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SERVICE MANUAL

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1. ee mTMTTT APPELS EE bbb 6666 60 0 ee Rate eee 202 CONVERSION TABLE CONTENTS Length Area Volume Mass Pressure Torque Temperature LENGTH SECTION 12 CONVERSION TABLES INDEX 9 9219 10 3188 10 7156 11 1125 11 5094 11 9063 12 3031 12 7000 PAGE sat dos eames 1209 205 208 EE Ce ge 208 EE EE 13 0969 13 4938 13 8906 14 2875 14 6844 15 0813 15 4781 15 8750 16 2719 16 6688 17 0656 17 4625 17 8594 18 2563 18 6531 19 0500 19 4469 19 8438 20 2406 20 6375 21 0344 21 4313 21 8281 22 2250 22 6219 23 0188 23 4156 23 8125 24 2094 24 6063 25 0031 25 4000 203 CONVERSION TABLE LENGTH FEET TO METERS 16 4042 19 6850 22 9659 26 2467 29 5276 32 8084 36 0892 39 3701 42 6509 45 9318 49 2126 52 4934 55 7743 59 0551 62 3360 65 6168 68 8976 72 1785 75 4593 78 7402 82 0
2. 10 142 23 10 20 30 40 50 60 995 61 1009 83 1024 06 1038 28 1052 50 1066 73 1080 95 1095 17 1109 39 1123 62 70 1137 84 1152 06 1166 27 1180 51 1194 73 1208 96 1223 18 1237 40 1251 62 1265 85 80 1280 07 1294 20 1308 52 1322 74 1336 96 1351 19 1365 41 1379 63 1393 85 1408 08 90 1422 30 1436 52 1450 75 1464 97 1479 19 1493 42 1507 64 1521 86 1536 08 1550 31 100 KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL 7256 9 1 7 7649 2 7747 3 8237 6 s 8629 9 8727 9 9218 3 2 9610 5 9708 6 10002 8 10100 8 10198 9 10297 0 10395 0 10493 1 10591 2 10689 2 KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS L oes arem arem Koren Tem aem p Wem E 6 118 7 138 8 158 9177 1000 10 197 17 335 18355 19 375 27532 28552 29 572 37 130 38 749 39 769 m s To 71 380 81 578 91 775 101 972 78 518 88 716 98 913 109 110 79 538 89 735 99 933 110 130 80 558 90 755 100 952 111 149 72 400 82 597 92 794 102 992 73 420 83 617 93 814 104 011 74 440 84 637 94 834 105 031 75 459 85 656 95 854 106 051 76 479 86 676 96 873 107 071 77 499 87 696 97 893 108 090
3. EEE hee 30 ENGINE ASSEMBLY 1 SECTION 3 ENGINE ASSEMBLY 1 TABLE OF CONTENTS ITEM SS s PAGE Disassembly args BA We eA eae cue Qu eg 32 31 ENGINE ASSEMBLY 1 E DISASSEMBLY These disassembly steps are based on the 4JG2PE engine ET deste lt 13 ek NN M Disassembly Steps 1 T 32 Cooling fan and spacer Cooling fan drive belt Cooling fan drive pulley Alternator and adjusting plate Fuel hose Leak off Injection pipe Fuel pipe Injection pump Breather hose Inlet manifold Oil pipe Starter motor Dipstick and guide tube Exhaust manifold Cil filter ENGINE ASSEMBLY 1 WV Important Operations Disassembly Steps 1 6 Fuel Injection Pipe with Clip 1 Loosen the injection pipe sleeve nuts at the dalivery valve side Do not apply excessive force to the injection pipes 2 Loosen the injection pipe clips 3 Remove the injection pipes 8 Injection Pump 1 Remove the six injection pump bracket bolts from the cylinder body timing gear case 2 Pull the injection pump with the injection pump timing gear free from the rear 14 Exhaust Manifold Loosen the exhaust manifold bolts a little at a time in the numerical order shown in the illustration 33
4. 208 CONVERSION TABLE TORQUE FOOT POUNDS TO KILOGRAMMETERS KILOGRAMMETERS TO FOOT POUNDS m qox 1 1 3 091 5 1 9 m ue ke is Ke Bs fme tms tbe wes 10 20 30 40 10 20 30 50 60 70 80 90 KILOGRAMMETERS TO NEWTONMETERS EC 4 m B ME DS 2 EE 3 LS e Ms wm wm Vm Nm Wm Wm Wm 706 08 715 89 725 69 735 50 745 31 7755 11 764 92 774 73 804 15 813 95 823 76 833 57 843 37 853 18 862 99 872 79 902 21 912 02 921 83 931 63 941 44 951 25 961 05 970 86 1000 28 1010 08 1019 89 1029 70 1039 50 1049 31 1059 12 1068 92 NEWTONMETERS TO KILOGRAMMETERS we Jo 2 o o oem em m em Xem 71 380 72 399 73 418 74 438 75 458 76 478 77 497 78 517 80 556 81 577 82 596 83 615 84 635 85 655 86 675 87 694 88 714 90 753 91 774 92 793 93 812 94 832 95 852 96 872 97 891 98 911 100 950 101 972 102 990 104 009 105 029 106 049 107 069 108 088 109 108 110 128 111 147 209 CONVERSION TABLE TEMPERATURE FAHRENHEIT TO CENTIGRADE ec 210 IDE 2290 ALUMINUM DYECAST TYPE TIMING GEARCASE PTO INSTALLATION PROCEDURE GEARCASE PTO AND RELATED PARTS 2 DUM 2 P dn A 3 PN 5 d our N 7 22 TR ud QP P d og Reassembly Steps 2b Timing
5. ERROR se 20 Injection pump identification 20 Lubricating system nr eene 20 Fuel system do CN AS CER MEL ee 21 Cooling system 444 44 ten deca ek 24 Valve clearance adjustment 25 Injection timing 2 26 Compression pressure measurement esee hn 27 Recommended 6 28 kits 2 Teret 29 19 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 piscine dd INJECTION PUMP IDENTIFICATION Pump Serial Number injection volume should be adjusted after referring to the adjustment data applicable to the injection pump installed PUMP NO 104646 1910 The injection pump identification number A is stamped NP VE4 11F1200LNP1593 on the injection pump identifications plate LICENCE BOSCH Note Alwa
6. 45 4590 90 9180 136 3770 181 8360 227 2950 272 7540 345 4884 390 9474 436 4064 481 8654 LITERS TO GALLONS 9 2392 9 4591 9 6791 10 1191 10 3391 10 5590 10 7790 10 9990 11 2190 11 4390 11 6590 11 8789 12 0989 12 3189 12 5389 12 7588 12 9788 13 1988 13 4188 13 6388 13 8587 14 0787 14 2987 14 5187 14 7387 14 9586 15 1786 15 3986 15 6186 15 8386 16 0585 16 2785 16 4985 16 7185 16 9385 17 1584 17 3784 17 5984 17 8184 18 0384 18 2583 18 4783 18 6983 18 9183 19 1383 19 3582 19 5782 19 7982 20 0182 20 2382 20 4581 20 6781 20 8981 21 1181 21 3381 21 5580 21 7780 21 9980 22 2180 22 4380 22 6579 22 8779 23 0979 23 3179 23 5379 23 7578 23 9778 206 MASS 88 185 110 231 132 277 154 324 176 370 198 416 220 462 71 380 81 578 91 775 101 972 90 390 112 436 134 482 156 528 178 574 200 621 222 667 102 992 92 594 114 640 136 687 158 732 180 780 202 825 224 871 706 08 804 15 902 21 1000 28 104 011 POUNDS TO KILOGRAMS 94 799 116 845 138 891 160 937 182 984 205 030 227 076 97 003 119 050 141 096 163 142 185 188 207 234 229 281 99 208 121 254 143 300 165 347 187 393 209 439 231 485 101 413
7. 185 ENGINE ELECTRICALS eceunsenesesunenenennnnnennee nen 147 5 173 SPECIAL TOOL LIST 199 CONVERSION 203 GENERAL INFORMATION SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS ITEM M PAGE General repair instructions 5 5 0 2 Notes on format of this 5 tn 2 Main data and specifications one ee eee EE 6 Tightening torque specifications arr RT TEE DENS 7 Augular nut and bolt tightening n 9 Special parts fixing nuts and er 11 GENERAL INFORMATION GENERAL REPAIR INSTRUCTIONS 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 Always use the proper tool or tools for the job at hand Where specified use the specially designed tool or tools Use genuine ISUZU parts Never reuse cotter pins gaskets O rings lock washers and self locking nuts Discard them as you remove them Replace them with new ones Always keep disassembled parts neatly in groups Th
8. PTO 1 Locating pin 9 Idler gear B 2 Idler gear shaft A 10 Idler gear C 3 Gasket 11 PTO gear 4 Gearcase 12 Gearcase cover 5 Locating pin 13 feed pipe 6 Stud bolt 14 Gasket 7 Idler gear A 15 Oil pan 8 Oil pipe 16 Cover 014E100055 020 100018 014E100086 idler gear shaft 1 Install the idler gear shaft A with facing up oil hole to the cylinder block 2 Install the locating pin to the cylinder block Note The gearcase is positioned by the locating pin and idler gear shaft A Gearcase 1 Install the gearcase with new gasket to the cylinder block Tighten the bolts to the specified torque kgf m Ib ft Gearcase Bolt Torque 14 24 1 4 2 4 10 17 2 Install the locating pin to the gearcase 3 Install the stud bolts to the gearcase Apply Loctite 262 or equivalent to the thread portion of stud bolt idler gear A 1 Install the camshaft with cam gear 2 Install the idler gear and thrust washer to the idler gear shaft Apply engine oil to the idler gear shaft e Install the thrust washers with the dimple of thrust washer facing to gear side Tighten the bolts to the specified torque kgf m Ib ft Bolt Torque 14 24 1 4 2 4 10 17 3 Install the oil pipe gearcase to idler gear shaft Tighten the bolts to the specified torque N m kgf m Ib ft Bolt Torque 10 15 1 0 1 5 7 2 11 Ft Timing
9. 0 4 40406 0 6 066 0 6 eee 4 4 40 0 646 606 610400006 0 06 6 0 6 6 042006 46044400606 EEE 0 0 eee ENGINE ASSEMBLY 3 96 REASSEMBLY Reassembly Steps 1 gt co 1 2 Tappet Cylinder body Crankshaft upper bearing Crankshaft with crankshaft timing gear Crankshaft thrust bearing Crahkshaft bearing cap with lower bearing Timing gear case Camshaft with camshaft timing gear and thrust plate Piston and connecting rod with upper bearing gt gt gt gt gt 10 11 12 13 14 15 16 16a Repair
10. 04 4 0 44 1440 06 2644 44 EEE SEE eee eee e eee Te eT eee eT eee ee eee eee eee ee ee eee eee eee ee ee eee eT eee eee lt 24 4 04 0 006 TTT 64 8 4 0 4 0 60 4 04 0064046 6 irri nenn ara enter nennen ee Ten hen nn ere reer ee Terr ere e eee reer eee eT eee ee Tee eee eee eee eee eer Te ere reer ere rr ee rr errr er rrer errr rere rer rr ree rer eer err ee rer terre trier i etter ee eee 84 ENGINE ASSEMBLY 3 SECTION 5 ENGINE ASSEMBLY 3 TABLE OF CONTENTS ITEM PAGE ReassembWV Kara dad wedge dd d ted os deba he 86 85 ENGINE ASSEMBLY 3 REASSEMBLY SINGLE UNIT ROCKER ARM SHAFT AND ROCKER ARM Reassembly Steps A 1 Rocker arm shaft 2 Rocker arm shaft snap ring 3 Rocker arm 4 Rocker arm shaft bracket 5 Rocker arm 6 Rocker arm shaft spring 7 Rocker arm shaft snap ring 86 ENGINE ASSEMBLY 3 WV Important Operations 1 Rocker Arm Shaft 1 Position the rocker arm shaft with the large oil hole 4g facing the front o
11. 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 Note Another method of heating the ring gear to invite ther mal expansion is to soak a rag in diesel fuel wrap the diesel fuel soaked rag around the rim of the ring gear and then light the rag PISTON Piston Grade Selection and Cylinder Liner Bore Measurement Refer to the Section CYLINDER BODY Item Cylinder Liner Bore Measurement for details on piston grade selection and cylinder or liner bore measurement PISTON RING Piston Ring Gap 1 Insert the piston ring horizontally into the cylinder liner 2 Use a piston inserted upside down to push the piston ring into the cylinder liner until it reaches either measuring point or measuring point Cylinder liner diameter is the smallest at these two points Do not allow the piston ring to slant to one side or the other It must be perfectly horizontal 3 Use a feeler gauge to measure the piston ring gap Measuring Point D 10 mm 0 39 in Measuring Point 2 120 mm 4 72 in If the piston ring gap exceeds the specified limit the piston ring must be replaced 77 ENGINE ASSEMBLY 2 78 Piston Ring Gap mm in
12. 12 Manufacturer s name 4 Rated voltage V Rated output A 35 Operating speed rpm 1000 13500 Rated output at rpm AN rpm 33 37 13 5 5000 No load output at 0 amperes V rpm 13 5 1000 or less Direction of rotation viewed from the Clockwise pulley side Polarity grounded Pulley diameter P C D Negative 80 3 15 Coil resistance at 20 C Rotor coil Stator coil Brush length Standard mmiin Limit 14 5 0 57 7 5 0 30 Slip ring diameter Standard mm in Limit 31 6 1 24 30 6 1 20 Shaft diameter Front mmiin Rear 15 0 0 59 mm in 12 0 0 47 Built in 5 81270 004 0 TR1Z 63 Regulator s applicable Isuzu Part No Manufacturer s code No 162 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 163 ENGINE ELECTRICALS DISASSEMBLY These disassembly steps are based on the built in IC regulator type Disassembly Steps Through bolt Rear cover and stator Pulley and fan Spacer collar Rotor with bearing Bearing retai
13. gear mark 014 100056 Idier gear 1 Press the bearing to the idler gear until the gear con tacts into bearing stopper 1 i e Use the bearing with spacers 2 e Apply load only on the outer of bearing when the bearing will be pressed to the gear 2 Install the idler gear shaft 3 to the gear 3 Install the idler gear asm to the gearcase 4 Tighten the bolt to the spacified torque N m kgf m Ib ft dq Bolt Torque 98 118 10 0 12 0 72 87 gear mark Align the timing mark X Y Z idler gear Sub assemble the bearing to the gear e Apply load only on the inner race of bearing when the bearing will be pressed to the gear PTO gear Sub assemble the bearing to the gear Apply load only on inner race of bearing when the bearing will be pressed to the gear EEES KEMLER 019 100004 013 100005 0138100007 Gearcase PTO Install the idler gear C and PTO gear to the gearcase Gearcase cover 1 Apply sealant to the gearcase 2 Install the gearcase cover to the gearcase 3 Tighten the bolts to the specified torque N m kgf m Ib ft Bolt Torque 14 24 14 24 1 0 17 M12 75 91 7 6 9 3 55 67 4 Install the oil feed pipe to the gearcase cover pan 1 Apply sealant TB1207B or equivalant to the No 5 bearing cap arches the bearing grooves and the timing gearcase arches as shown in the
14. D Isuzu part number 0 NIPPON DENSO part number Note Always check the identification number before begin ning a service operation Applicable service data will vary according to the ident ification number Use of the wrong service data will result in starter damage ENGINE ELECTRICALS MAIN DATA AND SPECIFICATION NIPPON DENSO Part No 228000 1890 V 12 Rated voltage Rated output kW 2 2 Rating Direction of rotation Viewed from the pinion side Clockwise Clutch type Roller Terminal voltage No Load V 11 5 Minimum current No Load A 120 Starter motor minimum operating speed No Load rpm 4000 Pinion gear Modules 2 75 Number of teeth 9 Outside diameter mmt in 33 0 4 3 Travel distance mm in 1 51 0 059 Yoke outside diameter mmiin 83 0 3 27 Brush length Standard mmi in 16 5 0 65 Limit mmiin 13 0 0 51 Brush spring standard fitting load kg Ib N 3 52 15 7 4 4 19 6 Commutator Outside diameter Standard mm in 35 0 1 38 Limit mmiin 34 0 1 34 Depth of undercut mica Standard 0 7 0 9 0 027 0 035 Limit 0 2 0 008 149 ENGINE ELECTRICALS CIRCUIT ARRANGEMENT FIELD COIL IDLE GEAR EH eessen KR 2 9 e l d D AL lt gt RING PINION
15. 0 008 0 014 1st Compression Ri 0 37 0 52 0 015 0 020 0 2 0 4 0 008 0 016 2nd Compression Ring Oil Ring 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 Piston Ring and Piston Ring Groove Clearance mm in Standard Limit 0 09 0 130 1st Compression Ring 0 0035 0 0051 0 15 0 006 0 05 0 090 2nd Compression Ring 0 002 0 SE 0 03 0 07 0 0012 0 0028 Visually inspect the piston If a piston ring groove is damaged or distorted the piston 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 mmiin Standard 33 995 34 000 1 3384 1 3386 33 970 1 3374 Piston Pin and Piston Clearance Use an inside dial indicator to measure the piston pin hole in the piston Piston Pin Hole Standard 34 004 34 012 1 3387 1 3391 Piston Pin and Piston Pin Hole Clearance mm in 0 004 0 015 0 0002 0 0006 Piston Pin and
16. MAINTENANCE RECOMMENDED LUBRICANTS Diesel engine oil Without turbocharger CC or CD grade ENGINE VISCOSITY CHART ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE Single grade SAE 20 20W Ambient 30 C 15 C 0 C 15 C 25 C 30 temperature 229 0 F 32 F 60 F 80 F 90 F Multi grade 28 MAINTENANCE ENGINE REPAIR KIT All of the numbered parts listed below are included in the Engine Repair Kit SO Cylinder head gasket Cylinder head cover gasket Head cover cap nut gasket Drain cock gasket Crankshaft rear oil seal Gear case gasket Gear case cover gasket pan drain plug gasket pan gasket Oil filter gasket 11 12 13 15 16 17 19 20 21 Water pump gasket Water outlet pipe gasket Thermostat housing gasket Intake manifold gasket Exhaust manifold gasket Crankshaft front oil seal Nozzle holder washer Corrugated washer Heat shield Heat shield washer Cyl block side gasket 29 MAINTENANCE eer een rr E
17. 10 Exhaust manifold 109 ENGINE ASSEMBLY 3 WV Important Operations Reassembly Steps 3 1 Intake Manifold Install the intake manifold gasket with the end hav ing the sharp corners facing the front of the engine 2 Injection Pump Installation 1 Turn the crankshaft slowly clockwise to align the camshaft timing check hole pointer with the camshaft timing gear O mark 2 2 Install the injection pump to the timing gear case Align the injection pump timing check hole pointer 3 with the timing gear mark 3 Tighten the injection pump bracket bolt 6 to the specified torque Injection Pump Bracket Bolt Torque kg m lb ft N m 1 4 2 4 10 1714 24 110 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 kg m Ib ft N m 2 0 4 0 14 29 20 39 9 Starter motor Tighten the starter bolts to the specified torque Starter Bolt Torque kg m Ib ft N m 6 7 8 7 48 63 60 85 10 Exhaust Manifold Tighten the exhaust manifold bolts to the specified torque a little at a time in the numeric
