Isuzu 4LB1 Workshop Manual
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Isuzu 4LB1 Workshop Manual

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INDUSTRIAL DIESEL ENGINE 4LB1, 4LC1, 4LE1

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  • Page 1 INDUSTRIAL DIESEL ENGINE 4LB1, 4LC1, 4LE1...
  • Page 2 WORKSHOP MANUAL ISUZU MOTORS LIMITED INDUSTRIAL DIESEL ENGINE 4LB1, 4LC1, 4LE1 ENGLISH - 9806/4000 - ISSUE 1 - FEBRUARY 09 A4-6-RANGE - Printed In England...
  • Page 3 Notes: 9806-4000...
  • Page 4 INDUSTRIAL DIESEL ENGINE 4LB1, 4LC1, 4LE1 MODELS WORKSHOP MANUAL ISUZU MOTORS LIMITED...
  • Page 5 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.
  • Page 6 TABLE OF CONTENTS SECTION 1. GENERAL INFORMATION........SECTION 2.

  • Page 7: Table Of Contents

    GENERAL INFORMATION SECTION 1 GENERAL INFORMATION TABLE OF CONTENTS CONTENTS PAGE GENERAL REPAIR INSTRUCTIONS ............... NOTES ON THE FORMAT OF THIS MANUAL .

  • Page 8: General Repair Instructions

    2. Always use the proper tool or tools for the job at hand. Where specified, use the specially designed tool or tools. 3. Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines. 4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove them.
  • Page 9 GENERAL INFORMATION 6. Each service operation section in this Workshop Manual begins with an exploded view of the applica- ble area. (Example) Major components Figures in parentheses “( )” show the order of disassembling or reassembling. Water Outlet Pipe (5) Packing (6) Thermostat (7) Water Pump ASM (8)
  • Page 10 . . . Specified Torque (Tighten) Special Tool Use Required for Recommended . . . Alignment (Marks) . . . (Isuzu Tool or Tools) Commercially Available Tool Use Required or . . . Directional Indication . . . Recommended . . .

  • Page 11: Appearance

    GENERAL INFORMATION APPEARANCE 1. MODELS 4LC1 AND 4LB1 AND 4LE1 (1) Left side view Fig. 2 (2) Right side view Fig. 3...
  • Page 12 GENERAL INFORMATION 2. MODEL 4LB1T (with turbocharger) (1) Left side view Fig. 4 (2) Right side view Fig. 5...

  • Page 13: Main Data And Specifications

    GENERAL INFORMATION MAIN DATA AND SPECIFICATIONS 1. MODELS 4LB1 AND 4LB1T Engine model(s) 4LB1 4LB1T Item Type In-line water cooled 4-cycle type, OHV: diesel engine Timing drive system Gear drive Number of piston rings Compression rings 2, and oil ring 1 No.
  • Page 14 GENERAL INFORMATION 2. MODELS 4LC1 AND 4LE1 Engine model(s) 4LC1 4LE1 Item Type In-line water cooled 4-cycle type, OHV: diesel engine Timing drive system Gear drive Number of piston rings Compression rings 2, and oil ring 1 No. of cylinders - bore × stroke 4 –...

  • Page 15: Tightening Torque Specifications

    GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified. STANDARD BOLT kg·m (lb.ft/N·m) Strength 4.8 (4T) 9.8 (9T) (7T) Class Refined Non-Refined Bolt Identification Bolt No mark Diameter ×...
  • Page 16 GENERAL INFORMATION TIGHTENING TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to the bolts unless otherwise specified. FLANGED HEAD BOLT kg·m (lb.ft/N·m) Bolt head marking Nominal size (dia. x pitch) 0.5〜0.9 0.6〜1.2 M 6 × 1 (3.61〜6.50/4.6〜8.5) (4.33〜8.67/5.88〜11.76) 1.1〜2.0...

  • Page 17: Angular Nut And Bolt Tightening Method

    GENERAL INFORMATION ANGULAR NUT AND BOLT TIGHTENING METHOD 1. Carefully wash the nuts and bolts to remove all oil and grease. 2. Apply a coat of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts. Fig.
  • Page 18 GENERAL INFORMATION 5. Draw another line [C-D] on the face of each of the parts to be clamped. This line should be an exten- Line sion of the line [A-B]. Fig. 9 6. Draw another line [F-G] on the face of each of the parts to be clamped.

