 2 1 3 4 10 16 17 13 15 20 21 8 5 11 Reassembly Steps – 3 ▲ 1. Intake manifold ▲ 2. Injection pump ▲ 3. Fuel injection pump with clip 4. Fuel leak off pipe 5. Oil pipe (Injection pump to cylinder body) 6. Fuel filter 7. Fuel pipe (Fuel filter to leak off) 8. Fuel pipe (Fuel filter to feed pump) 9. Fuel pipe (Fuel filter to injection pump) 10. Rear engine hanger 104 ▲ 11. Starter ▲ 12. Exhaust manifold 13. 14. ▲ 15. ▲ 16. 17. 18. 19. 20. 21.
ENGINE ASSEMBLY ( 3 ) Important Operations (Reassembly Steps-3) 1. Intake Manifold Install the intake manifold gasket with the end having the sharp corners facing the front of the engine. 2. Injection Pump 1) Turn the crankshaft slowly clockwise to align the camshaft timing check hole pointer 1 with the camshaft timing gear “O” mark 2 . 1 2 2) Install the injection pump to the timing gear case. 3 Align the injection pump timing check hole pointer 3 with the timing gear “O” mark 4 .
ENGINE ASSEMBLY ( 3 ) 3. Fuel Injection Pipe with Clip 1) Temporarily tighten the injection pipe sleeve nut. 2) Set the clip in the prescribed position. Note: Make absolutely sure that the clip is correctly positioned. An improperly positioned clip will result in injection pipe breakage and fuel pulsing noise. 3) Tighten the injection pipe sleeve nut to the specified torque. Injection Pipe Sleeve Nut Torque kgf·m(lb.ft/N·m) 2.0 – 4.0(14.4 – 28.9/19.6 – 39.2) 11.
ENGINE ASSEMBLY ( 3 ) 15. Alternator and Adjusting Plate Tighten the alternator bolts and the adjusting plate bolts to the specified torque. Alternator Bolt Torque kgf·m(lb.ft/N·m) 3.6 – 4.6 (26.0 – 33.3/35.3 – 45.1) Tighten the adjusting plate bolts to the specified torque after cooling drive belt installation. Adjusting Plate Bolt Torque kgf·m(lb.ft/N·m) 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5) 19. Oil Filter Tighten the oil filter bolts to the specified torque. Oil Filter Bolt Torque kgf·m(lb.ft/N·m) 1.
MEMO 108
LUBRICATING SYSTEM SECTION 6 LUBRICATING SYSTEM TABLE OF CONTENTS ITEM PAGE Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING SYSTEM MAIN DATA AND SPECIFICATIONS Item A-4JA1·A-4JB1 Oil pump type Trochoid Delivery volume Lit(qts)/min. Pump speed Delivery pressure 1000 2 kgf/cm (psi/kPa) Oil temperature °C(°F) Engine oil 4.0 (56.89/392.0) 47 – 53 (116.6 – 127.4) SAE 30 Oil filter type Full flow with cartridge paper element 2 Relief valve opening pressure kgf/cm (psi/kPa) 4.3 – 4.7 (61.14 – 66.83/421.4 – 460.6) Safety valve opening pressure kgf/cm2(psi/kPa) 0.8 – 1.2 (11.38 – 17.07/78.9 – 117.
LUBRICATING SYSTEM GENERAL DESCRIPTION LUBRICATING OIL FLOW Battery Warning Light Oil pressure switch Cylinder block oil gallery Idle gear shaft Oil filter and cooler assembly.
LUBRICATING SYSTEM OIL PUMP A-4J Series engine are equipped with a trochoid type oil pump. The oil filter and the water cooled oil cooler are a single unit to increase the cooling effect.
LUBRICATING SYSTEM MAIN OIL FILTER OIL FILTER WITH BUILT-IN OIL COOLER 113
LUBRICATING SYSTEM OIL PUMP DISASSEMBLY 1 5 4 3 2 051ET001 Disassembly Steps 1. Oil pipe 2. Strainer case 3. Pump cover 114 4. Vane ▲ 5.
LUBRICATING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Vane, Rotor, and Cover Clearance Use a feeler gauge to measure the clearance between the vane, the rotor, and the cover. If the clearance between the vane, the rotor, and the cover exceeds the specified limit, the rotor set (pin, shaft, rotor, and vane) must be replaced. Vane, Rotor, and Cover Clearance Standard 0.02 – 0.07 (0.0008 – 0.
LUBRICATING SYSTEM REASSEMBLY 5 1 2 3 4 051ET002 Reassembly Steps 1. Pump body with rotor and pinion 2. Vane 3. Pump cover 116 4. Strainer case 5.
LUBRICATING SYSTEM OIL FILTER WITH BUILT-IN OIL COOLER DISASSEMBLY 2 3 5 4 7 1 6 Disassembly Steps 1. Drain plug 2. Cartridge oil filter 3. Oil cooler 4. O-ring 5. Safety valve 6. Relief valve 7.