18. Idler Gear End Play mmY in Standard 0 080 0 180 0 003 0 007 ENGINE ASSEMBLY 1 Important Operations Disassembly Steps 3 3 Flywheel 1 Block the flywheel with a piece of wood to pre vent it from turning 2 Loosen the flywheel bolts a little at a time in the numerical order shown in the illustration SZ 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 Note Be careful not to damage the camshaft journal the cam and the camshaft during the disassembly procedure 8 Connecting Rod Cap with Lower Bearing if the connecting rod lower bearings are to be rein stalled mark their fitting positions by tagging each bearing with the cylinder number from which it was removed 9 Piston and Connecting Rod with Upper Bearing 1 Remove carbon deposits from the upper portion of the cylinder wall with a scraper before remov ing the piston and connecting rod 2 Move the piston to the top of the cylinder and tap it with a hammer grip or similar object from the connecting rod lower side to drive it out 38 ENGINE ASSEMBLY 1 If the connecting rod upper bearings are to be rein stalled mark their fitting positions by tagging each bearing with the cylinder number from which it was removed 10 Crankshaft Bearing Cap with Lower Bearing 1 Measur
19. 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 0 029 0 083 0 0011 9 0033 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 Install the bearings to the cylinder body 3 Carefully place the crankshaft on the bearings 4 Rotate the crankshaft approximately 30 to seat the bearing 5 Place the Plastigage arrow over the crankshaft journal across the full width of the bearing 6 Install the bearing caps with the bearing 7 Tighten the bearing caps to the specified torque Crankshaft Bearing Cap Bolt Torque kg m lb ft N m 16 0 18 0 116 130 157 177 Do not allow the crankshaft to turn during bearing cap installation and tightening 8 Remove the bearing cap 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 additionsl 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 cl
20. Replace fan Defective radiator cap or clogged Replace the radiator cap or clean Radiator radiator core the radiator core Water pump Defective water pump Repair or replace the water pump T Cylinder head and cylinder body sealing cap Defective sealing cap resulting in lace the sealing ca water leakage Replace OK Thermostat Defective thermostat Replace the thermostat SEES Continued on the next page 189 TROUBLESHOOTING 6 OVERHEATING Checkpoint Trouble Cause Countermeasure Continued from the previous page OK Cooling system clogged by Clean the foreign material from Cooling system e SZ foreign material the cooling system Fuel injection timing improperly Fuel injection timing adjusted Adjust the fuel injection timing 190 TROUBLESHOOTING 7 WHITE EXHAUST SMOKE Checkpoint Trouble Cause Countermeasure Fuel Water particles in the fuel Replace the fuel Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat Compression pressure Replace the related parts Defective valve seals Replace the valve seals the Worn valves stems and valve P inlet and exhaust valves Valve seals valves and the valve guides guides OK Pis
21. SEAR CLUTCH STARTER SWITCH 150 ENGINE ELECTRICALS DISASSEMBLY Disassembly Steps 1 gt gt gt Somnpunpwnm gt gt Hexagon nut Connecting lead wire Through bolt Starter seal Yoke Brush holder Armature Screw Starter housing Pinion clutch 11 12 13 14 15 16 17 Steel ball Starter pinion Idle gear Retainer Clutch roller Compression return spring Magnetic switch body 151 ENGINE ELECTRICALS 152 WV Important Operations 7 Yoke Starter Housing Magnetic Switch Body Apply setting marks across the end frame the yoke and the magnetic switch body This will ensure reassembly of the parts in their original positions Yoke Remove the yoke from the magntic switch 2 Brushes and Brush Holder Use a pair of long nose pliers to remove the brushes and pull out the brush holder Armature Remove the armature from the yoke Note If necessary tap the yoke end with a plastic hammer to remove the armature ENGINE ELECTRICALS 10 Pinion Clutch Remove the magnetic sub switch from the starter housing Note If the pinion is installed to the starter housing exter nally attached to the magnetic sub switch shaft it must be removed before the magnetic sub switch 11 Steel Ball Remove the steel ball from the pinion clutch 12 Starter Pinion 13 Idler gear Remove the starter pinion and the idler gea
22. ring 3 Apply a coat of molybdenum disulfide grease to the two piston skirts This will faciliate smooth break in when the 22 engine is first started after reassembly 4 Apply a coat of engin oil to the upper bearing surfaces Note Do not apply engine oil to the bearing back faces and the connecting rod bearing fitting surfaces 5 Apply a coat of engine oil to the cylinder wall 101 ENGINE ASSEMBLY 3 102 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 The bearing cap number at the side of the bearing cap and the connecting rod number must be the same Note It is absolutely essential that the bearing caps be installed in the correct direction Reversing the bearing cap direction will result in serious engine damage 10 Apply a coat of engine oil to the threads and setting faces of each connecting rod cap bolt 11 Tighten the connecting rod caps to the specified torque Connecting Rod Cap Bolt Torque kg m lb ft N m 2 8 3 2 45 60 20 23 27
23. 140 Japan TEL 03 5471 1111 First edition Apr 1996 604 01 200K
24. 31 11 Crankcase if so equipped 1 Apply sealant to the No 5 bearing cap arches the bearing grooves and the timing gear case arches at the positions shown in the illustration 2 Apply Isealant to the crankca e cylinder body fitting area 3 Tighten the crankcase bolts to the specified torque a little at a time in the sequence shown in the illustration Crankcase Bolt Torque kg m lb ft N m 1 4 2 4 10 1 17 3 13 7 23 5 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 kg m Ib ft N m 1 4 2 4 10 17 14 24 Note Take care not to damage the O rings when tightening the oil pipe bolts e 13 Crankshaft Rear Oil Seal TYPE 1 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 Oil Seal Installer 5 8840 0141 0 13 Crankshaft Rear Oil Seal TYPE Il 1 Tighten the adapter to the crankshaft rear and section with 2 bolts 2 Insert the oil seal into the peripheral section of adapter 3 Insert the sleeve into the adapter section and 1 tighten it with a bolt M12 x 1 75L 70 until the adapter section hits the sleeve 4 Remove the adapter and the sleeve 5 With the seal pressed in check the dimension of the oil eal section Standard Dimension 12 5 x 0
25. 47 ENGINE ASSEMBLY 1 WV Important Operations 1 Camshaft Timing Gear AAW 2 Thrust Plate 1 Clamp camshaft in a vise Take care not to damage the camshaft 2 Use the universal puller to pull out the camshaft timing gear 2 Universal Puller 5 8840 0086 0 3 Remove the thrust plate 3 48 ENGINE deet 2 SECTION A ENGINE ASSEMBLY 2 TABLE OF CONTENTS ITEM PAGE Inspection and repair 50 49 ENGINE ASSEMBLY 2 INSPECTION AND REPAIR Make the necessary adjustments repairs and part replacements if excessive wear or damage is discovered during inspection 50 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 mea sured values are greater than the specified limit but less than the maximum grinding allowance If the measured values exceed the maximum grind ing allowance the cylinder head must be replaced Cylinder Head Lower Face Warpage mmiin Standard Limit Maximum Grinding Allowance 0 05 0 002 or less 0 2 0 008 0 3 0 012 Cylinder Head Height Reference mm in Standard Limit 91 95 3 620 92 05 3 624 91 65 3 60 Note If the cylinder head lower face is reground valve depression mus
26. Camshaft End Play mm in 0 050 0 114 0 002 0 0044 0 2 0 008 Thrust Plate Replacement Thrust Plate Removal 1 Use the universal puller to remove the camshaft timing gear 2 z Universal Puller 5 8840 0086 0 2 Remove the thrust plate 3 Thrust Plate installation 1 Install the thrust plate 2 Apply engine oil to the bolt setting face and the bolt threads 3 Install the camshaft gear Camshaft Gear Torque kg m lb ft N m 10 0 12 0 72 87 98 118 ENGINE ASSEMBLY 2 The portion to be tested shall be held horizontally not to let the test solution flow The sliding surface of the pin Test liquid should not be applied to the area around the oil port Approximately 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 damege 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 Crankshaft Tufftriding Inspection 1 Use an organic cleaner to thoroughly clean the crankshaft There must be no traces of oil on the surfaces to be inspected 2 Prepare a 5 1096 solution of ammonium cuprous chloride dissolved in distilled water 3 Use a syringe to apply the solution to the surfac
27. ENGINE ASSEMBLY 1 Repair kit Disassembly Steps 2 1 Water by pass hose 10 Cylinder head gasket 2 Thermostat housing A 11 Crankshaft damper pulley 3 Water pump 12 Timing gear case cover A 4 Injection nozzle holder 13 Timing gear cover 5 Glow plug and glow plug connector 14 Timing gear oil pipe 6 Cylinder head cover 15 Idler gear B and shaft A 7 Rocker arm shaft and rocker arm A 16 Idler gear A 8 Push rod 17 Idler gear shaft A 9 Cylinder head Inverted Engine 34 Disassembly Steps 3 anpwn Oilpan Oil pan so crankcase equipped Crankcase If so equipped Fiywheel Fiywheel housing Oil pump with oil pipe Camshaft with camshaft timing gear and thrust plate Timing gear case Connecting rod cap with lower bearing gt gt 10 11 12 13 15 16 ENGINE ASSEMBLY 1 Repair kit Piston and connecting rod with upper bearing Crankshaft bearing cap with lower bearing Crankshaft thrust bearing Crankshaft with crankshaft timing gear Crankshaft upper bearing Tappet Crankshaft rear oil seal Cylinder body 35 ENGINE ASSEMBLY 1 WV Important Operations Disassembly Steps 2 4 Injection Nozzle Holder 1 Remove the nozzle holder fixing nuts 7 Rocker Arm Shaft and Rocker Arm Loosen the rocker arm shaft bracket bolts in numer ical order a little at a time Note Failure to loosen the rocker arm shaft bracket bolts in numerical ord
28. mm in 0 05 or Less 0 0020 Distortion Parallelism 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 0 35 0 014 0 175 0 290 0 0069 0 01 14 IDLER GEAR SHAFT AND IDLER GEAR Idler Gear Shaft Outside Diameter Use a micrometer to measure the idler gear shaft out side diameter the measured value is less than the specified limit the idler gear must be replaced Idler Gear Shaft Outside Diameter mm in 44 945 44 975 1 769 1 771 81 ENGINE ASSEMBLY 2 Idler Gear A Inside Diameter 1 Use an inside dial indicator to measure the idler gear Idler Gear Inside Diameter mmiin 45 0 45 03 45 10 1 7756 If the clearance between the idler gear shaft outside diamerer and the idler gear inside diameter exceeds the limit the idler gear must be replaced idler Gear Shaft and Idler Gear Clearance 0 025 0 085 0 2 0 0010 0 0033 0 008 1 7717 1 7718 Idler Gear B Bearing replacement Use a suitable bar and a bench press or hammer Bearing projection amount should be within the
29. 1 5 16 2 with an asterisk is used for female screws of soft material such as cast iron GENERAL INFORMATION JA ANGULAR NUT AND BOLT TIGHTENING METHOD E 1 Carefully wash the nuts and bolts to remove all oil d and grease 2 Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts 3 Tighten the nuts and bolts to the specified torque snug torque with a torque wrench OR BOLT Snug torque e 4 Draw a line A B across the center of each bolt Center line GENERAL INFORMATION 5 Draw another line C D on the face of each of the parts to be clamped This line should be an extension of the line Draw another line F G on the face of each of the parts to be clamped This line will be in the direction of the specified angle Q across the center E of the nut or bolt Use a socket wrench to tighten each nut or bolt to the point where the line A B is aligned with the tine F G Example Specified Angle and Tightening Rotation 1 6 of a turn c 9 10 GENERAL INFORMATION SPECIAL PARTS FIXING NUTS AND BOLTS Cylinder Head Cover Cylinder Head and Rocker Arm Shaft Bracket kg m Ib ft N m 1 0 2 0 7 14 10 20 Apply engine oil to thread portion 11 _ GENERAL INFORMATION Crankshaft Bearing Cap Connecting Rod Bearing Cap Crankshaft Damper Pulley F
30. 123 459 145 505 167 551 189 597 211 644 233 690 KILOGRAMS TO NEWTON 715 89 813 95 912 02 1010 08 725 69 823 76 921 83 1019 89 735 50 833 57 931 63 1029 70 745 31 843 37 941 44 1039 50 NEWTON TO KILOGRAMS 74 440 84 637 94 834 105 031 75 459 85 656 95 854 106 051 76 479 86 676 96 873 107 071 77 499 87 696 97 893 108 090 103 617 125 633 147 710 169 756 191 802 213 848 235 895 755 11 853 18 951 25 1049 31 78 518 88 716 98 913 109 110 CONVERSION TABLE 105 822 127 868 149 914 171 961 194 007 216 053 238 099 764 92 862 99 961 05 1059 12 79 538 89 735 99 933 110 130 108 026 130 073 152 119 174 165 196 211 218 258 240 304 774 73 872 79 970 86 1068 92 80 558 90 755 100 952 111 149 CONVERSION TABLE PRESSURE POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS 0 0703 0 1406 0 2109 0 2812 0 351 k 3515 0 4218 10 0 7031 0 7734 0 8437 0 9140 0 9843 1 0546 20 1 4764 1 5468 1 6171 1 6874 1 7577 30 2 1795 2 2498 2 3201 2 3904 2 4607 0 5625 0 1 2655 1 9686 2 6717 10 20 30 40 40 60 60 70 80 KILOGRAMS SQUARE TO POUNDS PER SQUARE INCHES i I 7 5 bris Tris ipsi Tires 85 34 128 01
31. 17 4354 20 0771 12 4161 15 0578 17 6995 20 3412 21 1338 21 3979 21 6621 21 9263 22 1904 22 4546 22 7188 22 9830 23 2471 23 5113 5 23 7755 24 0397 24 3038 24 5680 24 8322 25 0963 25 3605 25 6247 25 8889 26 1530 100 26 4172 26 6814 26 9455 27 2097 27 4739 27 7381 28 0022 28 2664 28 5306 28 7947 GALLONS IMP TO LITERS e es es oes oe D ee 4 5459 9 0918 13 6377 18 1836 22 7295 27 2754 31 8213 36 3672 40 9131 50 0049 54 5508 59 0967 63 6426 68 1885 72 7344 77 2803 81 8262 86 3721 95 4639 100 0098 104 5557 109 1016 113 6475 118 1934 122 7393 127 2852 131 8311 140 9229 145 4688 150 0147 154 5606 159 1065 163 6524 168 1983 172 7442 177 2901 186 3819 190 9278 195 4737 200 0196 204 5655 213 6573 222 7491 231 8409 236 3868 240 9327 245 4786 250 0245 259 1163 268 2081 277 2999 281 8458 286 3917 290 9376 295 4835 304 5753 3 313 6671 322 7589 327 3048 331 8507 336 8966 340 9425 354 5802 359 1261 368 2179 372 7638 377 3097 381 8556 386 4015 400 0392 404 5851 413 6769 418 2228 422 7687 427 3146 431 8605 445 4982 450 0441 459 1359 463 6818 468 2277 472 7736 477 3195 490 9572 495 5031
32. 1996_ Injection pump No 104646 1910 NP VE4 11F1200LNP 1593 Company _ ISUZU Pump rotation Counterclockwise viewed from drive side Maker No 8 97136 680 0 Refer to the service manual VE pump 5 Pub No EE14E 11041 for all procedures and details other than the following 1 Test condition 1 1 Nozzle 105780 0060 NP DNOSD1510 Injection pipe 157805 7320 2 x d 6 450mm 1 2 Nozzle holder 105780 2150 Fuel oil temperature 45 5 C 1 3 Nozzle opening pressure 13 0 MPa 133 3 kgf cm Supply pump pressure 20 kPa 0 2 kgf cm 1 4 Joint ass y 157641 4720 Tube ass y 157641 4020 1 5 Test oil ISO4113 or SAE J967d E C Mood Charge air press Difference in Adjustment i r min Settings kPa mmHg delivery cm A Fuimoadadjustmen 900 2 Supply pump 992320140202 KPa kateme Timing mm 4 1 320 5 Start fuel adj 68 0 3 0 m 1 000 st FUL Maximum speed adj 16 5 3 0 1 0009 55 s Tostspecitication 3 1 Timing device N r min 900 1 325 mm 0 6 0 2 1 294 3 2 Supply pump N r min 900 392 29 kPa kgf cm 4 0 0 3 3 3 Overflow delivery N r min 900 cm min 360 130 3 4 Fuel injection quantities Control lever Pump speed Fuel delivery Charge air press position r min cm3 1 000 st kPa mmHg Max speed 58 1 60 4 58 1 1 0 58 5 58 5 16 5 3 0 B
33. 2 Idler Gear A 1 Apply engine oil to the idler gear 1 and the idler gear shaft 2 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 X setting mark with the crankshaft timing gear 3 X setting mark 4 Align the idler gear Y Y setting mark with the camshaft timing gear Y setting mark 5 Tighten the idler gear bolt to the specified torque Idler Gear A Bolt Torque kg m Ib ft N m 3 Idler Gear B 1 Apply engine oil to the idler gear and the idler gear shaft 2 Align the idler gear Z setting mark with the idler gear D Z Z setting mark Idler Gear B Bolt Torque kg m lb ft N m 9 5 11 5 69 83 93 113 105 ENGINE ASSEMBLY 3 3 Idler Gear B and PTO Gear 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 sealant 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 speci fied torque Timing Case Cover Bolt Torque kg m Ib ft N m 1 25 0 4 Bar ne 1 4 2 4 10 17 14 24 7 Crankshaft Damper Pully 1 Block the flywheel ring gear with a piece of wood to prevent it from turning 2 Tighten the crankshaft damper pulley to the specified