  • Page 19: Tightening Torque On Major Components

    GENERAL INFORMATION TIGHTENING TORQUE ON MAJOR COMPONENTS 1. COOLING FAN AND WATER PUMP kg·m (ft. lbs.) 1.9 - 2.9 (13.7 - 21.0) 1.2 - 1.8 (8.7 - 13.0) 1.2 - 1.8 (8.7 - 13.0) 1.9 - 2.9 (13.7 - 21.0) To cylinder head 1.9 - 2.9 (13.7 - 21.0)
  • Page 20 GENERAL INFORMATION 2. CYLINDER HEAD AND CYLINDER HEAD COVER kg·m (ft. lbs.) 0.8 - 1.2 0.8 - 1.2 (5.8 - 8.7) (With turbocharger) (5.8 - 8.7) 0.8 - 1.2 (5.8 - 8.7) (Without turbocharger) 0.8 - 1.2 0.2 - 0.4 (5.8 - 8.7) (1.4 - 2.9) (Apply salant.)
  • Page 21 4.2 - 5.6 (30.4 - 40.5) 9.5 - 11.5 (68.7 - 83.2) Don't remove this bolt from connecting rod. 3.8 - 4.2 4LB1 (27.5 - 30.4) 2.3 - 2.7 (16.6 - 19.5) 4LC1 110 - 115 deg. 7.5 - 8.5 4LE1 (54.2 - 61.5)
  • Page 22 GENERAL INFORMATION 4. CYLINDER BLOCK AND OTHER COMPONENTS (2) kg·m (ft. lbs.) 2.0 - 2.5 2.5 - 3.5 (14.5 - 18.0) (18.0 - 25.3) 1.5 - 2.5 (10.8 - 18.0) 0.8 - 1.2 (5.8 - 8.7) 1.9 - 2.9 4.0 - 5.0 (13.7 - 21.0) (29.0 - 36.2) 0.8 - 1.2...
  • Page 23 GENERAL INFORMATION 5. CYLINDER BLOCK AND OTHER COMPONENTS (3) kg·m (ft. lbs.) Apply Locktite No.262 (2 locations) 0.8 - 1.2 (5.8 - 8.7) 1.2 - 1.6 (8.7 - 11.6) Rocate 3/4 turn after 0.8 - 1.2 contacted with (5.8 - 8.7) sealing surface.
  • Page 24 GENERAL INFORMATION 6. TURBOCHARGER kg·m (ft. lbs.) 2.2 - 3.2 (15.9 - 23.1) 2.2 - 3.2 (15.9 - 23.1) 1.9 - 2.9 (13.7 - 21.0) 1.0 - 1.5 (7.2 - 10.8) 1.0 - 1.5 (7.2 - 10.8) 0.8 - 1.2 (5.9 - 8.7) Fig.

  • Page 25: Gasket Location

    GENERAL INFORMATION GASKET LOCATION 1. LOCATIONS WHERE GASKETS ARE USED Gasket; joint bolt Gasket; nozzle holder Gasket; nozzle holder Gasket; headcover (※)Sealant should not be Corrugated applied. washer Gasket; heat shield Seal; valve Gasket; Gasket; water outlet pipe cylinder head Gasket;...
  • Page 26 GENERAL INFORMATION 2. LOCATIONS WHERE SEALANT IS APPLIED Location Condition for use Name of Name of Object to be Groove to be sealant Name of part mating part sealed applied Engine oil Oil pan Cylinder block Not provided TB1207C (10W-30) Engine oil Rocker bracket Cylinder head...

  • Page 27: Maintenance

    GENERAL INFORMATION MAINTENANCE 1. VALVE CLEARANCE AND ADJUSTMENT Note: The cylinder head bolts were previously tightened with the “Angular Tightening Method”. Therefore, it is not necessary to retighten the cylinder head bolts before adjusting the valve clearance. Fig. 21 1. Bring the piston in either the No. 1 cylinder or the No.
  • Page 28 GENERAL INFORMATION 2. LUBRICATIN SYSTEM Cartridge (Spin-On) Type Cartridge Removal Remover and Installer: Filter Wrench 1. Loosen the used oil filter by turning it counterclock- wise with the filter wrench. 2. Discard the used oil filter. Installation 1. Wipe the oil filter mounting face with a clean rag. Fig.
  • Page 29 “timing mark”, provided in the Groove mark timing gear case. TDC mark When the value is out of the range of the normal injection timing, adjust it accordingly. * Injection timing 4LB1, 4LC1, 4LE1 BTDC 16° Timing gear case cover Crank Note: pulley The injection timing varies according to the specifica- Fig.
  • Page 30 GENERAL INFORMATION Air bleeding from fuel (automatic air-bleeding system) For the automatic air-bleeding system When the starter switch is set to “OPERATION”, the electromagnetic pump is activated to force-feed fuel to the fuel pipe and the leak-off pipe, and air in the fuel system is automatically bled.
  • Page 31 Check to see if the spray condition and the injection pressure are normal. Adjust them to the specified value respectively when they don’t meet the standard valve. kg/cm (psi) 4LB1 Injection pressure 4LC1 (1920) 4LE1 About 4 Fig. 34 Using a nozzle tester, adjust the injection pressure with a shim.