LUBRICATING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Relief Valve 1. Attach an oil pressure gauge to the oil gallery near the oil filter. 2. Start the engine to check the relief valve opening pressure. Relief Valve Opening Pressure kgf/cm2(psi/kPa) 5.8 – 6.2 (82.49 – 88.18/569.0 – 608.2) Oil Cooler Water Leakage At Water Passage 1. Plug one side of the oil cooler water passage. 2.
LUBRICATING SYSTEM REASSEMBLY 6 5 3 4 1 7 2 Reassembly Steps 1. Oil filter body ▲ 2. Relief valve ▲ 3. Safety valve ▲ 5. Oil cooler ▲ 6. Oil filter cartridge ▲ 7. Drain plug 4.
LUBRICATING SYSTEM Important Operations 2. Relief Vale Tighten the relief valve to the specified torque. Relief Valve Torque kgf·m(lb.ft/N·m) 2.5 – 3.5 (18.1 – 25.3/24.5 – 34.3) 5. Oil Cooler 1) Align the oil filter holes with the body knock pins at installation. 2) Tighten the oil cooler to the specified torque. Oil Cooler Torque kgf·m(lb.ft/N·m) 2.5 – 3.5 (18.1 – 25.3/24.5 – 34.3) 6. Oil Filter Cartridge 1) Apply engine oil to the O-ring.
COOLING SYSTEM SECTION 7 COOLING SYSTEM TABLE OF CONTENTS ITEM PAGE Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM MAIN DATA AND SPECIFICATIONS Item Water pump type Pump to crankshaft speed ratio (To 1) Delivery volume Lit(qts)/min. Pump speed at 3000 rpm Water temperature at 30°C (86°F) Pump bearing type Thermostat type Valve initial opening temperature °C(°F) Valve full opening temperature °C(°F) Valve lift at fully open position mm(in.) 122 Centrifugal impeller 1.1 100 (105.5) Double row shaft Wax pellet with jiggle valve 82 (180) 95 (203) 8.0 (0.
COOLING SYSTEM GENERAL DESCRIPTION COOLANT FLOW The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat. To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the water pump and thermostat through the by-pass hose and back to the cylinder body. The coolant does not circulate through the radiator.
COOLING SYSTEM WATER PUMP THERMOSTAT A centrifugal type water pump forcefully circulates the coolant through the cooling system. A wax pellet type thermostat is used. The jiggle valve accelerates engine warm-up.
COOLING SYSTEM WATER PUMP DISASSEMBLY 2 1 4 6 7 5 3 Disassembly Steps ▲ 1. 2. ▲ 3. ▲ 4. O-ring Set screw Cooling fan center Impeller and seal unit ▲ 5. 6. 7.
COOLING SYSTEM Important Operations 3. Cooling Fan Center Remove the fan center with a bench press and a bar. 4. Impeller and Seal Unit Remove the impeller and seal unit with a bench press and bar. Note: Do not drive out the impeller with a hammer. Damage to the impeller will result.
COOLING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Bearing Unit Check the bearing for abnormal noise, biding, and other abnormal conditions.
COOLING SYSTEM REASSEMBLY 4 7 5 2 1 3 6 Reassembly Steps 1. 2. ▲ 3. ▲ 4. 128 Water pump body Thrower Bearing unit Set screw ▲ 5. ▲ 6. 7.
COOLING SYSTEM Important Operations 3. Bearing Unit 4. Set Screw 1) Align the bearing set screw hole with the pump body set screw hole. 2) Press the bearing unit into place. 3) Secure the bearing with the set screw. 5. Impeller and Seal Unit 1) 2) 3) Apply a thin coat of liquid gasket to the seal unit outer periphery. Install the seal unit. Measure the impeller protection from the water pump body fitting face. Impeller Projection mm(in.) 25.0 (0.98) 6.
COOLING SYSTEM Note: 1. The fan center and the impeller are installed to the water pump shaft with a press. Never attempt to remove and reinstall the fan center and the impeller a second time. Replace the entire water pump assembly. Removing and reinstalling the fan center and the impeller a second time may result in the breakdown of the water pump during engine operation and subsequent serious overheating problems. 2.
COOLING SYSTEM THERMOSTAT INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Operating Test 1. Completely submerge the thermostat in water. 2. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat. 1 3. Check the thermostat initial opening temperature. Thermostat Initial Opening Temperature 2 °C(°F) 82 (180) 4. Check the thermostat full opening temperature.
MEMO 132
FUEL SYSTEM SECTION 8 FUEL SYSTEM TABLE OF CONTENTS ITEM PAGE Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM MAIN DATA AND SPECIFICATIONS Item Injection pump type Plunger outside diameter mm(in.) Plunger lift mm(in.) Governor type Fuel feed pump type Injection nozzle type Number of injection nozzle orifices Injection nozzle orifice inside diameter mm(in.) 2 Injection nozzle opening pressure kg/cm (psi/MPa) Main fuel filter type 134 Bosch A type 9.0 (0.35) 3.25 – 3.35 (0.128 – 0.132) RSV variable speed mechanical type Single action Hole type 4 1.0 (0.039) 185 (2,630/18.