34. 4 Strainer case 1 Pump body with rotor and pinion 5 pipe 2 Vane 3 Pump cover 120 LUBRICATING SYSTEM OIL FILTER WITH BUILT IN OIL COOLER Option air DISASSEMBLY Disassembly Steps 5 Safety valve 1 Drain plug 2 Cartridge oil filter 6 Relief valve 3 Oil cooler 7 filter body 4 O ring 121 LUBRICATING SYSTEM ha INSPECTION AND REPAIR Make the necessary adjustments repairs and part replacements if excessive wear or damage is discovered during inspection Relief Vaive 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 kg cm psi kPa 5 8 6 2 82 88 569 608 Oil Cooler Water Leakage At Water Passage 1 Plug one side of the oil cooler water passage 2 Submerge the oil cooler in water 3 Apply compressed air 2 kg cm 28 psi 196 kPa to the other side of the oil cooler water passage If air bubbles rise to the surface there is water lea kage 122 Reassembly Steps 1 Oil filter body A 2 Relief valve A 3 Safety valve 4 O ring t A 5 A 6 7 REASSEMBLY Oil cooler Oil filter cartridge Drain plug LUBRICATING SYSTEM LUBRICATING SYSTEM WV Important Operations 2 Relief Vale Tighten the relief valve to the specified torque Relief Valve Torque kg m lb ft N m 2 5 3 5 18 25 25 34 5 Oil C
35. Bearing The crankshaft upper bearings have an oil hole and an oil groove The lower bearings do not a 1 Carefully wipe any foreign material from the 2 crankshaft upper bearing and the crankshaft upper bearing fitting surfaces 2 Locate the position mark applied at disassembly if the removed crankshaft upper bearings are to be reused 4 Crankshaft with Crankshaft Timing Gear Apply an ample coat of engine oil to the crankshaft Ca journals and the crankshaft bearing surfaces before installing the crankshaft Note Do not apply engine oil to the bearing back faces and the cylinder body bear ng fitting surfaces 99 ENGINE ASSEMBLY 3 5 Crankshaft Thrust Bearing 1 Apply an ample coat of engine oil to the crank shaft 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 Note Be sure that the bearing cap fitting surface is completely free of oil before applying the silicon adhesive Do not allow the silicon adhesive to obstruct the cylinder thread holes and bearings m 2 Install the bearing caps lt The bearing arrow marks must be facing the front of the engine The arrow mark journal number
36. Connecting Rod Small End Bushing Clearance Use a caliper calibrator and a dial indicator to measure the piston pin and connecting rod small end bushing clearance If the clearance between the piston pin and the connect ing rod small end bushing exceeds the specified limit replace the piston pin and or the connecting rod bushing Piston Pin and Connecting Rod Small End Bushing Clearance mm in 0 008 0 019 0 05 0 0003 0 0007 0 002 Connecting Rod Bushing Replacement Connecting Rod Bushing Removal 1 Clamp the connecting rod in a vise 2 Use the connecting rod bushing remover to remove the connecting rod bushing Connecting Rod Bushing Replacer 79 ENGINE ASSEMBLY 2 80 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 fitted with a reamer 2 to ream the piston pin hole Inner Diamter of Small End Bushing mm in 34 008 34 015 1 3389 1 3392 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 If either the measured distortion or parallelism exceed the specified limit the connecting rod must be replaced Connecting Rod Alignment Per Length of 100 mm 3 94 in
37. Partial oil filter Lubricating oil volume lit US gal Oil cooler if so equipped Cooling method Coolant volume engine only lit US gal Water pump Thermostat type Alternator V A Starter Water cooled four cycle in line overhead valve Swirl chamber Dry 4 95 4 x 107 3 76 x 4 21 3 059 187 20 1 710 x 555 x 733 28 0 x 21 9 x 28 9 244 538 1 3 4 2 6 Diesel fuel Bosch VE type Mechanical type 675 725 Throttle type 14 7 150 2 130 Cartridge paper element Sediment water level indicating type 2 94 30 427 0 40 0 016 0 40 0 016 Pressurized circulation Trochoid type Cartridge paper element full flow Not equipped 7 5 1 98 Water cooled built in oil filter Pressurized forced circulation 4 5 1 19 Belt driven impeller type Wax pellet type 12 35 12 2 2 Specifications marked with an asterisk will vary according to engine application GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified kom Ib ft N m Bolt Diameter x pitch mm M6 x 1 0 3 6 29 9 8 ur T REC CET le Hei as Ma x12 ee v M14x15 7 8 11 7 9 5 14 2 11 6 17 4 56 4 84 6 78 5 114 7 68 7 102 7 93 2 139 3 83 9 125 6 113 8 170 6 M16 x 1 5 10 6 16 0 13 8 20 8 16 3 24 5 76 7 1
38. Top Dead Center from the pointer 5 Set dial gauge in the 0 position Measuring device 5 8840 0145 0 6 Turn the crankshaft a little rightwise and leftwise and see if the pointer is stable in the 0 position 7 Turn the crankshaft in the normal direction and read the measuring device s indication at TDC Starting Timing mm in 8 If the injection timing is outside specified range continue with the following steps 9 Loosen the injection pump fixing nuts and bracket bolts 10 Adjust the injection pump setting angle e If injection timing will be advanced move the injection pump away from the engine e injection timing will be retarded move the injection pump toward the engine Tighten the pump fixing nut adjust bolt and pump distribution head plug to the specified torque Pump Fixing Bolt kg m Ib ft N m Injection Pump Distributor Head Plug kg m Ib ft N m 1 7 12 17 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 2008 0 Adapter 5 8531 7001 0 ES 4 Set a comression 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 kg cm psi MPa at 250 rpm 30 427 2 94 22 313 2 16
39. and the nozzle body in clean diesel fuel after lapping Nozzle Body and Needle Valve Inspection Check the nozzle body and the needle valve for damage and deformation The nozzle and body must be replaced if either of these two conditions are discovered during inspection 141 FUEL SYSTEM REASSEMBLY eo Reassembly Steps 1 Nozzle holder 5 Spacer A 2 Adjusting shim 6 injection nozzle 3 Spring 7 Holder nut 4 Pushrod A 8 Retaining nut 142 FUEL SYSTEM WV Important Operations 2 Adjust Shim Adjust Shim Availability mmY in Range 0 10 0 50 0 004 0 020 Increment 0 1 0 004 8 Retaining Nut Tighten to the retaining nut to the specified torque Retaining Nut Torque kg m Ibs ft N m 4 35 39 Injection Nozzle Adjustment 1 Attach the injection nozzle holder to the injection nozzle tester 2 Apply pressure to the nozzle tester to check that the injection nozzle opens at the specified pressure If the injection nozzle does not open at the specified pressure install or remove the appropriate number of adjusting shims to adjust it WARNING TEST FLUID FROM THE INJECTION NOZZLE TESTER WILL SPRAY OUT UNDER GREAT PRESSURE IT CAN EASILY PUNCTURE A PERSON S SKIN KEEP YOUR HANDS AWAY FROM THE INJECTION NOZZLE TESTER AT ALL TIMES 143 FUEL SYSTEM INJ PUMP CALIBRATION DATA ZEXEL No 104746 1910 ISUZU Part No 897 136 6800 Dale 2 IS FEB
40. improperly adjusted Adjust the valve clearance Damaged rocker arm Replace the rocker arm Loose flywheel bolts Retighten the flywheel bolts Worn or damaged crankshaft and or thrust bearings Replace the crankshaft and or the thrust bearings Worn or damaged crankshaft and or connecting rod bearings Replace the crankshaft and or the connecting rod bearings Worn or damaged connecting rod bushing and piston pin Replace the connecting rod bushing and or the piston pin wor E Gelee NG Replace the piston and the cylin cylinder liner 1 rae der liner Foreign material in the cylinder 197 TROUBLESHOOTING DEET DEET DEET lt 00 00 E EEE SE EEE 198 SPECIAL TOOL LIST SECTION 11 SPECIAL TOOL LIST 199 SPECIAL TOOL LIST SPECIAL TOOL LIST 5 8840 2008 1 5 8840 0086 0 Compression Gauge Compression Gauge Adaptor Valve Spring Compressor Valve Guide Replacer Cylinder Liner Installer Camshaft
41. kPa pressure Oil cooler type if so equipped Safety valve opening kg cm psi kPa pressure 114 Trochoid 17 5 4 61 3 85 1000 4 0 57 392 47 53 116 6 127 4 SAE 30 Full flow with cartridge paper element 4 3 4 7 61 67 422 461 0 8 1 2 11 17 78 118 Water cooled 2 3 2 7 33 38 225 265 LUBRICATING SYSTEM GENERAL DESCRIPTION LUBRICATING OIL FLOW iud Warning Light pressure switch Cylinder block oil gallery Idle gear shaft Oil pipe filter and cooler assembly Filter ren _ H Tee oil filter Main flow if so equipped oil filter Relief valve Regulating valve Vacuum pump Camshaft bearing Crank shaft bearing Rocker arm shaft Rocker arm Connecting rod bearing Timing gears Oil strainer Oil pan The 4J Series engine lubricating system is a full flow type Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter It is then delivered to the vital parts of the engine from the cylinder body oil gallery 115 LUBRICATING SYSTEM OIL PUMP 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 116 LUBRICATING SYSTEM MAIN OIL FILTER 117 LUBRICATING SYSTEM OIL
42. kit Connecting rod cap with lower bearing Crankcase If so equipped Oil pump with oil pipe Crankshaft rear oil seal Flywheel housing Flywheel Oil pan pan If so crankcase equipped Inverted Engine Reassembly Steps 2 A A A gt 6 00 MON QU I9 gt gt gt 1 Idier gear shaft Idler gear A Idier gear Timing gear oil pipe Timing case cover Timing gear case cover Crankshaft damper pulley Cylinder head gasket Cylinder head gt gt gt 10 11 Water pump 13 14 15 16 17 ENGINE ASSEMBLY 3 Repair kit Push rod Rocker arm shaft and rocker arm Thermostat housing Water by pass hose Glow plug and glow plug connector seal Injection nozzle holder Cylinder head cover 97 ENGINE ASSEMBLY 3 Reassembly Steps 2a Timing Gear Case PTO 1 Timing gear case 4 PTO Gear 2 Under plate 5 Adapter PTO 3 PTO Idle gear 6 Timing case cover 98 ENGINE ASSEMBLY 3 WV 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 and the cylinder body tappet insert holes 2 2 Locate the position mark applied at disassembly if the tappet is to be reused Note The tappet must be installed before installing the camshaft 3 Crankshaft Upper
43. only the crankshaft pilot bearing outer races with the hammer Do not strike the bearing inner races Bearing damage and reduced bearing service life will result 75 ENGINE ASSEMBLY 2 76 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 If the measured value is between the standard and the specified limit the flywheel may be reground If the measured value exceeds the specified limit the flywheel must be replaced Flywheel Friction Surface Depth 1 mmiin 1 0 0 04 or more Note Because a ridge is produced at the flywheel friction sur face as illustrated do not measure the friction surface wear amount at the non ridge area but be sure to measure it at the rear friction surface which is shown in the illustration by shaded area Ring Gear Inspect the ring gear If the ring gear teeth are broken or excessively worn the ring gear must be replaced Ring Gear Replacement Ring Gear Removai Strike around the edges of the ring gear with a hammer and chisel to remove it p
44. plunger spring Me Worn plunger Worn camshaft In line pump only Worn roller tappet In line pump only nS Worn cam disc VE pump only Continued on the next page 180 Countermeasure Repair or replace the governor lever _ Adjust or replace the regulator valve Replace the plunger spring Replace the plunger assembly Replace the camshaft Replace the roller tappet Replace the cam disc TROUBLESHOOTING 2 UNSTABLE IDLING Checkpoint Trouble Cause Countermeasure wee 4355515 Continued from previous page OK Valve clearance Improperly Adjust the valve clearance Valve clearance adjusted Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat Compression pressure Replace the related parts 181 TROUBLESHOOTING 3 INSUFFICIENT POWER Checkpoint Air cleaner OK Fuel Fuel filter Fuel feed pump Injection nozzle OK Fuel injection pipes ne Continued on the next page 182 Trouble Cause Clogged air cleaner Water particles in the fuel Clogged fuel filter element Defective fuel feed pump Injection nozzle sticking Injection nozzle injection starting pressure too low Improper spray condition Fuel injection pipes damaged or obstructed NG Countermeasure Clean or replace the air cleaner element Replace the fuel Replace
45. replacement procedure The valve and the valve guides must be replaced as a set Never replace only one or the other 44 ENGINE ASSEMBLY 1 _ PISTON AND CONNECTING ROD Disassembly Steps A 1 Connecting rod bearing 5 Connecting rod A 2 Piston ring A 6 Piston pin snap ring 3 Piston pin snap ring A 7 Piston A 4 Piston pin 45 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 Piston Ring 1 Clamp the connecting rod in a vise Take care not to damge 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 Piston ring stretching will result in reduced piston ring tension Piston Pin Snap Ring Piston Pin Use a pair of snap ring pliers to remove the piston pin snap rings 5 Connecting 7 Piston Tap the piston pin out with a hammer and a brass bar If the pistons are to be reinstalled mark their instal lation positions by tagging each piston with the cylinder number from which it was removed 46 ENGINE ASSEMBLY 1 _ CAMSHAFT CAMSHAFT TIMING GEAR AND THRUST PLATE Disassembly Steps 1 Camshaft timing gear 3 Feather key A 2 Thrust plate 4 Camshaft
46. rocker arm fitting portion outside diameter If the measured value is less than the specified limit the rocker arm shaft must be replaced Rocker Arm Shaft Outside Diameter mm in 18 98 19 00 0 747 0 748 18 85 0 742 Rocker Arm Shaft and Rocker Arm Clearance 1 Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter Rocker Arm Bushing Inside Diameter mm in o Limit 19 01 19 03 0 748 0 749 19 05 0 750 2 Measure the rocker arm shaft outside diameter If the measured value exceeds the specified limit replace either the rocker arm or the rocker arm shaft Rocker Arm and Rocker Arm Shaft Clearance mmY in Standard Limit 0 01 0 05 0 0004 0 002 0 2 0 008 58 ENGINE ASSEMBLY 2 3 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 If the contact surfaces have light step wear or scoring they may be honed with an oil stone If the step wear or scoring is severe the rocker arm must be replaced CYLINDER BODY 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 1
47. rust ing 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 If there is continuity the brush holder must be repaired or replaced PINION CLUTCH Pinion Inspection Use your hand to turn the pinion in the direction of star ter motor rotation The pinion should turn freely Try to turn the pinion in the opposite direction The pinion should lock 157 ENGINE ELECTRICALS Reassembly Steps Magnetic switch body Compression return spring Clutch roller Retainer Idler gear Starter pinion Steel ball Pinion clutch Starter housing Screw gt gt gt 158 11 12 13 15 16 17 Armature Brush holder Yoke Starter seal Through bolt Connecting lead wire Hexagon nut 3 X INSULATOR ENGINE ELECTRICALS WV Important Operations 2 Compression Return Spring Apply a coat of engine oil to the compression return spring 3 Clutch Roller 4 Retainer Apply a coat of engine oil to the clutch roller and the retainer 12 Brushes and Brush Holder 1 2 3 4 Install the negative b
48. spec A C Do o ified height d Projection 0 _ 0 4 0 6 0 016 0 024 23 7 24 0 0 933 0 945 TIMING GEAR CASE COVER Replace the crankshaft front oil seal if it is excessively worn or damaged Crankshaft Front Oil Seal Replacement Oil Seal Removal Use a plastic hammer and a screwdriver to tap around the oil seal to free it from the gear case Take care not to damage the oil seal fitting surfaces 82 ENGINE ASSEMBLY 2 Oil Seal Installation 1 Apply a coat of engine oil to the oil seal lip circum ference 2 Use the oil seal installer and the installer grip to insert the oil seal 1 mm 0 039 in into the front por tion of the timing gear case Oil Seal Installer 5 8840 2061 0 83 ENGINE ASSEMBLY 2 trite tire rite ee sesnenssseosussansorsenesessanossesesesesesssssssasssssassessessessessssosessssesessaseseessnsssssssessesanseneunreressesessesesesesnssessstsreetenessspssresespanesasaseseusesassssseceseeserorsseeresesesusseeesesereasssrarssesereuecseseneserenerserseen TOTEM Pree TET ee eee eee Cree eee eee ree ee eee ee eye Teer ee reer eeereee er rere eer ese rere re ee ee Pere 4146 06 2 006 60 6 2 4 86 4 0 00 044 0
49. the related parts Valve clearance improperly adjusted Adjust the valve clearance Valve clearance Valve spring Valve spring weak or broken Replace the valve spring Continued on the next page 184 Checkpoint Continued from the previous page OK Exhaust system Full load adjusting screw seal TROUBLESHOOTING INSUFFICIENT POWER Trouble Cause Countermeasure Exhaust pipe clogged Clean the exhaust pipe Open and improperly set Adjust and reseal the adjusting adjusting screw seal screw 185 TROUBLESHOOTING 4 EXCESSIVE FUEL CONSUMPTION Checkpoint Fuel system Ne Air cleaner idling speed Injection nozzle Fuel injection timing Injection pump OK Valve clearance NS Continued on the next page 186 Trouble Cause Fuel leakage Clogged air cleaner element Poorly adjusted idling speed Injection nozzle injection starting pressure too low Improper spray condition Fuel injection timing improperly adjusted Defective delivery valve resulting is fuel drippage after fuel injection Valve clearance improperly adjusted NG Countermeasure Repair or replace the fuel system related parts Clean or replace the air cleaner element Adjust the idling speed Adjust or replace the injection nozzle Adjust the fuel injection timing Replace the delivery valve Adjust the valve clearance TROUBLESHOOTING 4 EXCESSIVE FUEL CONSUM
50. to install the oil seal to the cylinder body Oil Seal Installwe 5 8840 0141 0 Symbols indicate the type of service operation or step to per formed detailed explanation of these symbols follows 14 Flywheel Housing 1 Apply liquid gasket to the shaded area shown in the illustration 2 Tighten the flywheel housing bolts to the speci fied torque a little at a time in the sequence shown in the illustration Flywheel Housing Bolt Torque kg m b ft N m LIN LS Service data and specifications are given in this table 8 The following symbols appear throughout this Workshop Manual They tell you the type of service operation or step to perform Adjustment REN Removal Installation Disassembly Cleaning Important operation requiring extra care iG Reassembly iets Specified torque tighten Special tool use required or Se Alignment marks 5 recommendedilsuzu tool or tools Commercially available tool use Directional indication required recommended Lubrication oil Inspection ite Measurement eds Lubrication grease Le e D V E Sealant application imm ra GENERAL INFORMATION eg 9 10 11 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 thou
51. to the out side terminals 3 Wind the stator lead wires around the rectifier lead wires included in the Rectifier Service Kit and sol der them 169 ENGINE ELECTRICALS 170 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 mmiin 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 30 Brushes are provided with a line which indicates limit of usage ENGINE ELECTRICALS REASSEMBLY Reassembly Steps gt gt IC regulator Rectifier with brush holder Stator Rear cover and stator Front cover 7 Ball bearing 8 Bearing retainer 9 Rotor with bearing 10 Spacer collar A 11 Pulley and fan 12 Through bolt 171 ENGINE ELECTRICALS WV 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 specifie
52. torque Crankshaft Damper Pulley Bolt Torque kg m lb ft N m 20 1 24 5 145 177 197 240 Take care not to damage the crankshaft damper pulley boss 8 Cylinder Head Gasket The cylinder gasket TOP mark must be facing up Use the head gasket of the thickness 1 65 mm Part No 897066 1970 106 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 q 3 Tighten the cylinder head bolts to the specified po torque in two steps following the numerical iL s order shown in the illustration D Cer NER 1250 W s Qo ER Ds Cylinder Head Bolt Torque kg m Ib ft N m OLY NOO GO 1st stop 2nd stop 3rd stop A gor EIF Ge 4 5 5 5 33 40 44 54 60 75 60 75 11 Rocker Arm Shaft and Rocker Arm Tighten the rocker arm shaft bracket bolts in the numerical order shown in the illustration Rocker Arm Shaft Bracket Bolt Torque kg m lb ft N m 5 0 6 0 36 43 49 59 12 Water Pump 1 Temporarily tighten the water pump bolt marked with an arrow in the illustration This bolt will be tightened to the specified to torque when the alternator adjusting plate is installed 2 Tighten the other water pump bolts to the s
53. 15 7 103 0 156 9 99 8 150 4 135 3 204 0 118 9 177 2 159 9 240 3 M18 x 1 5 15 4 23 0 19 9 29 9 23 4 35 2 i 111 1 166 4 151 0 225 6 143 9 216 3 195 2 391 3 169 3 254 6 229 5 345 2 M20 x 1 5 21 0 31 6 27 5 41 3 32 3 48 5 151 9 228 6 205 9 307 9 198 9 298 7 269 7 405 0 233 6 350 8 316 8 475 6 M22 x 1 5 25 6 42 2 370 555 22 433 049 185 2 305 2 251 1 413 8 267 6 401 4 362 9 544 3 313 2 469 4 424 6 636 5 else 36 6 55 0 43 9 72 5 565 847 264 7 397 8 358 9 539 4 317 5 523 9 430 5 711 0 408 7 612 6 554 1 830 6 7 2 0 3 4 2 8 4 6 3 7 6 1 naut 14 5 24 6 19 6 32 4 20 3 33 3 27 5 45 1 _ 26 8 44 1 36 3 59 8 uio um 4 6 7 0 5 8 8 6 7 8 10 9 33 3 50 6 45 1 68 7 42 0 62 2 56 9 84 3 52 8 78 8 71 6 106 9 DE 7 8 10 9 9 0 13 4 10 9 16 3 52 8 78 8 71 6 106 9 65 1 96 9 88 3 131 4 78 8 118 9 106 9 159 9 ee 10 2 15 2 13 2 19 8 15 6 23 4 73 8 110 0 100 0 149 1 95 5 143 2 129 5 194 2 112 8 169 3 162 8 229 5 An asterisk indicates that the bolts are used for female threaded parts that are made of soft materials such as casting Those shown in parentheses in the strength class indicate the classification by the old standard GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tight
54. 181 7005 185 4859 40 193 0568 196 8422 200 6276 204 4131 208 1985 211 9839 215 7693 219 5548 223 3402 50 230 9110 234 6965 238 4819 242 2673 246 0527 249 8382 253 6236 25774090 261 1945 60 268 7653 272 5507 276 3362 280 1216 283 9070 287 6924 291 4779 295 2633 299 0487 70 306 6196 310 4050 314 1904 317 9759 321 7613 325 5467 329 3321 333 1176 336 9030 80 344 4738 348 2593 352 0447 355 8301 359 6156 363 4010 367 1864 370 9718 374 7573 382 3281 386 1135 389 8990 393 6844 397 4698 401 2553 405 0407 408 8261 412 6115 37 8543 75 7085 113 5629 151 4171 189 2713 227 1256 264 9799 302 8342 340 6884 378 5427 LITERS TO GALLONS U S 1 do Lun cs IU x sewer ERN NN RN NN MN MN NE NE NN MEN 2 1134 2 3775 4 7551 5 0193 7 3968 7 6610 10 0385 10 3027 12 6803 12 9444 15 3220 15 5861 17 9637 18 2279 20 6054 20 8696 10 5669 13 2086 15 8503 18 4920 10 8311 13 4728 16 1145 18 7562 11 0952 13 7369 16 3787 19 0204 11 3594 14 0011 16 6428 19 2846 11 6236 14 2653 16 9070 19 5487 11 8877 14 5295 17 1711 19 8129 12 1519 14 7936
55. 210 85 3018 88 5827 91 8635 95 1444 98 4252 101 7060 104 9869 108 2677 111 5486 114 8294 118 1102 121 3911 124 6719 127 9528 131 2336 134 5144 137 7953 141 0761 144 3570 147 6378 150 9186 154 1995 175 4803 160 7612 164 0420 167 3228 170 6037 173 8845 177 1654 180 4462 183 7270 187 0079 190 2887 193 5696 196 8504 200 1312 203 4121 206 6929 209 9738 213 2546 216 5354 219 8163 223 0971 226 3780 232 9396 236 2205 239 5013 242 7822 246 0630 249 3438 252 6247 255 9055 259 1864 265 7480 269 0289 272 3097 275 5906 278 8714 282 1522 285 4331 288 7139 291 9948 298 5564 301 8373 305 1181 308 3990 311 6798 314 9606 318 2415 321 5223 324 8032 331 3648 334 6457 337 9265 341 2074 344 4882 347 7690 351 0499 354 3307 357 6116 MILES TO KILOMETERS 77 249 78 858 93 342 94 951 101 389 103 000 104 607 106 217 107 826 109 435 111 045 112 654 114 263 115 873 117 482 119 091 120 700 122 310 123 919 125 529 127 138 128 748 130 357 131 966 133 576 135 185 136 794 138 404 140 013 141 622 143 232 144 841 146 450 148 060 149 669 151 278 152 888 154 497 156 106 157 716 159 325 160 934 162 544 164 153 165 762 167 372 168 981 170 590 172 200 173 809 175 418 KILOMETERS TO MILES me miss me mi ne RS 204 CONVERSION TABLE SQUARE INCHE
56. 3 mm Oil Seal Installer 5 8840 2359 0 14 Flywheel Housing 1 Apply sealant to the shaded area shown in the illustration 2 Tighten the flywheel housing bolts to the speci fied torque a little at a time in the sequence shown in the illustration Flywheel Housing Bolt Torque kg m lb ft N m M10x1 25 3 6 4 6 26 33 35 45 M12x1 5 7 5 9 3 54 67 74 91 103 ENGINE ASSEMBLY 3 15 Flywheel 1 Block the flywheel with a piece of wood to pre vent it from turning 2 Apply a coat of engine oil to the threads of the flywheel bolts 3 Tighten the flywheel bolts in the numerical order shown in the illustration Flywheel Bolt Torque kg m lb ft N m 11 5 12 5 83 90 113 123 16 Oil Pan 1 Apply sealant to the No 5 bearing cap arches the bearing grooves and the timing gear arches at the positions shown in the illustration 2 Fit the gasket rear lipped portion into the No 5 bearing cap groove Be absolutely sure that the lipped portion is fitted snugly in the groove is I 3 Tighten the oil pan bolts to the specified torque a little at a time in the sequence shown in the illustration Oil Pan Bolt Torque kg m Ib ft N m 0 6 1 0 4 3 7 2 6 10 104 ENGINE ASSEMBLY 3 V Important Operations Reassembly Steps 2 1 Idler Gear Shaft The idler gear shaft oil hole must be facing up
57. 39 095 671 870 688 257 704 644 721 031 737 418 753 805 770 192 802 966 819 353 835 740 852 127 868 514 884 901 901 289 917 676 934 063 966 837 983 224 999 611 1015 998 1032 385 1048 772 1065 159 1081 546 1097 933 1130 707 1147 094 11 1179 869 1196 256 1212 643 1229 030 1245 417 1261 804 1294 578 1310 965 1343 739 1360 126 1376 513 1392 900 1409 288 1425 675 1458 449 1474 836 1507 610 1523 997 1540 384 1556 771 1573 158 1589 545 1622 319 1638 706 1671 481 1687 868 1704 255 1720 642 1737 029 1753 416 1786 190 163 871 327 741 491 612 655 483 1278 191 1442 062 1605 932 1769 803 CUBIC CENTIMETERS TO CUBIC INCHES 205 CONVERSION TABLE VOLUME GALLONS U 5 TO LITERS uer weis EE 3 7854 7 5709 11 3563 15 1417 18 9271 22 7126 26 4980 30 2834 34 0633 41 6397 45 4251 49 2105 52 9960 56 7814 60 5668 6435231 68 1377 71 9231 10 79 4940 83 2794 87 0648 90 8502 94 6357 98 4211 102 2065 105 9920 109 7774 20 117 3482 121 1337 124 9191 128 7045 132 4901 136 2754 140 0608 143 8462 147 6316 36 155 2025 158 9879 162 7734 166 5588 170 3442 174 1296 177 9151
58. 4 piston is at onthe compression stroke Adjust the No 1 or the No 4 cylinder valve clearances ER while their respective cylinders are at TDC on the com pression stroke Valve Clearance mm in 0 40 0 016 Loosen each valve clearance adjusting screw as shown in the illustration At TDC on the compression stroke of the No 1 cylinder Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end 4 Turn the valve clearance adjusting screw until a slight drag can be felt on the feeler gauge 5 Tighten the lock nut securely 25 MAINTENANCE ge mimo f ORS asl Ci iy sl 55 X 4 OS le 26 Rotate the crankshaft 360 Realign the crankshaft damper pulley TDC line with the timing pointer 8 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 Rotate the crankshaft clockwise to align the cam shaft gear timing mark 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 4 Set crankshaft damper pulley Top Dead Center mark about 45 before
59. 5 0 509 3 3 Tappet and Cylinder Body Clearance mm in Standard Limit 0 03 0 001 0 1 0 004 ENGINE ASSEMBLY 2 Push Rod Curvature 1 Lay the push rod on a surface plate 2 Roll the push rod along surface plate and mea sure the push rod curvature with thickness gauge If the measured value exceeds the specified limit the push rod must replaced Push Rod Curvature Limit 0 3 0 012 3 Visually inspect both ends of the push rod for excessive wear and damage The push rod must be replaced if these conditions are discovered during inspection CAMSHAFT Visually inspect the journals the cams the oil pump drive gear and the camshaft bearings for excessive wear and damage The camshaft and the camshaft bearings must be replaced if these conditions are discovered during inspection Camshaft Journal Diameter Use a micrometer to measure each camshaft journal diameter in two directions X and Y Y If the measured value is less than the specified limit the camshaft must be replaced Camshaft Journal Diameter mm in 49 945 49 975 49 60 1 966 1 968 1 953 66 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 Cam Height mmi in Standard 42 08 1 65 Camshaft Run Out 1 Mount
60. 5 mm 0 43 0 59 If the measured value exceeds the specified limit the cylinder liner must be replaced Cylinder Liner Bore mm in 95 421 95 460 95 5 3 7567 3 7583 3 7598 Note The inside of the dry type cylinder liner is chrome plated it cannot be rebored or honed If the inside of the cylinder liner is scored or scorched the cylinder liner must be replaced Cylinder Liner Projection Inspection 1 Hold a straight edge 1 along the top edge of the cylinder liner to be measured 2 Use a feeler gauge 2 to measure each cylinder liner projection Cylinder Liner Projection mm in 0 0 10 0 0 004 The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0 03 mm 0 0012 in 59 ENGINE ASSEMBLY 2 Cylinder Liner Replacement Cylinder Liner Removal 1 Remove the cylinder body dowel 2 Set the cylinder liner remover to the cylinder liner 3 Check that the remover shaft ankle is firmly gripping the cylinder liner bottom edge 4 Slowly turn the remover shaft handle counterclock wise to pull the cylinder liner free Cylinder Liner Remover Ankle 5 8840 2304 0 Cylinder Liner Remover 9 8523 1169 0 NOTE Take care not to damage the cylinder body upper during the cylinder liner removal procedure Cylinder Body Upper Face Warpage Use a straight edge O and a feeler gauge to measure the four sides and the two diagonals of the cy
61. A 2 Piston pin snap ring A 6 Piston ring A 3 Connecting rod A 7 Connecting rod bearing A 4 Piston pin 90 ENGINE ASSEMBLY 3 WV Important Operations Front mark ISUZU mark 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 The piston head front mark and the connecting rod ISUZU casting mark must be facing the same direction 4 Piston pin 1 Apply a coat of engine oil to the piston pin and the piston pin hole 2 Use your fingers to force the piston pin into the piston until it makes contact with the snap ring 3 Use your fingers to force the piston pin snap ring into the piston snap ring groove 4 Check that the connecting rod moves smoothly on the piston pin 91 ENGINE ASSEMBLY 3 6 Piston Ring 1 Use a piston ring replacer to install the three piston rings Piston Ring Replacer Install the piston rings in the order shown in the illustration Oii ring Coil expander type 2 2nd compression ring Taper type 3 1st compression ring Barrel face type Note Install the compression rings with the stamped side facing up Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil before installing
62. Bearing Replacer Camshaft Timing Gear Universal Puller _ Crankshaft Timing Gear Remover Crankshaft Timing Gear Installer 9 8522 0020 0 9 8840 2000 0 Crankshaft Pilot Bearing Remover 200 SPECIAL TOOL LIST ITEM NO ILLUSTRATION PART NO PARTS NAME 11 5 8840 0019 0 Sliding Hammer 75 Crankshaft P ot Bearing 5 8522 0024 0 Installer 5 8840 2061 0 5 8840 2033 0 Crankshaft Front Oil Seal Installer Valve Stem Oil Seal Installer Crankshaft Rear Oil Seal 5 8840 0141 0 Installer 5 8840 2304 0 9 8523 1169 0 5 8840 2362 0 5 8840 2359 0 Cylinder Liner Remover Ankle Cylinder Liner Remover Rear Oil Seal Remover Rear Cil Seal Installer 201 SPECIAL TOOL LIST AE ENE EPI PN AE EE EEN EE EE EE EE EE EE EE AE EE E EE EE EE EE EE EE P EE EE EE EE EE EE EE EE EE he hae DETETEEEEEEEEEEEETEEEEEEEEEEEEEEEEEETEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEETEEETEEEEEETEETTETTEETTTTTETTTTETTTTTTTTTTETTTTTTETTTTTTTTTETTTEEEEEAAAAAAAAAhAAAhd hd dhh hdh h hdhdh dddeddld g DEET a a a an aaia aianei aaa iaa aaa aa aaa aaa a ia aria aia aia a aian ania a PIP T E E E E EEE T 6 A T A a a a a aae aa aa a a maa aaae aa aaa aaa 066466 0066 a 040066 6 6 a aai PEERI REEE AIEE T EEPE TN E AT A T E E A T TETTEI TERE E EET ALEE T een TEE IE PEEP A E A E LPEE T E
63. Cylinder Liner Installation Using The Special Tool clean the cylinder liners and bores Pu y 2 D 2 D 3 9 a 42 0 22 gt lt 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 into the cylinder body 2 from the top of the cylinder body 4 Set the cylinder liner installer 3 to the top of the cylinder liner Cylinder Liner Installer 5 8840 2313 0 5 Position the cylinder body so that the installer center 3 is directly beneath the bench press shaft center 4 Note Check that the cylinder liner is set perpendicular to the bench press and that there is no wobble 6 Use the bench press to apply a seating force of 500 kg 1 102 5 15 4 900 N to the cylinder liner 7 Apply a force of 2 500 kg 5 512 5 16 24 500 N to fully seat the cylinder liner 8 After installing the cylinder liner measure the cylinder liner projection Refer to Cylinder Liner Projection Inspection 2 Cylinder Liner Installation Using Dry Ice if the cylinder liner is a chrome plated dry type it is advisable to use dry ice during the installation procedure Cooling the cylinder liner with dry ice will cause the cylinder liner to contact thus making insta
64. ENGINE SERVICE MANUAL ISUZU 4JG2 REFERENCE ONLY FORK LIFT HDF20 30 2 SERIES 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 1996 and later models NOTICE Before using this Workshop Manual to assist you in performing engine service and maintenance operations it is recommended that you carefully read and throughly understand the information contained in Section 1 under the headings General Repair Instruction and Notes on The Format of This Manual SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION 10 SECTION 11 SECTION 12 TABLE OF CONTENTS GENERAL 1 MAINTENANCE 2 2 19 ENGINE ASSEMBLY 1 uc 31 DISASSEMBLY ENGINE ASSEMBLY 2 SEEN 49 INSPECTION AND REPAIR ENGINE ASSEMBLY 3 NOR 85 REASSEMBLY LUBRICATING 5 5 MEE COOLING SYSTEM 125 FUEL 5 5