FUEL SYSTEM GENERAL DESCRIPTION COOLANT FLOW Fuel filter Nozzle Water separator Injection pump Fuel tank The fuel system consists of the fuel tank, the water separator (if so equipped), the fuel filter, the injection pump, and the injection nozzle. The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other foreign material are removed from the fuel.
FUEL SYSTEM INJECTION NOZZLE Nozzle holder Adjusting shim Spring Spring seat Injection nozzle Retaing nut A hole (with 4 orifices) type injection nozzle is used. It consists of the nozzle body and the needle valve assembly. The injection nozzle sprays pressurized fuel from the injection pump into the combustion chamber through the nozzle body injection orifice.
FUEL SYSTEM FUEL FILTER AND WATER SEPARATOR Drain Level A cartridge type fuel filter and a water separator are used. As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches the injection pump. The water separator has an internal float.
FUEL SYSTEM INJECTION NOZZLE DISASSEMBLY 6 5 7 4 3 2 1 Disassembly Steps 1. ▲ 2. 3. 4. 138 Retaining nut Injection nozzle Spacer Spring seat 5. 6. 7.
FUEL SYSTEM Important Operations Performance this test before disassembling the injection nozzle. 1) Install the injection nozzle to the nozzle tester. 2) Use the nozzle tester to apply compressed fuel at 185 kgf/cm 2 (2,630 psi/18.1 MPa) to the injection nozzle. 3) Check the area around the nozzle seat for fuel leakage. If there is fuel leakage, the injection nozzle and the injection body must be replaced as a set. 2. Injection Nozzle 1) Remove the injection nozzles from the nozzle holders.
FUEL SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Injection Nozzle Needle Inspection 1. Remove the nozzle needle from the nozzle body. 2. Carefully wash the nozzle needle and the nozzle body in clean diesel fuel. 3. Check that the nozzle needle moves smoothly inside the injection nozzle body.
FUEL SYSTEM REASSEMBLY 2 3 1 4 5 6 7 Reassembly Steps 1. ▲ 2. 3. 4. Nozzle holder Adjusting shim Spring Spring seat 5. 6. ▲ 7.
FUEL SYSTEM Important Operations 3. Adjust Shim Adjust Shim Availability Range 0.50-0.50 (0.02-0.06) Increment 0.025 (0.001) Total No. of Shims 7. mm(in.) 40 Retaining Nut Tighten to the retaining nut to the specified torque. Retaining Nut Torque kgf·m(lbs.ft./N·m) 4.0 – 5.0 (28.9 – 36.2/39.2 – 49.0) Injection Nozzle Adjustment 1. Attach the injection nozzle holder to the injection nozzle tester. 2.
FUEL SYSTEM INJECTION PUMP DATA INJECTION PUMP IDENTIFICATION Refer to the Item “INJECTION PUMP IDENTIFICATION” on Page 1– of the “SERVICING” Section of this Workshop Manual. INJECTION VOLUME ADJUSTMENT TEST CONDITIONS Injection Nozzle Injection Nozzle Holder Injection Starting Pressure Injection Line Dimensions Inside Diameter Outside Diameter Length Transfer Pump Pressure Testing Diesel Fuel Operating Temperature Pump Rotation Direction kgf/cm2(psi/MPa) mm(in.) kgf/cm2(psi/kPa) °C(°F) ZEXEL No.
FUEL SYSTEM INJECTION QUANTITY Adjusting Point Rod Position Pump Speed (mm) (rpm) A D Injection Quantity (cc/1000 Strokes) Maximum Variation (%) Fixed Remarks 8.3 1,500 64 – 65 ± 2.5 Lever Basic About 6.6 500 9.5 – 13.5 ± 15.0 Rack Adjust max. var. bet. cyl. at R = 6.6. Adjust governor as per. gov. adj. spec. Above 14.0 100 (70 – 85) — Lever Confirm that the timing of D is advanced 1°30’ from A. Pre-Stroke: No.1 Plunger 3.3 ± 0.
FUEL SYSTEM Speed Lever Angle 35°±3° 12°±5° Stop 25°±5° 145
MEMO 146
ENGINE ELECTRICALS SECTION 9 ENGINE ELECTRICALS TABLE OF CONTENTS ITEM PAGE Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ELECTRICALS STARTER STARTER IDENTIFICATION 1 C 2 3 12V HITACHI 4 MADE IN JAPAN A 4 1 Isuzu part number 2 Manufacturer‘s code number 1 2 Hitachi starter are identified by name plate attached to the yoke. (Illustration) 3 24V HITACHI 3 Rated voltage 4 Manufacturer‘s production mark MADE IN JAPAN Note: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number.
ENGINE ELECTRICALS MAIN DATA AND SPECIFICATION Isuzu Part No. Hitachi code No. Rated voltage Rated output Rating Direction of rotation (Viewed from the pinion side) Clutch type Terminal voltage (No. Load) Minimum current (No. Load) Starter motor minimum operating speed (No. Load) V kW Sec 8-97084-877-0 8-94423-452-0 S13-11 S24-07 12 2.2 24 3.5 30 Clockwise Roller V A 11 160 23 90 rpm 3900 3100 Pinion gear Modules Number of teeth Outside diameter Travel distance mm(in.) mm(in.) 2.75 9 33.
ENGINE ELECTRICALS GENERAL DESCRIPTION This starter is equipped with a reduction gear between the armature shaft and the flywheel ring gear drive pinion. This construction enable the starter to reduce 27% of the armature shaft revolution speed at the pinion contributing to achieve more compact size and higher cold engine starting ability than the non-reduction gear type starter.
ENGINE ELECTRICALS DISASSEMBLY 3 6 2 18 13 12 16 5 4 19 15 14 7 17 20 1 8 9 10 11 Disassembly Steps ▲ 1. 2. ▲ 3. ▲ 4. ▲ 5. ▲ 6. ▲ 7. 8. 9. 10. Lead wire Bolt Magnetic switch Torsion spring Plunger Shim Through bolt Rear cover Brush holder Yoke 11. 12. ▲ 13. ▲ 14. 15. 16. 17. 18. 19. 20.
ENGINE ELECTRICALS Important Operations 1. Lead Wire Disconnect lead wire at the magnetic switch. 3. Magnetic Switch Remove the magnetic switch fixing bolts, then remove the switch from the shift lever. 4. Torsion Spring 5. Plunger 6. Shim Remove the torsion spring, plunger and shim from the magnetic switch. 7. Through bolt Remove the yoke, armature and brush holder together from the gear case.
ENGINE ELECTRICALS 9. Brush Holder Using long-nose pliers remove the 4 brushes. 13. Bearing retainer Remove the bearing retainer, then remove the pinion from the gear case. 14. Snap Ring Remove the snap ring using a screw driver or equivalent, then disassemble the pinion assembly.
ENGINE ELECTRICALS INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. ARMATURE 2 Armature Short Circuit Test 1 1. Place the armature on a growler tester 1. 2. Hold a hack saw blade 2 against the armature core while slowly rotating the armature. If the armature is short circuited, the hack saw blade will vibrate and will be attracted to the armature core. A short circuited armature must be replaced.
ENGINE ELECTRICALS Commutator Run-Out Test Use a dial indicator and a V-block to measure the commutator runout. If the measure value exceeds the limit, the commutator must be replaced. Commutator Run-Out mm(in.) Standard Limit 0.02 (0.0008) 0.05 (0.002) Commutator Outside Diameter Measurement Use a vernier caliper to measure the commutator outside diameter. If the measured value exceeds the limit, the armature must be replaced. Commutator Outside Diameter mm(in.) Standard Limit S13 – 11 30.0 (1.
ENGINE ELECTRICALS YOKE Field Winding Ground Test Use a circuit tester to check the field winding ground. 1. Touch one probe to the brush field winding end. 2. Touch the other probe to the bare surface of the yoke body. There should be no continuity. If there is continuity, the field windings are grounded. Repair or replace the field windings. Field Winding Continuity Test Use a circuit tester to check the field winding continuity. 1. Touch one probe to the field winding lead wire. 2.
ENGINE ELECTRICALS Brush Spring Inspection Visually check the brush spring for weakness and rusting. Replace the brush spring if it is weak or rusted. Use a spring balancer to measure the spring tension. If the measured valve exceeds the limit, the brush spring must be replaced. Brush Holder Insulation Test Use a circuit tester to check the brush holder insulation. 1. Touch one probe to the field winding lead wire. 2. Touch the other probe to the brush. There should be no continuity.
ENGINE ELECTRICALS Check for continuity across magnetic switch “S” terminal and “M” terminal. If no continuity exists, series coil are open and should be replaced.
ENGINE ELECTRICALS REASSEMBLY 1 2 7 8 13 14 10 3 4 6 11 12 19 9 5 20 18 17 16 15 Reassembly Steps 1. 2. 3. ▲ 4. ▲ 5. ▲ 6. 7. 8. ▲ 9. 10. Magnetic switch Shim Plunger Torsion spring Shift lever Dust cover Bolt Overrunning clutch Pinion Return spring 11. 12. 13. 14. 15. 16. ▲ 17. 18. ▲ 19. ▲ 20.
ENGINE ELECTRICALS Important Operations 4. Torsion Spring 5. Shift Lever Set the torsion spring to the hole in magnetic switch. Insert the shift lever, via the torsion spring, into plunger hole in the magnetic switch. 6. Dust Cover Install the magnetic switch in gear case. Make sure to install the dust cover. Dust Cover Bolt Torque kgf·m(lb.ft./N·m) 0.7 – 0.8 (5.1 – 5.8/6.9 – 7.9) 9. Pinion Install the pinion after applying grease to the reduction gear. 17.