65. N 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 When the coolant temperature reaches 76 5 C 170 F the thermostat will begin to open and a gradually increasing amount of coolant will circulate through the radiator The thermostat will be fully open when the coolant temperature reaches 90 C 194 F of the coolant is now circulating through the radiator for effective engine coolant 127 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 128 COOLING SYSTEM WATER PUMP DISASSEMBLY Disassembly Steps A 1 O ring A 5 Bearing unit 2 Set screw 6 Thrower A 3 Cooling fan center 7 Water pump body A 4 impeiier and seal unit 129 COOLING SYSTEM V 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 wil
66. PTION Checkpoint Trouble Cause Countermeasure Continued from the previous page OK Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat Compression pressure Replace the related parts OK Valve spring Valve spring weak or broken Replace the valve spring 187 TROUBLESHOOTING 5 EXCESSIVE OIL CONSUMPTION Checkpoint Trouble Cause Countermeasure Engine oil unsuitable Replace the engine oil Too much engine oil Correct the engine oil volume Engine oil Oil leakage from the oil seal Replace the oil seal and or the il Oil seal and gasket and or the gasket gasket OK Air breather Clogged air breather Clean the air breather Defective valve seals Inlet and exhaust valves Replace the valve seals the Worn valves stems and valve Valve seals g id s valves and the valve guides OK Replace the piston rings or properly install Piston rings worn broken or Piston rings improperly installed Replace the cylinder liners worn Cylinder liners 188 TROUBLESHOOTING 6 OVERHEATING Checkpoint Trouble Cause Countermeasure Cooling water Insufficient cooling water Replenish the cooling water Fan coupling if so equipped Oil leakage from the fan coupling Replace the fan coupling Fan belt loose or cracked causing Fan belt
67. PUMP t DISASSEMBLY 051 001 Disassembly Steps 4 Vane 1 Oil pi en 5 Pump body with rotor and pinion 2 Strainer case 3 Pump cover 118 LUBRICATING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments repairs and part replacements if excessive wear or damage is dis covered 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 mmiin Standard e 0 02 0 07 0 0008 0 0026 0 15 0 006 Rotor and Vane Clearance Use a feeler gauge to measure the clearance between the rotor and the vane If the clearance between the rotor and the exceeds the specified limit the rotor kit shaft rotor and vane must be replaced Rotor and Vane Clearance mm in Standard 0 14 0 006 or less 0 20 0 008 Vane and Pump Body Clearance Use a feeler gauge to measure the clearance between the vane and the pump body If the clearance between the vane and the pump body exceeds the specified limit the entire pump assembly must be replaced Vane and Pump Body Clearance mmiin Standard Limit 0 20 0 27 0 008 0 011 0 40 0 016 11 LUBRICATING SYSTEM REASSEMBLY Reassembly Steps
68. S TO SQUARE CENTIMETERS 103 226 109 677 116 129 122 580 129 032 135 484 141 935 148 387 154 838 161 290 167 742 174 193 180 645 187 096 193 548 200 000 206 451 212 903 219 354 225 806 232 258 238 709 245 161 251 612 258 064 264 516 270 967 277 419 283 870 290 322 296 774 303 225 309 677 316 128 322 580 329 032 335 483 341 935 348 386 354 838 361 290 367 741 374 193 380 644 387 096 393 548 399 999 406 451 412 902 419 354 425 806 432 257 438 709 445 160 451 612 458 064 464 515 470 967 477 418 483 870 490 322 496 773 503 225 509 676 516 128 522 580 529 031 535 483 541 934 548 386 554 838 561 289 567 741 574 192 580 644 587 096 593 547 599 999 606 450 612 902 619 354 625 805 632 257 638 708 645 160 651 612 658 063 664 515 670 966 677 418 683 870 690 312 696 773 703 224 SQUARE CENTIMETERS TO SQUARE INCHES CUBIC INCHES TO CUBIC CENTIMETERS in e RR emiee ad ei sme ented Led emiteel 16 387 32 774 49 161 65 548 81 935 98 322 1 14 7091 131 097 147 484 180 258 196 645 213 032 229 419 245 806 262 193 278 580 294 967 311 354 344 128 360 515 376 902 393 290 209 677 426 064 442 451 458 838 475 225 507 999 524 386 540 773 557 160 573 547 589 934 606 321 622 708 6
69. al order shown in the illustration _ Exhaust Manifold Bolt Torque kg m Ib ft N m 1 4 2 4 10 17 14 24 12 Alternator and Adjusting Pl te Tighten the alternator bolts and the adjusting plate bolts to the specified torque Alternator Bolt Torque kg m lb ft N m 1 4 2 4 10 17 14 24 Tighten the adjusting plate bolts to the specified torque after cooling drive belt installation Adjusting Plate Bolt Torque kg m lb ft N m 1 4 2 4 10 17 14 24 111 ENGINE ASSEMBLY 3 13 Oil Filter a Tighten the oil filter bolts to the specified torque el Cil Filter Bolt Torque kg m lb ft N m 1 4 2 4 10 17 14 24 112 LUBRICATING SYSTEM SECTION 6 LUBRICATING SYSTEM TABLE OF CONTENTS ITEM Main data and specifications 5 2 114 General description 115 118 Oil filter with built in 121 113 LUBRICATING SYSTEM MAIN DATA AND SPECIFICATIONS Item _ 4JG2 Oil pump type Delivery volume Lit US UK gal min Pump speed rpm kg cm psi kPa Oil temperature C F Delivery pressure Engine oil Oil filter type Relief valve opening kg cm psi kPa pressure Safety valve opening kg cm psi
70. ater separator and the fuel filter where water particles and other foreign material are removed from the fuel Fuel fed by the injection pump plunger is delivered to the injection nozzle in the measured volume at the optimum timing for efficient engine operation 136 FUEL SYSTEM INJECTION NOZZLE Adjust shim Nozzle holder Retaining nut Nozzle 080ET002 The injection nozzle sprays pressurized fuel from the injection pump through the injection nozzle orifices and into the combustion chamber 137 FUEL SYSTEM FUEL FILTER AND WATER SEPARATOR MM nl ooo o RENE Ee EH n H O41ETOOS 041 7004 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 When the float reaches the drain level remind you to drain the water from the water separator 138 FUEL SYSTEM INJECTION NOZZLE DISASSEMBLY Disassembly Steps 1 Retaining nut 5 Pushrod 2 Holder nut 6 Spring A 3 Injection nozzle 7 Adjusting shim 4 Spacer 8 Nozzle holder 139 FUEL SYSTEM V Important Operations 1 2 ME 2 140 Performance this test before d
71. 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 0 02 0 0008 0 10 0 004 Camshaft and Camshaft Bearing Cleareance Use an inside dial indicator to measure the camshaft bearing inside diameter Camshaft Bearing Inside Diameter mmiin 50 0 50 03 50 08 1 9685 1 9696 1 9716 if the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit the camshaft bearing must be replaced Camshaft Bearing Clearance mm in 0 025 0 085 0 0010 0 0033 0 12 0 005 Camshaft Bearing Replacement amshaft Bearing Removal 1 Remove the cylinder body plug plate 2 Use the camshaft bearing replacer to remove the camshaft bearing Bearing Replacer 5 8840 2038 0 67 ENGINE ASSEMBLY 2 68 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 2 push the thrust plate 2 as far as it will go toward the cam shaft gear 2 Use a feeler gauge to measure the clearance between the thrust plate and the camshaft journal If the measured value exceeds the specified limit the thrust plate must be replaced
72. d torque Pulley and Fan Nut Torque kg m lb ft N m 5 0 6 5 36 47 49 64 172 TROUBLESHOOTING SECTION 10 TROUBLESHOOTING TABLE OF CONTENTS ITEM PAGE Hard Starting vore EY RECO DE ERA E RR ORA WEDGES Eee XO dre ADU Va 175 Unstable 179 Insufficient power 182 Excessive fuel consumption Saki dec kos Be as 186 Excessive oil consumption NER add addis 188 Overheating nn ne na ea 189 White exhaust smoke e Le a ara au a 191 Dark exhaust smoKe 2 oe kek oe EROS REA IR Y RU NEE 192 Oil pressure does not 193 Abnormal engine 195 173 TROUBLESHOOTING 174 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 Starting 1 Starter inoperative er E 2 Starter operates but engine does not turn over 3 Engine turns over but does not start Unstable Idling Insufficient Power Excessive Fuel Consumption Excessive Oil Consumption Overhea
73. diode shows no continuity it is open circuit The rectifier assembly must be replaced 4 Touch the circuit tester negative probe to the recti fier holder 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 The recti fier assembly must be replaced Rectifier Negative Diode Continuity Test Use a circuit tester to test the rectifier continuity 1 Touch the circuit tester negative probe to the recti fier holder 2 Touch the circuit tester positive probe to each of the diode terminals in turn 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 The rec tifier assembly must be replaced 4 Touch the circuit tester positive probe to rectifier holder 5 Touch the circuit tester negative probe to each of the diode terminals in turn 6 Note the meter reading for each diode terminal None of the diode should show continuity If a diode shows continuity it is shorted The recti fier assembly must be replaced Rectifier Assembly Replacement Procedure Use the Rectifier Service Kit to replace the rectifier assembly in the following steps 1 Connect the three inside lead wires to the N termi nals 2 Connect the three outside lead wires
74. e by pass valve spring Relief valve sticking and or weak by pass valve spring Relief valve and by pass valve OK Oil pump Clogged oil pump strainer Clean the oil pump strainer Replace the oil pump related parts Worn oil pump related parts Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing m Continued on next page 193 TROUBLESHOOTING 9 OIL PRESSURE DOES NOT RISE Checkpoint Trouble Cause Countermeasure Continued from the previous page OK Replace the camshaft and the camshaft bearings Worn camshaft and camshaft Camshaft bearing Replace the crankshaft and or the bearings Crankshaft and bearings Worn crankshaft and bearings 194 TROUBLESHOOTING 10 ABNORMAL ENGINE NOISE 1 Engine Knocking Checkpoint Trouble Cause Countermeasure Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure Fuel Fuel unsuitable Replace the fuel Fuel injection timing improperly adjusted injection timing Adjust the fuel injection timing Improper injection nozzle starting Adjust or replace the injection Injection nozzle ES pressure and spray condition nozzle Blown out head gasket Replace the head gasket or the Compression pressure N Broken piston ring piston ring 2 Gas Leakage Noise Tighten the exhaust pipe connections Replace the exhaust pipes Lo
75. e the crankshaft end play at the center journal of the crankshaft Do this before removing crankshaft bearing caps imeem s If the measured value exceeds specified limit the crankshaft thrust bearing must be replaced Crankshaft End Play mm in mis 0 10 0 004 0 30 0 012 2 Loosen the crankshaft bearing cap bolts in numerical order a little at a time If the crankshaft bearings are to be reinstalled mark their fitting positions by tagging each bearing with the cylinder number from which it was removed 13 Crankshaft Upper Bearing If the crankshaft upper bearings are to be reinstalled mark their fitting positions by tagging each bearing with the cylinder number from which it was removed 7 14 Tappet If the tappets are to be reinstalled mark their fitting positions by tagging each tappet with the cylinder number from which it was removed ENGINE ASSEMBLY 1 15 Rear Oil Seal With the oil seal pushed in deep install the special tool as shown in the illustration and remove the oil seal Oil Seal Remover 5 8840 2362 0 40 ENGINE ASSEMBLY 1 gt DISASSEMBLY SINGLE UNIT ROCKER ARM SHAFT AND ROCKER ARM Disassembly Steps A 1 Rocker arm shaft snap ring 5 Rocker arm shaft spring A 2 Rockerarm 6 Rocker arm shaft snap ring A 3 Rocker arm shaft bracket 7 Rocker arm shaft 4 7 Rocker arm 41 ENGINE ASSEMBLY 1 42 V important Operations 1 Rock
76. e to be inspected Hold the surface to be inspected perfectly horizontal to prevent the solution from running Note Do not allow the solution to come in contact with the oil ports and their surrounding area Judgement 1 Wait for thirty to forty seconds If there is no discoloration after thirty or forty sec onds the crankshaft is usable If discoloration appears the surface being tested will become the color of copper the crankshaft must be replaced 2 Steam clean the crankshaft surface immediately after completing the test 69 ENGINE ASSEMBLY 2 emeng Note The ammonium cuprous chloride solution is highly cor rosive 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 Crankshaft Run Out mmlin Standard Limit 0 05 0 002 or less 0 08 0 003 Bearing Tension Check to see ifthe bearing has enough tension so that a good finger pressure is needed to fit the bearing into position Crankshaft Journal and Crankpin Diameter 1 Use a micrometer to measure crankshaft journal diameter across points 1 1 and 2 2 2 Use the m
77. earance exceeds the limit the crankshaft and or the bearing must be replaced Crankshaft Journal and Bearing Clearance mmlin 0 031 0 063 0 11 0 0012 0 0025 0 0043 Crankshaft Bearing Selection When installing new crankshaft bearings or replacing old bearings select and install bearing part No 897063 2590 Identification color Black Crankpin and Bearing Clearance 1 Clean the crankshaft the connecting rod the bear ing cap and the bearings 2 Install the bearing to the connecting rod and the bearing cap Do not allow the crankshaft to move when installing the bearing cap 3 Prevent the connecting rod from moving 4 Attach the Plastigage to the crankpin Apply engine oil to the Plastigage to keep it from falling 73 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 kg m lb ft N m 2 8 3 2 20 23 727 31 45 60 7 Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container 6 Remove the bearing cap 2 If the measured value exceeds the specified limit perform the following additional steps 1 Use micrometer to measure crankpin out f side diameter 2 Use an inside dial indicator to measure the
78. elow 5 0 Idling 350 21 8 2 0 450 Below 5 0 Switch OFF 350 IDLE Magnet valve Max cut in voltage 8 V Test voltage 12 14 V 144 FUEL SYSTEM 4 Control lever angle Full speed S Idling Starting injection quantity adjustment Adjust the specified starting injection quantity Item 2 5 using the adjusting bolt and then lock the nut BOLT dei 6 9 NUT 0 6 0 9 m L 7 4 11 1 145 FUEL SYSTEM T e IILIILLILLILILILIILLLLLLLLLDLLLEI seueepoossosvassoesesasssosocovanesesuosasosessesessosesoessenesesessscosocosevsesosasoesacoeasovesesseoncesooscocvesoocesesoevoesoseesosesoasocsoasoocooscccessesosossesoccssseonasoseeoessocecososooaccaaececescacesesesovassocosescsncecesoposssecocaneces Re EEE EEE EEE Zain TEE DEET ee 06 6 146 ENGINE ELECTRICALS SECTION 9 ENGINE ELECTRICALS TABLE OF CONTENTS ITEM i Starter EE 148 lt 4 44 4 544 4 161 147 ENGINE ELECTRICALS 148 STARTER STARTER IDENTIFICATION NIPPON DENSO starter are identified by name plate attached to the yoke Illustration
79. ening torque values given in the table below are applicable to the bolts unless otherwise specified FLANGED HEAD BOLT kg m Ib ft N m Bolt head 3 61 6 50 4 6 8 5 4 33 8 67 5 88 11 76 1 1 2 0 1 4 2 9 19 3 4 Merl 7 95 14 46 10 78 19 61 4 33 8 67 5 88 11 76 13 74 24 59 18 63 33 34 M10 x 1 25 _ 23 39 3 6 6 4 4 3 7 2 17 35 28 20 23 53 38 24 26 03 44 12 35 30 59 82 31 10 52 07 42 16 70 60 2 3 3 8 3 5 58 4 1 6 8 16 63 27 48 22 55 37 26 25 31 41 95 34 32 56 87 29 65 49 18 40 20 66 68 5 6 8 4 7 9119 8 7 13 0 40 50 60 75 54 91 82 37 57 14 86 07 77 47 116 69 62 92 94 02 85 31 127 48 3 5 9 5 7 3 10 9 8 1 12 2 37 61 56 41 50 99 76 49 52 80 78 83 71 58 106 89 58 58 88 24 79 43 119 64 8 5 12 7 11 7 17 6 12 6 18 9 61 48 91 85 83 35 124 54 84 62 127 30 114 73 172 59 91 13 136 70 123 56 185 34 7 6 11 5 11 1 16 6 11 8 17 7 57 14 85 34 77 47 115 71 80 28 120 06 108 85 162 79 85 34 128 02 115 71 173 57 _ 11 8 17 7 17 1 26 5 18 0 27 1 85 34 128 02 115 71 173 57 125 85 189 50 170 63 256 93 130 19 196 01 176 52 265 76 11 2 16 7 16 6 24 9 17 2 25 7 81 00 120 79 109 83 163 77 120 06 180 10 162 79 244 18 124 40 186 61 168 67 253 01 16
80. er Arm Shaft Snap Ring 2 Rocker Arm 3 Rocker Arm Shaft Bracket 1 2 3 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 arm shaft bracket with the cylinder number from which it was removed ENGINE ASSEMBLY 1 CYLINDER HEAD 4 Disassembly Steps A 1 Split collar 5 Valve stem oil seal 2 Valve spring upper seat 6 Valve spring lower seat 7 Cylinder head 3 Valve spring A 4 Intake and exhaust valves 43 ENGINE ASSEMBLY 1 V Important Operations 1 Split Collar 1 Place the cylinder head on a flat wooden surface 2 Use the spring compressor to remove the split Sellar Ru Ge 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 If there is excessive valve wear or damage the valve must be replaced Refer to Page 54 of Inspection and Repair for the valve and valve seat insert procedure Note If there is excessive valve guide wear or damage the valve guide must be replaced Refer to Page 53 of Inspection and Repair for the valve guide