ENGINE ELECTRICALS 19. Through Bolt Tighten the through bolts to the specified torque a little at a time. Through Bolt Torque kgf·m(lb.ft./N·m) 0.5 – 0.7 (3.6 – 5.1/4.9 – 6.9) 20. Lead Wire Tighten the lead wire to the specified torque. Lead Wire Torque kgf·m(lb.ft./N·m) 0.8 – 1.0 (5.8 – 7.2/7.8 – 9.8) Inspection After Reassembly The pinion jumps out as the magnetic switch “S” terminals is connected to the battery positive terminal and negative terminal is connected to the gear case.
ENGINE ELECTRICALS ALTERNATOR 2 ALTERNATOR IDENTIFICATION 1 4 Hitachi alternators are identified by name plate attached to the rear cover. (Illustration) R 1 Isuzu part number L 2 Manufacturer‘s code number IC REG BUILT IN Hitachi. Ltd. Japan 3 3 Rated output 4 Manufacturer‘s production mark Note: Always check the identification number before beginning a service operation. Applicable service data will vary according to the identification number.
ENGINE ELECTRICALS MAIN DATA AND SPECIFICATION Engine Model to be Equipped A – 4J Series Manufacturer‘s name HITACHI Isuzu Part No. Manufacturer‘s Code No. Rated voltage Rated output Operating speed Rated output at rpm No-load output at 0 amperes V A rpm A/V/rpm V/rpm 8-94423-756-0 8-94431-560-0 5-81200-335-0 LR135-127 LR215-50 LR200-24 12 35 1000–13500 33-37/13.5/5000 13.
ENGINE ELECTRICALS GENERAL DESCRIPTION The alternator consists of the front cover, the rotor, the stator, the built-in IC regulator (some engines use a Tirrell alternator with separate regulator), and the rear cover. This small size and light weight alternator provides excellent reliability. Its simple construction makes it very easy to service. The built-in IC regulator minimizes circuit wiring.
ENGINE ELECTRICALS DISASSEMBLY These disassembly steps are based on the built-in IC regulator type. 5 6 7 3 8 4 12 11 1 10 2 9 Disassembly Steps 1. 2. ▲ 3. ▲ 4. 5. 6. Through bolt Rear cover and stator Pulley and fan Spacer collar Rotor with bearing Bearing retainer 7. 8. ▲ 9. ▲ 10. 11. 12.
ENGINE ELECTRICALS Important Operations 3. Pulley and Fan (1) Clamp the rotor shaft in a soft jaw vise. (2) Loosen the pulley lock nut 1. 1 (3) Remove the pulley 2 along with the spacer collar. 2 4. Rotor and Bearing (1) Use a plastic hammer or a press 1 to remove the rotor from the front cover 2. 1 (2) Remove the spacer collar. 2 8. Front Cover Use screwdrivers to pry the front cover 1 from the stator 2. 1 Note: Do not attempt to pry the coil wires from the stator. 2 9. Stator 10.
ENGINE ELECTRICALS INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. ROTOR AND BEARING Check the face of the slip rings for contamination and roughness. If found to be roughened, dress with a fine sand paper (#500 – 600). If found to be contaminated, clean with a cloth saturated with alcohol. Ball Bearing Check that the ball bearings rotate smoothly. If the ball bearings are noisy, they must be replaced.
ENGINE ELECTRICALS Rotor Coil Continuity Test Use an circuit tester to test the rotor coil continuity. 1. Touch both circuit tester probes to the rotor coil slip rings. 2. Note the circuit tester reading. The circuit tester should register approximately 9 ohms. 3. If the circuit tester does not show continuity, check the connections between the lead wire and the slip rings. If breaks are founded, repair and repeat the rotor coil continuity test.
ENGINE ELECTRICALS 4. Note the circuit tester reading. If the two readings (Steps 2 and 4) are identical, the stator coil has continuity. If the two circuit tester readings are different, there is no stator continuity. 5. Check the neutral junction (arrow mark) for breaks. If breaks are found, repair and repeat the stator coil continuity test. If there is still no stator coil continuity, the stator must be replaced. Stator Coil Ground Test Use an circuit tester to test the stator coil for grounding. 1.
ENGINE ELECTRICALS 3. Note the meter reading for each diode terminal. All of the diode should show continuity. If a diode shows no continuity, it is open circuit. The rectifier assembly must be replaced. 4. Touch the circuit tester negative probe to the rectifier holder. GOOD BAD 5. Touch the circuit tester positive probe to each of the diode terminals in turn. 6. Note the meter reading for each diode terminal. None of the diodes should show continuity. If a diode shows continuity, it is shorted.
ENGINE ELECTRICALS Note: 1. The stator lead wires must be cut to the proper length before they are connected to the rectifier lead wires. If the stator lead wires are too long or too short, trouble may occur. Stator Lead Wire Length mm(in.) 33.5 (1.32) 2. Take care not to damage the rectifier paint surfaces. BRUSH Use a vernier caliper to measure the brush. If the measured value exceeds the limit, the brush must be replaced. Brush Length mm(in.) Standard Limit 8-94423-756-0 14.5 (0.57) 7.5 (0.
ENGINE ELECTRICALS REASSEMBLY 9 8 7 11 6 10 1 2 12 3 5 4 Reassembly Steps 1. 2. ▲ 3. ▲ 4. 5. 6. 172 Rear cover IC regulator Rectifier with brush holder Stator Rear cover and stator Front cover ▲ 7. 8. 9. 10. ▲ 11. 12.
ENGINE ELECTRICALS Important Operations 3. Rectifier with Brush Holder 4. Stator When connecting stator coil leads and diode leads using solder, use long-nose pliers and finish the work as quickly as possible to prevent the heat from being transferred to the diodes. 11. Pulley and Fan Tighten the pulley and fan to the specified torque. Pulley and Fan Nut Torque kgf·m(lb.ft./N·m) 5.0 – 6.5 (36.2 – 47.7/49.0 – 63.
MEMO 174
TROUBLESHOOTING SECTION 10 TROUBLESHOOTING TABLE OF CONTENTS ITEM PAGE Hard starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Unstable idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Insufficient power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING TROUBLESHOOTING Refer to this Section to quickly diagnose and repair engine problems. Each troubleshooting chart has three headings arranged from left to right. (1) Checkpoint (2) Trouble Cause (3) Countermeasure This Section is divided into ten sub-sections: 1. Hard Starting 1) Starter inoperative 2) Starter operates but engine does not turn over 3) Engine turns over but does not start 2. Unstable Idling 3. Insufficient Power 4. Excessive Fuel Consumption 5.
TROUBLESHOOTING 1. 1.
TROUBLESHOOTING 1. 2.
TROUBLESHOOTING 1. 3.
TROUBLESHOOTING 1. 3.
TROUBLESHOOTING 2.
TROUBLESHOOTING 2.
TROUBLESHOOTING 2.
TROUBLESHOOTING 3.
TROUBLESHOOTING 3.
TROUBLESHOOTING 3.
TROUBLESHOOTING 3.
TROUBLESHOOTING 4.
TROUBLESHOOTING 4.
TROUBLESHOOTING 5.
TROUBLESHOOTING 6.
TROUBLESHOOTING 6.
TROUBLESHOOTING 7.
TROUBLESHOOTING 8.
TROUBLESHOOTING 9.
TROUBLESHOOTING 9.
TROUBLESHOOTING 10. ABNORMAL ENGINE NOISE 1. Checkpoint Engine Knocking Trouble Cause Countermeasure Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.
TROUBLESHOOTING 10. ABNORMAL ENGINE NOISE 2. Checkpoint Gas Leakage Noise Trouble Cause Countermeasure Continued from the previous page OK Exhaust manifold NG Loosely connected exhaust manifold and/or glow plugs NG Tighten the exhaust manifold connections OK Cylinder head gasket NG Damaged cylinder head gasket 3.
TROUBLESHOOTING 10. ABNORMAL ENGINE NOISE 4.
MEMO 200
SPECIAL TOOL LIST SECTION 11 SPECIAL TOOL LIST 201
SPECIAL TOOL LIST SPECIAL TOOL LIST ITEM NO. 202 ILLUSTRATION PART NO.
SPECIAL TOOL LIST ITEM NO. ILLUSTRATION PART NO.
MEMO 204
REPAIR STANDARDS SECTION 12 REPAIR STANDARDS TABLE OF CONTENTS ITEM PAGE General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Repair standards chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 General Rules 1.
Name of Part Cylinder Body Engine Body 206 Time for engine disassembly and repair Major Category L/h Lubricating oil consumption New engine performance is assumed 100% Warm engine engine speed 200 rpm (varies depending on altitude) Comments 5 (71.1/490) Pressure test: 3 minutes kgf/cm2 (psi/kPa) Leaks require repair or replacement Not repairable; must be replaced 0.05 (0.002) or less Difference in liner projection between neighboring cylinders not to exceed 0.
Name of Part Cylinder Head Major Category Same for ( inlet & exhaust ) (Valve) Must not protrude from lower surface of cylinder head 45 A Cylinder head bolts tightening torque kgf·m(lb·ft/N·m) 2nd Step 8.2 – 9.2 (59.4 – 66.5/ 80.4 – 90.2) 10.0 – 11.0 (72.4 – 79.6/ 98.1 – 107.9) 3.0 – 5.0 (21.7 – 36.1/ 29.4 – 49.0) 8.0 – 9.0 (57.9 – 65.1/ 78.4 – 88.2) New bolt Reused bolt 5 (71.1 – 490) Water-pressure test, 3 minutes kgf/cm2 (psi/kPa) 0.2 (0.008) 0.2 (0.008) 2.5 (0.098) 2.2 (0.087) 1.