81. er a little at a time will adversely effect the rocker arm shaft 9 Cylinder Head Loosen the cylinder head bolts in numerical order a little at a time Note z Failure to loosen the cylinder head bolts in numerical order a little at a time will adversely effect the cylinder head lower surface 11 Crankshaft Damper Pulley 1 Block the flywheel with a piece of wood to pre vent it from turning 2 Use the damper pulley remover to remove the damper pulley Damper Pulley Remover 36 ENGINE ASSEMBLY 1 216 Idler Gear A Measure the camshaft timing gear backlash the crankshaft timing gear backlash and 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 mea sured Hold both the gear to be checked and the adjoining gear stationary 2 2 Move the gear to be checked as far as possible to both the right and the left Take the dial indicator reading If the measured value exceeds the specified limit the timing gear must be replaced Timing Gear Backlash mmY in Standard Limit 0 10 0 17 0 0039 0 0067 0 30 0 012 Gear A End Play Measurement Insert a feeler gauge between the idler gear and the thrust collar to measure the gap and determine the idler gear end play If the measured value exceeds the specified limit the thrust collar must be replaced
82. etossesoresssceeesshesesousesstoveosssosesecsocoscsscesosssvososostvoecoaootet ssoscsoceseetesssoevesosessosesseeesossaesesqeseesqeneceeosesveeeeeesetesseetoaeevevaoocssecseseqocovossesonee qertetetoemsnumsesseste esset 2 66065480044 060 04600 6 4 0 06060660 06620 0 609960900009 960606 6400044 6600460 604 400640666 06 449 0 60 46 96600646 460060540459 64640604800 66 0 04466 0 4 514 44 42 0 2440004 6006620 000006 00 00 6 USER 442 02 465000 04 66 406960 6 0006 06 06 406 06 6 66 9 lt 990990 6 0066994606609060006 0 066004646 4 0406 06 44446 444 6644944449404044404400000 0 000 02 660006 0 6 6006000660000606 0 0 8 4 909009496 90 00606 0060 0666606900946606640 6666 64 6 4 6 06 0 00064409606 66 lt 6 00065 0 00444000694066080600006606 66 6 6 En 554455455 51555010100015055405100550400000 0204014 001 606 5165 150 5 001 0 0 1 1016 E O AEE EEN MAINTENANCE SECTION 2 MAINTENANCE TABLE OF CONTENTS ITEM NEM PAGE Model identification
83. f bearing inside diameter If the crankpin and bearing clearance exceeds the specified limit the crankshaft and or the bearing must be replaced Crankpin and Bearing Clearance mm in 0 029 0 066 0 10 0 0011 0 0026 0 0039 Crankshaft Timing Gear Replacement Crankshaft Timing Gear Removal 1 Use the crankshaft gear remover 1 to remove the crankshaft gear 2 2 Remove crankshaft feather key Crankshaft Timing Gear Remover 9 8840 2057 0 Crankshaft Timing Gear Installation 1 Install the crankshaft gear 2 Use the crankshaft gear installer 4 to install the crankshaft gear 2 The crankshaft gear timing mark X X must be facing outward Crankshaft Gear Installer 9 8522 0020 0 74 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 bear ing 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 Tap around the edges of the crankshaft pilot bearing outer races with a brass hammer to drive the bear ing into the crankshaft bearing installation hole Pilot Bearing Installer 5 8522 0024 0 Note Strike
84. f the engine 2 Install the rocker arm shaft together with the rocker arm the rocker arm shaft bracket and the spring 87 ENGINE ASSEMBLY 3 CYLINDER HEAD 4 Reassembly Steps 1 Cylinder head A 5 Valve spring 2 Valve spring lower seat 6 Valve spring upper seat A 3 Valve stem oil seal A 7 Splitcollar A 4 Intake and exhaust valve 88 ENGINE ASSEMBLY 3 V 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 Valve Spring 1 Turn the cylinder head up to install the valve springs 2 Install the valve springs with the fine pitched end painted pink facing down Take care not to allow the installed valves to fall free 7 Split Collar 1 Use the spring compressor to push the valve spring into position Spring Compressor 9 8523 1423 0 2 Install the split collar to the valve stem 3 Set the split collar by tapping around the bead of the collar with a rubber hammer 89 ENGINE ASSEMBLY 3 PISTON AND CONNECTING ROD Reassembly Steps A 1 Piston 5 Piston pin snap ring
85. ght 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 Components and parts are listed in the singular form throughout the Manual Directions used in this Manual are as follows Front E 4 The cooling fan side of the engine viewed from the flywheel Right The right hand side viewed from the same position Left The teft hand side viewed from the same position Rear The flywheel side of the engine Cylinder numbers are counted from the front of the engine The front most cylinder is No 1 and rear most cylinder is the final cylinder number of the engine The engine s direction of rotation is counterclockwise viewed from the flywheel GENERAL INFORMATION MAIN DATA AND SPECIFICATIONS a Engine type Combustion chamber type Cylinder liner type No of cylinders Bore x Stroke mm in Total piston displacement cc cid Compression ratio To 1 Engine dimensions mmiin Length x Width x Height Engine weight Dry kg Ib Fuel injection order Fuel injection timing B T D C degrees Specified fuel Injection pump Governor Low idie speed rpm Injection nozzle Injection starting pressure MPa kg cm psi Fuel filter type Water sedimentor if so equipped Compression pressure MPa kg cm2 psi Valve clearance at cold Intake mm in Exhaust mmiin Lubrication method Oil pump Main oil filter type
86. iameter Refer to the Item Valve Stem Outside Diameter Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter Valve Guide Replacement Valve Guide Removal Use a hammer and the valve guide replacer to drive out the valve guide from the cylinder head lower face Valve Guide Replacer 9 8523 1212 0 53 ENGINE ASSEMBLY 2 Valve Guide Installation 1 Apply engine oil to the valve guide outer circumfer ence 2 Attach the valve guide replacer to 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 51 Note If the valve guide has been removed both the valve and the valve guide must be replaced as a set VALVE AND VALVE SEAT INSERT Valve Stem Outside Diameter Measure the valve stem diameter at three points If the measured value is less than the specified limit the valve and the valve guide must be replaced as a set Valve Stem Outside Diameter mmyY in eee 7 946 7 961 7 88 Intake Valve 0 3128 0 3134 0 3102 Val 7 921 7 936 7 850 xhaust Valve 0 3118 0 3124 0 3099 Valve Thickness Measure the valve thick
87. icrometer to measure the crankshaft journal diameter at the two points 3 and 4 8 Repeat Steps 1 and 2 to measure the crankpin diameter If the measured values are less than the limit the crankshaft must be replaced 70 ENGINE ASSEMBLY 2 Crankshaft Journal Diameter mmiin 69 917 69 932 69 910 2 7526 2 7531 2 7524 Crankpin Diameter mmiin Standard Limit 52 915 52 930 52 906 2 0833 2 0839 2 0829 Crankshaft Journal and Crankpin Uneven Wear mm in 0 05 0 002 or less 0 08 0 003 Crankshaft Journal and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankshaft journal diameter exceeds the specified limit the bearing and or the crankshaft must be replaced Crankshaft Bearing Cap Bolt Torque kg m Ib ft N m 16 0 18 0 116 130 157 177 Crankshaft Journal and Bearing Clearance mm in Standard Limit 0 031 0 063 0 0012 0 0025 0 11 0 0043 Connecting Rod Bearing Inside Diameter 1 Install the bearing to the connecting rod big end 2 Tighten the bearing cap to the specified torque Connecting Rod Bearing Cap Bolt o Q 3 2 2 8 3 2 45 60 20 23 727 31 3 Use inside dial indicator to measure connect ing rod bearing inside diameter ENGINE ASSEMBLY 2 72 Crankpin and Bearing Clearance
88. ier caliper to measure the slip ring outside diameter If the measured value exceeds the limit the rotor must be replaced Slip Ring Outside Diameter mm in 31 6 1 24 30 6 1 20 166 ENGINE ELECTRICALS 2 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 Note the circuit tester reading The circuit tester should register approximately 9 ohms 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 If there is still no rotor coil continuity the rotor must be replaced Rotor Coil Ground Test Use an circuit tester to test the rotor coil for grounding aj Touch the other circuit tester probe to one of slip Touch one of the circuit tester probes to the rotor shaft rings Note the circuit tester reading Touch the circuit tester probe to the other slip ring Note the circuit tester reading The circuit tester should show infinity no needle movement at both measuring points If the circuit tester does not show infinity the needle moves at both measuring points the rotor is grounded and must be replaced STATOR COIL Stator Coil Continuity Test Use an circuit tester to test the stator coil continuity Touch the circuit tester probe
89. illustration 2 Fit the gasket rear lipped portion into the No 5 bear ing cap groove i Be absolutely sure that the lipped portion is fitted snugly in the groove 3 Tighten the oil pan nuts and bolts to the specified torque a little at a time in the sequence shown in the illustration N m kgf m Ib ft Pan Nut and Bolt Torque 14 24 1 4 2 4 10 17 1 4JG2 IDE 2290 PAGE 12 CORRECTION 2 4JG2 IDE 2290 PAGE 104 Oil pan fixing torque in case of the engine specification which is not equipped with the crankcase CORRECTION 3 Tighten the oil pan bolts to the specified torque a little at a time in the sequence shown in the illustration Oil Pan Bolt Torque kgf m lIb ft N m 1 4 2 4 10 1 17 3 13 7 23 5 3 4JG2 IDE 2290 PAGE 104 Oil pan fixing torque in case of the engine specification which is equipped with the crankcase ADDITION Tighten the oil pan bolts to the specified torque starting from and alternately as shown in the illustration and work out toward the arrow directions Oil Pan Bolt Torque kgf m Ib ft N m 0 6 1 0 4 4 7 2 5 9 9 8 Copyright reserved for this manual may not reproduced or copied in whole or in part without the written consent of ISUZU MOTORS LIMITED WORKSHOP MANUAL INDUSTRIAL 4482 IDE 2290 Issued by ISUZU MOTORS LIMITED ENGINE SALES PLANNING OFFICE 6 26 1 Minami oi Shinagawa ku Tokyo
90. is will ensure a smooth reassembly operation is especially important to keep fastening parts separate These parts vary in hardness and design depending on their installation position All parts should be carefully cleaned before inspection or reassembly Oil ports and other openings should be cleaned with compressed air to make sure that they are completely free of obstructions Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly 8 If necessary use a sealer on gaskets to prevent leakage zech Nut and torque specifications should be carefully followed 10 Always release the air pressure from any machine mounted air tank s before die aetna the engine or disconnecting pipes and hoses To not do so is extremely dangerous Always check and recheck your work No service operation is compiete untii you have done this NOTES ON THE FORMAT OF THIS MANUAL This Workshop Manual is applicable to ISUZU industrial engine or engines which is or are stated in the title When more than two engine models are dealt in the manual such engines have common parts and components as well as data and specifications unless otherwise specified 1 Find the applicable section referring to the Table of Contents at the beginning of the Manual 2 Common technical data such as general maintenance items service specifications and tightening torques are included in the Gene
91. isassembling the injection nozzle Install the injection nozzle to the nozzle tester Use the nozzie tester to apply compressed fuel at 14 7 MPa 150 kg cm 2 130 psi to the injection nozzle 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 Injection Nozzle Remove the injection nozzles from the nozzle holders The nozzle needle valve and combinations must be interchange Immerse the injection nozzles in a tool tray filled with clean diesel fuel to protect them from dust nozzle body FUEL SYSTEM INSPECTION AND REPAIR Make the necessary adjustments repairs and part replacements if excessive wear or damage is discovered during inspection 080 003 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 If the nozzle needle does not moves smoothly it must be repaired See Nozzle Lapping Procedure below Nozzle Lapping Procedure 1 Lap the nozzle needle and the nozzle body by applying a compound of oxidized chrome and animal oil 3 Note Do not apply an excessive amount of the oxidized chrome and animal oil compound to the injection needle valve seat area 2 Carefully wash the needle valve
92. l allow the new fuel filter to seat properly Apply a light coat of engine oil to the O ring Turn in the fuel filter until the sealing face comes in contact with the O ring Turn in the fuel filter an additional 2 3 of a turn with a filter wrench Filter Wrench 5 8840 0253 0 J 22700 21 MAINTENANCE 8 Loosen the bleeder plug on the injection pump overflow valve 9 Operate the priming pump until fuel begins to flow from the fuel filter 10 Retighten the bleeder plug 11 Operate the priming pump several times and check for fuel leakage The use of ISUZU genuine fuel filter is strongly recommended Water Separator Water Sedimentor Optional Equipment Check the water separator float 1 level If the float has reached level loosen the drain plug 3 at the bottom side of the water separator to drain the water Drain Plug Torque kg m lb ft N m Fuel Filter with Water Level Sensor Water Draining Procedure The indicator light will come on when the water level in the water separator exceeds the specified level Drain the water and foreign material from the water separator with the following procedure 1 Open the engine hood and place a container Approxi mately 0 2 liter capacity at the end of the vinyl hose beneath the drain plug on the separator 2 Loosen the drain plug by turning it counterclockwise Approximately 5 turns and operate the priming pump u
93. l result 130 COOLING SYSTEM ST INSPECTION AND REPAIR Make the necessary adjustments repairs and part replacements if excessive wear or damage is discovered during inspection Bearing Unit Check bearing for abnormal noise biding and other abnormal conditions 131 COOLING SYSTEM REASSEMBLY Reassembly Steps 1 Water pump body A b Impeller and seal unit 2 Thrower A 6 Cooling fan center A 3 Bearing unit 7 O ring A 4 Setscrew 132 COOLING SYSTEM WV Important Operations 3 Bearing Unit 4 SetScrew 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 Apply a thin coat of liquid gasket to the seal unit outer periphery 2 Install the seal unit 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 i 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 The water pump assembly must be replaced whenever the fan center and impeller pressure force falls below 200 kg 3 Do not attempt to strike the bearing into position with a hamme
94. linder body upper face Cylinder Body Upper Face Warpage mmY in 0 05 0 002 or less 0 2 0 008 If the measured value is more than limit cylinder body must be replaced Cylinder Body Height Reference i mm in Standard 272 945 273 105 10 7458 10 7521 60 ENGINE ASSEMBLY 2 Cylinder Liner Grade Selection Measure the cylinder body inside diameter and select the appropriate cylinder liner grade Standard Fitting Interference mmY in 0 001 0 019 0 0004 0 00075 If the cylinder liner fitting interference is too small engine cooling efficiency will be adversely affected If the cylinder liner fitting interference is too large it will be difficult to insert the cylinder liner into the cylinder body Cylinder Body Bore Measurement 1 Take measurements at measuring point 1 across positions W X X Y Y and Z Z Measuring Point D 88 mm 3 46 in 2 Calculate the average value of the four measure ments to determine the correct cylinder grade Cylinder Liner Outside Diameter Measurement 1 Take two measurements each at measuring points and Measuring Point 20 mm 0 79 in Measuring Point 50 mm 1 97 in Measuring Point 150 mm 5 90 in 2 Calculate the average value of the six measure ments to determine the correct cylinder liner grade 61 ENGINE ASSEMBLY 2 Cylinder Liner Installation 1
95. llation easier Note It is important that the cylinder liner be inserted to the cylinder body immediately after it has been cooled 62 ENGINE ASSEMBLY 2 eg WARNING DRY ICE MUST BE USED WITH GREAT CARE CARE LESS HANDLING OF DRY ICE CAN RESULT IN SEVERE FROSTBITE Cylinder Bore and Cylinder Liner Outside Diameter Combination Reference mm in Cylinder Liner Cylinder Bore Outside Diameter 97 001 97 010 97 011 97 020 3 8189 3 8193 3 8193 3 8197 2 97 011 97 020 97 021 97 030 3 8193 3 8197 3 8197 3 8201 3 97 021 97 030 97 031 97 040 3 8197 3 8201 3 8201 3 8205 41 021 41 000 41 04 41 05 63 ENGINE ASSEMBLY 2 64 Piston Grade Selection Measure the cylinder liner bore after installing the cylinder liner Then select the appropriate piston grade for the installed cylinder liner 1 Measure the cylinder liner bore There are two measuring points D and Measure the cylinder liner bore in four different direction W W X X and Z Z at both mea suring points EE Calculate the average value of the eight measure ments to determine the correct cylinder liner bore Measuring Points 1 20 mm 0 79 2 160 mm 6 30 in Cylinder Liner Bore mm in 95 421 95 460 95 5 3 7567 3 7583 3 7598 Note It is most important that the correct piston grade be used Failure to select the cor