Main Operating Parts Name of Part Pistons 208 Piston Ring Major Category 0.15 (0.006) 0.15 (0.006) 0.050 – 0.075 (0.002 – 0.003) 0.030 – 0.070 (0.0012 – 0.0028) Oil ring 0.15 (0.006) 1.5 (0.059) Dia. 30.95 (1.2185) Limit 2nd compression ring 0.090 – 0.125 (0.0035 – 0.0049) 1st compression ring 1.11 – 1.59 (2.45 – 3.50/ 10.9 – 16.0) 0.10 – 0.30 (0.004 – 0.012) 0.20 – 0.40 (0.008 – 0.016) 30.992 – 30.98 (1.2202 – 1.2197) 4.0 – 6.0 (8.82 – 13.2/ 39.2 – 58.8) Dia. 31.0 (1.
Main Operating Parts Name of Part Crankshaft Connecting Rods Major Category Nominal Dimension Clearance between connecting rod bearing and crankpin Connecting rod bearing runout 0.029 – 0.066 (0.0011 – 0.0026) 16.0 – 18.0 (115.7 – 130.2/ 156.9 – 176.5) 0.10 (0.
Main Operating Parts Name of Part Connecting Rods 210 Camshaft Major Category Journal wear Clearance between journal and bearing Dia. 50 (1.969) 49.945 – 49.975 (1.9663 – 1.9675) 0.025 – 0.085 (0.001 – 0.0033) 8.0 – 9.0 (57.9 – 65.1/ 78.4 – 88.2) Bearing cap bolt tightening torque (angular tightening method) kgf·m (lb·ft/N·m) Journal uneven wear 0.05 (0.002) or less Big end to small end hole parallelism (per 100 mm) 0.175 – 0.290 (0.007 – 0.0114) 0.05 (0.002) or less Dia. 50 (1.969) Dia.
Name of Part Camshaft Major Category 0.20 (0.008) 0.05 – 0.114 (0.002 – 0.0045) Camshaft end play 41.65 (1.64) Limit 0.10 (0.004) 42.08 (1.65) Assembly Standard Value 0.02 (0.
212 Name of Part Inspection Item 13.0 (0.512) 1.8 (0.071) mm Inclination Dia. 18.85 (0.742) Dia. 18.98 – 19.00 (0.747 – 0.748) Rocker arm shaft wear Adjust 0.2 (0.008) 0.40 (0.016) 2.5 (0.098) 48.2 (1.90) 29.0 (63.9/284.4) 0.01 – 0.05 (0.0004 – 0.002) 1.5 (0.06) or less 49.7 (1.96) 32.6 (71.9/319.6) 1.5 (0.059) 0.25 (0.0098) 0.2 (0.008) Dia. 7.88 (0.3102) Limit Clearance between rocker arm shaft and bushing Valve clearance (inlet & exhaust) (cold) mm Exhaust 13.0 (0.
Valve System Intake System Name of Part Tappet Air cleaner Major Category Out diameter Air cleaner element condition Tappet wear Clearance between tappet and cyl. body Inspection Item Nominal Dimension 0.10 (0.0039) 12.95 (0.5098) 12.97 – 12.99 (0.5106 – 0.5114) Limit 0.03 (0.
Lubricating System Initial operating pressure of main oil filter relief valve kgf/cm2 (psi/kPa) Clogging and damage to oil filter ( Pumping rate L/min 1000 rpm, SAE #30, pumping pressure 4 kgf/cm2 (56.9 psi/392 kPa) oil temp.
Cooling System Fuel System Name of Part Water pump Piping, etc. Major Category ) L/min A Temperature at whic thermostat lift reaches 8mm(0.315in) or more. Adjust Repair or replace if impeller and pump body are touching Replace Repair Procedure Replace 0.2 (0.0079) Limit Fuel filter element clogging or damage 95°C (203°F) 80 – 84°C (176 – 183°F) 8 – 12 (0.31 – 0.47) 0.3 – 1.3 (0.0118 – 0.
Electrical Name of Part Charge/ Discharge indication Wiring Alternator 12V, 35A (Hitachi 1-81200-756-0) Starter 12V, 2.2 kW (Hitachi 8-97084-879-0) Inspection Item Repair If warning indicator lights when engine is operating at normal speeds, check and repair electrical system. Repair Procedure Replace Commutator Undercut depth O.D. Jeries coil Magnetic resistance (Ω) switch (at 20°C [68°F]) Shut coil resistance (Ω) Dia. 29.0 (1.14) 0.2 (0.008) Dia. 30.0 (1.18) 0.5 – 0.8 (0.02 – 0.03) 0.
Final Inspection Electrical Name of Part Starter 12V, 2.2 kW (Hitachi 8-97084-879-0) Preheater Major Category 4.0 – 4.5 (392 – 441) 90% or more 110% or less Lubricating oil pressure kgf/ cm2 (psi/KPa) Output check Fuel consumption check 5% or less Adjust Inspect Inspect Cylinder compression pressure kgf/ cm2 (psi/MPa) about 200 rpm Difference in compression between cylinders kgf/ cm2 (psi/MPa) about 200 rpm 30 minutes or more Engine run-in operation 31 (441/3.
MEMO 218
CONVERSION TABLE SECTION 13 CONVERSION TABLES INDEX CONTENTS PAGE Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE LENGTH FEET TO METERS ft. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 m m m m m m m m m m –––0 3.048 6.096 9.144 12.192 15.240 18.288 21.336 24.384 27.432 30.480 0.305 3.353 6.401 9.449 12.497 15.545 18.593 21.641 24.689 27.737 30.785 0.610 3.658 6.706 9.754 12.802 15.850 18.898 21.946 24.994 28.042 31.090 0.914 3.962 7.010 10.058 13.106 16.154 19.202 22.250 25.298 28.346 31.394 1.219 4.267 7.315 10.363 13.411 16.459 19.507 22.555 25.603 28.651 31.
CONVERSION TABLE AREA SQUARE INCHES TO SQUARE CENTIMETERS in2 ––– 10 20 30 40 50 60 70 80 90 100 in2 0 1 2 3 4 5 6 7 8 9 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 –––00 64.516 129.032 193.548 258.064 322.580 387.096 451.612 516.128 580.644 645.160 6.452 70.968 135.484 200.000 264.516 329.032 393.548 458.064 522.580 587.096 651.612 12.903 77.419 141.935 206.451 270.967 335.483 399.999 464.515 529.031 593.547 658.063 19.355 83.871 148.387 212.903 277.419 341.935 406.451 470.967 535.
CONVERSION TABLE VOLUME GALLONS (U.S.) TO LITERS U.S. gal. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 liters liters liters liters liters liters liters liters liters liters U.S.gal. –––00 37.8543 75.7085 113.5628 151.4171 189.2713 227.1256 264.9799 302.8342 340.6884 378.5427 3.7854 41.6397 79.4940 117.3482 155.2025 193.0568 230.9110 268.7653 306.6196 344.4738 382.3281 7.5709 45.4251 83.2794 121.1337 158.9879 196.8422 234.6965 272.5507 310.4050 348.2593 386.1135 11.
CONVERSION TABLE MASS POUNDS TO KILOGRAMS lbs. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 kg kg kg kg kg kg kg kg kg kg lbs. –––0 4.536 9.072 13.608 18.144 22.680 27.216 31.751 36.287 40.823 45.359 0.454 4.990 9.525 14.061 18.597 23.133 27.669 32.205 36.741 41.277 45.813 0.907 5.443 9.979 14.515 19.051 23.587 28.123 32.659 37.195 41.731 46.267 1.361 5.897 10.433 14.970 19.504 24.040 28.576 33.112 37.648 42.184 46.720 1.814 6.350 10.886 15.422 19.958 24.494 29.030 33.
CONVERSION TABLE PRESSURE POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS lb/in2 0 1 2 3 4 5 6 7 8 9 lb/in2 (psi) kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 (psi) ––– 10 20 30 40 50 60 70 80 90 100 –––0 0.7031 1.4061 2.1092 2.8123 3.5154 4.2184 4.9215 5.6246 6.3276 7.0307 0.0703 0.7734 1.4764 2.1795 2.8826 3.5857 4.2887 4.9918 5.6949 6.3979 7.1010 0.1406 0.8437 1.5468 2.2498 2.9529 3.6560 4.3590 5.0621 5.7652 6.4682 7.1713 0.
CONVERSION TABLE TORQUE FOOT POUNDS TO KILOGRAMMETERS ft. lbs. ––– 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 9 kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m kgf-m ft lbs. –––0 1.383 2.765 4.148 5.530 6.913 8.295 9.678 11.060 12.443 13.826 0.138 1.521 2.903 4.286 5.668 7.051 8.434 9.816 11.199 12.581 13.964 0.277 1.659 3.042 4.424 5.807 7.189 8.572 9.954 11.337 12.719 14.102 0.415 1.797 3.180 4.562 5.945 7.328 8.710 10.093 11.475 12.858 14.240 0.553 1.936 3.318 4.
CONVERSION TABLE TEMPERATURE FAHRENHEIT TO CENTIGRADE °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C -60 -58 -56 -54 -52 -50 -48 -46 -44 -42 -40 -38 -36 -34 -32 -30 -28 -26 -24 -22 -20 -18 -16 -14 -12 -10 -8 -6 -4 -51.1 -50.0 -48.9 -47.8 -46.7 -45.6 -44.4 -43.3 -42.2 -41.1 -40.0 -38.9 -37.8 -36.7 -35.6 -34.4 -33.3 -32.2 -31.1 -30.0 -28.9 -27.8 -26.7 -25.6 -24.4 -23.3 -22.2 -21.1 -20.0 -2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 -18.9 -17.8 -16.7 -15.
Copyright reserved for this manual may not be reproduced or copied, in whole or in part, without the written consent of ISUZU MOTORS LIMITED. WORKSHOP MANUAL (INDUSTRIAL) A-4JA1, A-4JB1 (IDE-2310) Issued by ISUZU MOTORS LIMITED POWERTRAIN SERVICE & PARTS POWERTRAIN OPERATIONS 6-26-1, Minami-oi, Shinagawa-ku,Tokyo, 140-8722, Japan TEL 03-5471-1111 First edition Jul.
IDE-2310 PRINTED IN JAPAN