96. lternator A Crankshaft damper pulley B Alternator pulley C Cooling fan drive pulley D Depress the drive belt mid portion with a 10 kg 22 15 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 Check the thermostat initial opening temperature Thermostat Initial Opening Temperature C F 76 5 170 4 Check the thermostat full opening temperature Thermostat Full Opening Temperature C F 90 194 Valve Lift at Fully Open Position mm in 8 0 0 31 Thermostat E Agitating Rod 3 Wooden Piece 24 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 kg m lb ft N m 5 0 6 0 36 43 49 59 s 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 1 intake and exhaust valve push rods If the No 1 cylinder intake and exhaust valve push rods have play the No 1 piston is at TDC on the compression stroke if the No 1 cylinder intake and exhaust valve push rods are depressed the No
97. lywheel and Pan kg m lb ft N m 2 8 3 2 gt 45 60 20 23 27 31 Apply engine to thread portion 16 0 18 0 116 130 157 177 Apply engine oil to thread portion 12 GENERAL INFORMATION Timing Gear Case Flywheel Housing Camshaft and Timing Gear kg m Ib ft N m 3 6 4 6 26 33 35 45 15 93 54 67 74 91 10 0 12 0 72 87 98 118 1 0 1 5 7 11 10 15 13 GENERAL INFORMATION Cooling and Lubricating System kg m lb ft N m 1 4 2 4 17 14 24 10 24 1 4 2 4 10 17 14 24 N 10 17 14 24 10 17 14 24 1 4 2 4 10 17 14 1 4 2 4 10 17 14 24 14 JA GENERAL INFORMATION Intake and Exhaust Manifold kg m lb ft N m 1 4 2 4 10 17 14 24 ZN vii v D o V 1 10 17 14 24 GENERAL INFORMATION Engine Electrica kg mi lb ft N m 1 4 2 4 1 5 2 0 10 17 14 24 11 14 15 20 1 4 2 4 10 17 14 24 6 7 8 7 49 63 66 86 16 GENERAL INFORMATION Fuel Injection System kg m lb ft N m 1 4 2 4 10 17 14 24 1 4 2 4 10 17 14 24 17 GENERAL INFORMATION MEMO dd ET E T EE E I TTT 744 4544 4 4 0 e mue soie rehenes etes tetese eesoeeseetoses
98. must corre spond to the journal to which the bearing cap is installed 3 Apply a coat of engine oil to the bearing cap bolts Tighten the crankshaft bearing cap bolts to the specified torque a little at a time in the sequence shown in the illustration Crankshaft Bearing Cap Torque kg m lb ft N m 16 0 18 0 116 130 157 177 5 Check to see that the crankshaft turns smoothly by rotating it manually 2 7 Timing Gear Case 1 Tighten the timing gear case with timing gear a case gasket to the specified torque Timing Gear Case Bolt Torque kg m lb ft N m 1 4 2 4 10 17 14 24 2 Cut away any excessive flash from the timing gear gasket 100 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 kg m lb ft N m 1 4 2 4 10 17 14 24 4 Check to see that the camshaft turns smoothly by rotating it manually 9 Piston and Connecting Rod with Upper Bearing 10 Connecting Rod Bearing Cap with Lower Bearing 1 Apply a coat of engine oil to the circumference of each piston ring and piston 2 Position the piston ring gaps as shown in the illustration D 1st compression ring 2 2nd compression ring 3
99. nd or the Weak brush spring brush spring OK Piston crank bearing seizure Repair or replace the related Engine or other damage parts 176 TROUBLESHOOTING 1 HARD STARTING 3 ENGINE TURNS OVER BUT DOES NOT START Checkpoint Trouble Cause Countermeasure Defective engine stop mechanism Replace the engine stop Engine stop mechanism control wire improperly adjusted mechanism In line pump T Adjust the control wire Defective fuel cut solenoid valve Replace the fuel cut solenoid VE pump valve FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP Fuel Fuel tank is empty Fill the fuel tank OK de Clogged or damaged fuel lines nepalr BETH ms fushings Fuel piping ioosefudllineconnectid s Retighten the fuel line connections OK Fuel filter overflow valve does Repair or replace the fuel filter Fuel filter not close overflow valve A Replace the fuel filter element or Clogged fuel filter element the EE E OK Fuel system Air in the fuel system Bleed the air from the fuel system Continued on the next page 177 TROUBLESHOOTING 1 HARD STARTING 3 ENGINE TURNS OVER BUT DOES NOT START FUEL IS BEING DELIVERED TO THE INJECTION PUMP Checkpoint Continued from the previous page OK Injection nozzle Injection pump Injection pump VE pump 178 Trouble Cause Injection nozzle injection starting pressure too low Improper spray condition Defective fuel injection nozzle resulting in f
100. ner gt gt e Ok eg 164 Ball bearing Front cover Stator S Rectifier with brush holde IC regulator Rear cover ENGINE ELECTRICALS WV Important Operations 3 Pulley and Fan 1 Clamp the rotor shaft in a soft jaw vise 2 Loosen the pulley lock nut 3 Remove the pulley along with the spacer collar 4 Rotor and Bearing 1 Use a plastic hammer or a press 1 to remove the rotor from the front cover 0 2 Remove the spacer collar 8 Front Cover Use screwdrivers to pry the front cover 1 from the stator 0 Note Do not attempt to the coil wires from the stator 9 Stator 10 Rectifier with Brush Holder Use a soldering iron 1 and a pair of long nose pliers 2 to remove the rectifiers Note Hold the rectifier leads between the rectifier and the soldering iron with the long nose pliers This will protect the rectifier from the heat 165 ENGINE ELECTRICALS INSPECTION AND REPAIR Make the necessary adjustments repairs and part replacements if excessive wear or damage is dis covered 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 Use a vern
101. ness If the measured value is less than the specified limit the valve and the valve guide must be replaced as a set Intake and Exhaust Valve Thickness mm in Standard Umi GIE 10 23 ENGINE ASSEMBLY 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 Valve Depression mmY in O Standard mit 0 73 0 029 1 28 0 050 0 70 0 028 1 20 0 047 Valve Contact Width 1 Check the valve contact faces for roughness and unevenness Make smooth the valve contact surfaces 2 Measure the valve contact width If the measured value exceeds the specified limit the valve seat insert must be replaced Valve Contact Width Intake 1 7 0 067 2 2 0 087 2 0 0 079 2 5 0 078 Valve Seat Insert Replacement Valve Seat Insert Removal 1 Arc weld the entire inside circumference 1 of the valve seat insert 2 2 Allow the valve seat insert to cool for a few minutes This will invite contraction and make removal of the valve seat insert easier 55 ENGINE ASSEMBLY 2 3 Use a screwdriver to pry the valve seat insert free Take care not to damage the cylinder head si 4 Carefully remove carbon and other f
102. ombustion chamber the hot plug hole and the hot plug machined faces for cracking and other damage If cracking or damage is present the cylinder head must be replaced Note Be absolutely certain that there are not scratches or protuberance on the combustion chamber surfaces which will be in contact with the hot plug after it is installed There flaws will prevent the hot plug from seating correctly 51 ENGINE ASSEMBLY 2 52 Hot plug installation Inspect the hot plugs for excessive wear and other damage Replace the hot plugs if either of these conditions are discovered 1 Align the hot plug knock ball with the cylinder head groove 2 and tap it temporarily into position with a plastic hammer 2 Place an appropriate metal plate 3 thick over the hot plug upper surface 2 3 Use a press 5 to exert a pressure of 44000 54000N 4500 5500 9923 12128 Ibs on the metal plate covering the hot plug upper surface This will drive the hot plug into position 4 Lightly tap the hot plug heads to make sure that they are firmly seated 5 Repeat the procedure Steps 1 4 for the remaining hot plugs CAUTION Do not apply pressure greater than that specified Dam age to the cylinder head will resuit 6 Use a surface grinder to grind off any hot plug surface protuberances The hot plug surfaces must be perfectly flush with the cylinder head 7 After grinding make sure that the hot pl
103. ooler 1 Align the oil filter holes with the body knock pins at installation 2 Tighten the oil cooler to the specified torque Cooler Torque kg m lb ft N m 2 5 3 5 18 25 25 34 6 Oil Filter Cartridge 1 Apply engine oil to the O ring 2 Turn in the cartridge oil filter until the filter seal ing face makes contact with the O ring 3 Turn in the cartridge oil filter an additional 1 and 1 4 of a turn 7 Drain Plug Tighten the drain plug to the specified torque Drain Plug Torque kg m lb ft N m 1 0 2 0 7 2 14 9 8 20 124 COOLING SYSTEM SECTION 7 COOLING SYSTEM TABLE OF CONTENTS ITEM PAGE Main data and specifications 126 General description osse een E 127 Water DUM swa 129 Thermo tat acter E 134 125 COOLING SYSTEM MAIN DATA AND SPECIFICATIONS Water pump type Centrifugal impeller Pump to crankshaft speed ratio To 1 1 1 Delivery volume Lit US UK gal min 100 26 3 22 2 Pump speed at 3000 rpm Water temperature at 30 C 86 F EA Pump bearing type Double row shaft Thermostat type Wax pellet with jiggle valve Valve initial opening temperature C F 76 5 170 Valve full opening temperature C F 90 194 Valve lift at fully open position 8 0 0 31 126 COOLING SYSTEM J GENERAL DESCRIPTIO
104. oreign material E from the cylinder head insert bore Valve Seat Insert Installation 1 Carefully place the attachment having a smaller outside diameter than the valve seat insert on the valve seat insert 2 Note The smooth side of the attachment must contact the valve seat insert 2 Use a bench press 3 to gradually apply pressure to the attachment and press the valve seat insert into place Note Do not apply an excessive amount of pressure with the bench press Damage to the valve seat insert will result Valve Seat Insert Correction 1 Remove the carbon from the valve seat insert sur face 2 Use a valve cutter 15 45 and 75 blades to l minimize scratches and other rough areas This will bring the contact width back to the standard value Remove only the scratches and rough areas Do not cut away too much Take care not to cut away unblemished areas of the valve seat surface Valve Seat Angle 45 Note Q Use an adjustable valve cutter pilot Do not allow the valve cutter pilot to wobble inside the valve guide 56 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 Check that the valve contact width is correct Check that the valve seat insert surface is in contact with the entire circumference of the val
105. osely connected exhaust pipes pipes Broken exhaust pipes Replace the washers Tighten the injection nozzles and or the glow plugs Injection nozzles and or glow plugs Loose injection nozzles and or glow plugs Continued on the next page 195 TROUBLESHOOTING Checkpoint Continued from the previous page OK Exhaust manifold Cylinder head gasket Fan belt OK Cooling fan Water pump bearing Alternator or vacuum pump Valve clearance 196 10 ABNORMAL ENGINE NOISE 2 Gas Leakage Noise Trouble Cause Loosely connected exhaust mani fold and or glow plugs Damaged cylinder head gasket 3 Continuous Noise Loose fan belt Loose cooling fan Worn or damaged water pump bearing Defective alternator or vacuum pump Valve clearance improperly adjusted Countermeasure Tighten the exhaust manifold connections Replace the cylinder head gasket Readjust the fan belt tension Retighten the cooling fan Replace the water pump bearing Repair or replace the alternator or the vacuum pump Adjust the valve clearance Checkpoint Valve clearance OK Rocker arm OK Flywheel Crankshaft and thrust bearings Crankshaft and connecting rod bearings Connecting rod bushing and piston pin OK Piston and cylinder liner TROUBLESHOOTING 10 ABNORMAL ENGINE NOISE NG 4 Slapping Noise Trouble Cause Countermeasure Valve clearance
106. p and down about 10 times until water is drained approximately 0 1 liter 3 After draining securely tighten the drain plug by turning it clockwise and operate the priming pump manually up and down several times 4 After starting the engine check see that there is no fuel leak from the drain plug Also check to see that the fuel filter water indicator light has turned off If water separator requires frequent draining have the fuel tank drained fro removal of water at your Isuzu Dealer 22 About 4 MAINTENANCE Air Bleeding 1 Loosen the bleeder screw on the injection pump overflow valve 2 Operate the priming pump until fuel mixed with foam flows from the bleeder screw 3 Tighten the bleeder screw 4 Operate the priming pump several times and check for fuel leakage Injection nozzle Check to see if the spray condition and the injection pressure are normal Adjust them to the specified value respectively when they t meet the standard valve kg cm psi MPa eran Using a nozzle tester adjust injection pressure with a shim Special tool Nozzle tester WARNING TEST FLUID FROM THE INJECTION NOZZLE TESTER WILL SPRAY OUT UNDER HIGH PRESSURE IT CAN EASILY PUNCTURE PERSON S SKIN KEEP YOUR HANDS AWAY FROM THE INJECTION NOZZLE TESTER AT ALL TIMES 23 MAINTENANCE COOLING SYSTEM Cooling Fan Drive Belt Fan belt tension is adjusted by moving the a
107. peci fied torque Water Pump Bolt Torque kg m Ib ft N m 1 4 2 4 10 17 14 24 13 Thermostat Housing 1 Install the thermostat housing 2 Tighten the thermostat housing bolts to the specified torque Thermostat Housing Bolt Torque kg m lIb ft N m 1 4 2 4 10 17 14 24 10 ENGINE ASSEMBLY 3 Nozzle heat shield 108 15 Glow Plug and Glow Plug Connector 1 Tighten the glow plugs to the specified torque Glow Plug Torque kg m lb ft N m 1 5 2 0 11 14 15 20 2 Install the glow plug connectors 16 injection Nozzle Holder 1 Install the heat shield washer and the heat shield to the cylinder head from the nozzle holder installation hole side Lightly tap the flange into place with a brass bar Gasket The heat shield flange side must be facing up NOTE Colgate washer Always install a new heat shield Never reuse the old Gasket heat shield heat shield 2 Tighten the holder nut to the specified torque kg m lb ft N m 6 0 7 0 43 51 59 69 ENGINE ASSEMBLY 3 Lh a D Will d rl Chr Se ixi 8 Reassembly Steps 3 A 1 Intake manifold 11 Dipstick and guide tube A 2 Injection pump A 12 Alternator A 3 Fuelinjection pipe with clip A 13 Oil filter 4 Fuelleak off pipe 14 Fan pulley 5 Fuel pipe IN 15 Cooling fan belt 6 Fuel pipe OUT 16 Cooling fan and spacer 7 Breather hose 8 Oil pipe A 9 Starter motor
108. r from the starter housing 14 Retainer 15 Clutch Roller starter housing 153 ENGINE ELECTRICALS INSPECTION AND REPAIR Make the necessary adjustments repairs and part replacements if excessive wear or damage is dis covered during inspection ARMATURE Armature Short Circuit Test 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 Armature Winding Ground Test Check for continuity across the commutator segments and the core If there is continuity the armature is internally grounded due to insulation failure and must be replaced Armature Winding Continuity Test Check for continuity across the commutator segment If there is no continuity the armature coil is open and must be replaced 154 ENGINE ELECTRICALS Commutator Run Out Test Use a dial indicator and a V block to measure the com mutator runout If the measured value exceeds the limit the commutator must be replaced 0 02 0 0008 0 05 0 002 Fa Commutator Run Out mm in Commutator Outside Diameter Measurement Use a vernier caliper to measure the commutator out side diameter If the measured value exceeds the limit the armature must be replaced Commuta
109. r or similar object Damage to the bearing will result 133 COOLING SYSTEM THERMOSTAT 6 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 3 Check the thermostat initial opening temperature Thermostat Initial Opening Temperature C F 76 5 170 2 4 Check the thermostat full opening temperature Thermostat Full Opening Temperature C F 90 194 Valve Lift at Fully Open Position mm in 8 0 0 31 D Thermostat Agitating Rod Wooden Piece 134 FUEL SYSTEM SECTION 8 FUEL SYSTEM TABLE OF CONTENTS ITEM General description 2 136 Injection nozzle 137 Injection pump data 144 135 FUEL SYSTEM GENERAL DESCRIPTION FUEL FLOW Water separator Fuel filter Over pipe Injection nozzle VE Type 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 w
110. ral Information section The section ENGINE ASSEMBLY is an exception This parts are divided in three sections to facilitates indexing Each section is divided into sub sections dealing with disassembly inspection and repair and reassembly GENERAL INFORMATION BEE 4 When the same servicing operation is applicable to several different units the manual will direct you to the appropriate page 5 Forthe 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 Disassembly Steps 2 1 Water by pass hose 10 2 Thermostat housing A 11 3 Water pump 4 4 injection nozzle holder 12 5 Glow plug and glow plug connector 13 7 6 Cylinder head cover 14 7 Rocker arm shaft and rocker arm 15 8 Push rod 16 9 Cylinder head 17 Repair kit Cylinder head gasket Crankshaft pulley with dust seal Timing gear case cover Timing gear cover Timing gear pipe idler gear B and shaft Idler gear A gear shaft 2 Inverted Engine SS Parts marked with an asterisk are included the repair kit Parts within a square frame are to be removed and installed as a single unit and their disassembly steps or reas sembly steps are sho
111. rect piston grade will result in engine failure Always measure the cylinder bore and select the correct piston grade 2 Measure the piston outside diameter Piston Measuring Point 71 mm 2 80 in Piston Grade mm in 95 365 95 384 95 385 95 404 3 7545 3 7553 3 7553 3 7561 Cylinder Liner and Piston Clearance mm in 0 037 0 075 0 0015 0 0030 Note Cylinder liner kit clearances are preset However the cylinder liner installation procedure may result in slight decreases in cylinder liner clearances Always measure the cylinder liner clearance after installation to be sure that it is correct 4 p ENGINE ASSEMBLY 2 TAPPET AND PUSH ROD 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 1 Normal contact 2 Cracking 3 Pitting 4 Irregular contact ST 5 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 If the tappet is damaged it must be replaced Tappet Outside Diameter Measure the tappet outside diameter with a micrometer If the measured value is less than the specified limit the tappet must be replaced Tappet Outside Diameter Standard Limit 12 97 12 99 0 510 0 511 12 9
112. rush on the brush holder side to the brush holder negative hole 2 The brush holder negative hole is not insulated Install the positive brush 3 on the yoke side to the brush holder positive hole 4 The brush holder positive hole is separated from the plate with the insulator Check that the positive brush lead wires are not grounded Install the brush holder to the yoke Take care not to damage the brush holder or the yoke Do not spill oil on the brush holder or the yoke 159 ENGINE ELECTRICALS 160 13 Yoke 1 Install the yoke to the magnetic switch The yoke must engage the notch on the magnetic switch 2 Securely set the rubber boot to the magnetic switch C terminal 15 Throttle Bolt Tighten the through bolt to the specified torque Through Bolt Torque kg m lb ft N m 1 1 1 5 8 0 10 8 11 15 ENGINE ELECTRICALS ALTERNATOR ALTERNATOR IDENTIFICATION Hitachi generators are identified by name plate attached to the rear cover Illustration Isuzu part number Manufacturer s code number 9 Rated output REG BUILT IN Hitachi 0 Manufacturer s production mark Note Always check the identification number before begin ning a service operation Applicable service data will vary according to the ident ification number Use of the wrong service data will result alternator damaged 161 ENGINE ELECTRICALS MAIN DATA AND SPECIFICATION
113. s to two of the bare stator wires Note the circuit tester reading Move one of the circuit tester probes to a third wire 167 ENGINE ELECTRICALS 4 Note the circuit tester reading 168 3 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 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 8 2 Touch one circuit tester probe to the bear metal surface of the stator Touch the other circuit tester probe to a bare stator lead wire Note the circuit tester reading The circuit tester should show infinity no needle movement If the circuit tester shows a value other than infinity the needle moves the stator is grounded and must be replaced RECTIFIER Rectifier Positive Diode Continuity Test Use an circuit tester to test rectifier continuity 8 2 Touch circuit tester positive probe to rectifier holder Touch the circuit tester negative probe to each of the diode terminals in turns ENGINE ELECTRICALS Eng 3 Note the meter reading for each diode terminal of the diode should show continuity If a
114. t be checked Exhaust Manifold Fitting Face Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage Regrind the manifold cylinder head fitting faces if the measured values are greater than the specified limit but less than the maximum grinding allowance the measured values exceed the maximum grinding allowance the cylinder head must be replaced ENGINE ASSEMBLY 2 Manifold Fitting Face Warpage mm in Standard linit Maximum Grinding Allowance 0 05 0 002 or less 0 2 0 008 0 4 0 016 HOT PLUG Hot plug depression 1 Clean the cylinder head lower side taking care not to damage the hot plug surfaces 2 Use a straight edge and feeler gauge to measure hot plug depression in a straight line from the No 1 hot plug to the No 4 hot plug If the measured value exceeds the limit the hot plugs must be replaced Depression Limit mm in 0 02 0 0008 Hot plug removal 1 Insert a 3 0 5 0 0 12 0 20 in diameter bar into the nozzle holder fitting hole unit it makes contact with the hot plug 2 Lightly tap the bar with a hammer to drive the hot plug free If the measured value exceeds the limit the hot plugs must be replaced Combustion chamber inspection 1 Remove the carbon adhering to the inside of the combustion chamber Take care not to damage the hot plug fitting positions 2 Inspect the inside of the c
115. the fuel filter element or the fuel filter cartridge Repair or replace the fuel feed pump Replace the injection nozzle Adjust or replace the injection nozzle Replace the fuel injection pipes Checkpoint Trouble Cause Continued from the previous page OK Defective regulating valve Injection pump VE pump only Defective delivery valve Defective timer Worn cam disc VE pump only Improper control lever operation Defective injection timing Weak governor spring Continued on the next page TROUBLESHOOTING i een 3 INSUFFICIENT POWER Countermeasure Repair or replace the regulating valve Replace the delivery valve Repair or replace the timer Replace the cam disc Adjust or replace the control lever Adjust the injection timing Repair or replace the injection pump timer Replace the governor spring 183 TROUBLESHOOTING 3 INSUFFICIENT POWER Checkpoint Trouble Cause Countermeasure Continued from the previous page OK Injection pump Worn plunger Replace the plunger assembly Replace the camshaft Worn camshaft In line pump only Worn roller tappet In line pump only Replace the roller tappet Worn cam disc VE pump only Replace the cam disc Blown out cylinder head gasket Worn cylinder liner Piston ring sticking or broken Improper seating between the valve and the valve seat Compression pressure Replace
116. the oil ring 2 Apply engine oil to the piston ring surfaces 3 Check that the piston rings rotate smoothly in the piston ring grooves 7 Connecting Rod Bearing Carefully wipe any oil or other foreign material from the connecting rod bearing back face and the connecting rod bearing fitting surface 92 ENGINE ASSEMBLY 3 CAMSHAFT CAMSHAFT TIMING GEAR AND THRUST PLATE Reassembly Steps 1 Camshaft 3 Thrust plate 2 Feather key A 4 Camshaft timing gear 93 ENGINE ASSEMBLY 3 V Important Operations 4 Camshaft Timing Gear 1 Install the thrust plate D 2 Apply engine oil to the bolt threads 3 Install the camshaft timing gear with the timing mark stamped side facing out Camshaft Timing Gear Bolt Torque kg m lb ft N m 10 0 12 0 72 87 98 118 94 ENGINE ASSEMBLY 3 ee ibl DEET EEE hr rrr rrrt rr Ter rrr rrrirrrririr irre iri iit er eee 56 4 2 446 660400 66 6
117. ting White Exhaust Smoke Dark Exhaust Smoke Oil Pressure Does Not Rise Abnormal Engine Noise TROUBLESHOOTING 1 HARD STARTING 1 STARTER INOPERATIVE Checkpoint Trouble Cause Countermeasure Neutral switch If so equipped Defective neutral switch Replace the neutral switch Loose battery cable terminals Clean and or retighten the bat Batte e Poor connections due to rusting tery cable terminals Battery discharged or weak Recharge or replace the battery Fan belt loose or broken Adjust or replace the fan belt Fusible link Fusible link shorted Replace the fusible link OK Defective starter switch Replace the starter switch or Starter switch starter relay the starter relay OK Starter NG Defective magnetic switch or Repair or replace the magnetic starter relay switch OK Starter Defective starter Repair or replace the starter motor 175 TROUBLESHOOTING en 1 HARD STARTING 2 STARTER OPERATES BUT ENGINE DOES NOT TURN OVER Checkpoint Trouble Cause Countermeasure Loose battery cable terminals Clean and or retighten the bat B avery Poor connections due to rusting tery cable terminals Battery discharged or weak Recharge or replace the battery Fan belt loose or broken Adjust or replace the fan belt OK Starter Defective pinion gear Replace the pinion gear Defective magnetic switch Repair or replace the magnetic switch Brush wear Replace the brush a
118. ton rings Piston rings worn broken or Replace the piston rings or improperly installed properly install Cylinder lines scored or worn Cylinder liners Replace the cylinder liners 191 TROUBLESHOOTING 8 DARK EXHAUST SMOKE Trouble Cause Checkpoin Air cleaner Clogged air cleaner element Injection nozzle injection starting Injection nozzle pressure too low Improper spray condition Fuel injection timing improperly Fuel injection timing adjusted Defective delivery valve resulting Injection pump in fuel drippage after fuel injection Excessive injection volume 192 Countermeasure Clean or replace the air cleaner element Adjust or replace the injection nozzle Adjust the fuel injection timing Replace the delivery valve Adjust the injection volume TROUBLESHOOTING RNC cc cc 9 OIL PRESSURE DOES NOT RISE Checkpoint Trouble Cause Countermeasure Replace the engine oil Correct the engine oil volume Improper viscosity engine oil TER Engine oil 4 9 Too much engine oil Repair or replace the oil pres sure gauge or unit Replace the indicator light Defective oil pressure gauge or unit Defective indicator light Oil pressure gauge or unit Oil pressure indicator light OK Replace the oil filter element or Oil filter Clogged oil filter element the oil filter cartridge Replace the relief valve and or th
119. tor Outside Diameter mm in Limit 35 0 1 38 34 0 1 34 Segment Mica Depth Measurement Use a depth gauge to measure the segment mica depth If the measured value exceeds the limit the segment mica must be undercut Segment Mica Depth mm in 5 0 8 d 03 0 2 0 008 Bearing Inspection Visually inspect the bearing If the bearing is worn or damaged it must be replaced 155 ENGINE ELECTRICALS YOKE i Field Winding Ground Test 22 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 Touch the other probe to the brush There should be continuity If there is no continuity the field windings are open Repair or replace the field windings BRUSH AND BRUSH HOLDER Brush Length Measurement A Use a vernier caliper to measure the brush length If the measured value exceeds the limit the brush and or the yoke must be replaced Brush Length mmiin 16 5 0 65 13 0 0 51 156 ENGINE ELECTRICALS Brush Spring Inspection Visually check the brush spring for weakness and
120. uel drippage after fuel injection Defective injection pump contro rack operation Injection pump plunger worn or stuck Injection pump drive shaft seizure or other damage Injection pump governor spring seizure Countermeasure Adjust or replace the injection nozzle Replace the delivery valve Repair or replace the injection pump control rack Replace the injection pump plunger assembly Replace the injection pump drive sh ft Replace the injection pump governor spring TROUBLESHOOTING 2 UNSTABLE IDLING Checkpoint Trouble Cause Countermeasure idling system idling improperly adjusted Adiust the idling Repair or replace the fast idling speed control device Defective fast idling speed Fast idling speed control device control device Adjust the accelerator control system Accelerator control system improperly adjusted Accelerator control system OK Fuel system Fuel system leakage or blockage Repair or replace the fuel system Air in the fuel system Bleed the air from the fuel system Water particles in the fuel system Change the fuel OK Fuel filter NG Clogged fuel filter element Me the fuel filter cartridge Continued on the next page 179 TROUBLESHOOTING 2 UNSTABLE IDLING Checkpoint Trouble Cause Continued from the previous page OK Defective governor lever operation injection pump Regulator valve improperly adjusted VE pump only Broken
121. ug surfaces are completely free of protuberances The hot plug surfaces must also be free of depres sions Once again lightly tap the hot plug heads to make sure that they are firmly seated Heat shield removal After removing the hot plugs use a hammer 1 and a brass bar 0 to lightly tap the lower side of the seat shield 3 and drive it free ENGINE ASSEMBLY 2 Gasket Nozzle a Colgate washer Nozzle heat shield Gasket heat shield Valve Stem Clearance Standard 0 039 0 071 0 20 ntake Vaive 0 0015 0 0028 0 008 0 064 0 096 Exhaust Valve 0 0025 0 0038 Measuring Method Il 1 2 Heat shield installation Install the heat shield washer and the heat shield to the cylinder head from the nozzle holder installation hole side Lightly tap the flange into place with a brass bar The heat shield flange side must be facing up NOTE Always install a new heat shield Never reuse the old heat shield 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 Move the valve head from side to side Read the dial indicator Note the highest dial indication If the measured values exceed the specified limit the valve and the valve guide must be replaced as a set mm lt in 0 25 0 0098 Measure the valve stem outside d
122. ve VALVE SPRING Valve Spring Free Height Use a vernier caliper to measure the valve spring free height If the measured value is less than the specified limit the valve spring must be replaced Valve Spring Free Height mm in Standard Limit 49 7 1 96 48 2 1 90 Valve Spring Inclination Use a surface plate and a square to measure the valve spring inclination if the measured value exceeds the specified limit the valve spring must be replaced Valve Spring Inclination Standard Limit 1 5 0 06 or less 2 5 0 984 or more Valve Spring Tension Use a spring tester to measure the valve spring tension If the measured value is less than the specified limit the valve spring must be replace Valve Spring Tension Compressed Height Limit 38 9 mm 1 53 in 32 6 71 7 29 0 63 8 i T SQ gZ 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 mmiin Standard Limit 0 2 0 008 0 6 0 024 Rocker Arm Shaft Outside Diameter Use a micrometer to measure the
123. wn in the illustrations respectively The number tells you the service oper ation sequence Removal of unnumbered parts is unne cessary unless replacement is required The Repair Kit indicates that a repair kit is available The parts listed under Disassembiy Steps or Reassembly Steps are in the service operation sequence The removal or installation of parts marked with a triangle A is an important operation Detailed infor mation is given in the text m LL III L GENERAL INFORMATION 7 Below is a sample of the text of the Workshop Manual This is the item shown in the illus tration It is marked with a triangle A 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 Letters and numbers contained in a Camshaft Timing Gear Bolt Torque kg m lb ft N m circle refer to the illustration 22 110 1 0 79 5 7 2 107 8 3 9 8 Special tools are identified by the tool name and or number The illustration shows how the spe cial tool is to be used 13 Crankshaft Rear Seal 1 Apply engine oil to the oil seal lip circumfer ence and the oil seal outer circumference 2 Use the oil seal installer
124. ys check the identification number before beginn ing a service operation Applicable service data will vary according to the ident ification number Use of the wrong service data will result in reduced engine performance and engine damage LUBRICATING SYSTEM Main Oil Filter Replacement Procedure 1 Loosen the drain plug to drain the engine oil 2 Wait a few minutes and then retighten the drain plug 3 Loosen the used oil filter by turning it counterclock wise with a filter wrench Filter Wrench 20 MAINTENANCE Clean the oil filter 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 spec ified level if required 9 Start the engine and check for oil leakage from the main oil filter FUEL SYSTEM Fuel Filter Replacement Procedure 1 Loosen the used fuel filter by turning it counter clockwise with the filter wrench Filter Wrench 5 8840 0253 0 J 22700 Remove the level sensor from the filter by turning it counterclockwise with a wrench Install the level sensor to the new fuel filter with a wrench Level Sensor Torque kg m Ib ft N m Clean the filter cover fitting faces This wil

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