  • Page 32: Recommended Lubricating Oil

    GENERAL INFORMATION RECOMMENDED LUBRICATING OIL TYPE OF LUBRICANTS (API) DIESEL ENGINE OIL; CC OR CD GRADE ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE SAE 5W–20 [Single grade] SAE 20, 20W SAE 40 SAE 10W SAE 30 Ambient –25°C –20°C...
  • Page 33 ENGINE 27 SECTION 2 ENGINE TABLE OF CONTENTS CONTENTS PAGE DISASSEMBLY ....................28 INSPECTION AND REPAIR .
  • Page 34 ENGINE DISASSEMBLY 1. EXTERNAL PARTS (Left-hand side) Fig. 37 (1) Cooling fan and spacer (2) Fan belt (3) Fan pulley (4) Generator (5) Starter (6) Exhaust manifold and gasket (7) Cylinder head cover and air intake pipe (8) Water outlet pipe and thermostat (9) Water pump assembly...
  • Page 35 ENGINE 29 2. EXTERNAL PARTS (Right-hand side) (12) (13) (10) (11) (14) (16) (17) (15) (18) Fig. 38 (10) Injection pipe ..4 pcs. (11) Fuel hose (12) Fuel leak off pipe (13) Fuel pipe (14) Engine stop solenoid (15) Injection pump housing cover...
  • Page 36 ENGINE Injection pipe Injection pipe Leak off pipe Leak off pipe Fuel pipe Eye bolt Loosen the sleeve nuts on the nozzle holder side and on the injection pump side, and then disconnect the Fuel pipe injection pipes. Disconnect the leak off pipe together with gaskets. Nozzle holder Remove the eye bolt, and then disconnect the fuel Injection pump...
  • Page 37 ENGINE 31 Backlash of timing gear mm (in.) STANDARD LIMIT CRANK GEAR/ 0.04 IDLER GEAR (0.0017) (0.0079) CAM GEAR/ 0.03 IDLER GEAR (0.0012) (0.0079) IDLER GEAR END PLAY mm (in.) STANDARD LIMIT 0.058 – 0.115 (0.0023 – 0.0045) 0.2 (0.0079) CRANKSHAFT END PLAY mm (in.) STANDARD...
  • Page 38 ENGINE 3. INTERNAL PARTS Disassembly Steps (1) Rocker Bracket Assembly (2) Push Rods (3) Rear Hanger (4) Front Hanger (5) Cylinder Head Assembly (6) Cylinder Head Gasket (7) Tappets (8) Oil Pan (9) Oil Strainer (10) Oil Pipe (11) Crank Pulley (12) Flywheel (13) Flywheel Housing (14) Timing Gear Case (without PTO)
  • Page 39 ENGINE 33 Internal Parts (1/3) (14) (18) (17) (16) (15) Fig. 45...
  • Page 40 ENGINE Internal Parts (2/3) (20) (13) Do not pull out this bolt. ※ (12) (21) (10) Rear (19) (11) Fig. 46...
  • Page 41 ENGINE 35 Internal Parts (3/3) When provided with PTO (14-2) (14-1) (15) Fig. 47...
  • Page 42 ENGINE Rocker bracket Install of Push rod bolts (6) Remove the rocker bracket assembly. Install of (M6 × 1 ..5 bolts and 6 nuts) bolts (5) Pull out the push rods (8 pcs.). Rocker Bracket Fig.
  • Page 43 ENGINE 37 Cylinder Head Assembly Glow plug (2) Split collar (4) Connector (1) Seal; valve Spring seat (5) Guide; valve Valve spring (6) Studs are applied with sealing agent. Do not pull them out. (5 locations) Nozzle holder (3) Valve (7) Hot plug Seat;...
  • Page 44 ENGINE Timing Gear Bearing Wear ring Cam shaft (8) Bearing Snap ring (7) Cam gear (6) Fly weight ASM (5) Shaft; idle gear (3) Lock nut Idle gear (2) Sleeve (4) Thrust collar Crankshaft Crank gear Crank pulley (1) Washer Fig.
  • Page 45 ENGINE 39 Timing gear Remove the idle gear and the idle gear shaft. Pull out the sleeve from the tip end of the cam shaft. Remove the lock nut of the cam shaft gear, and then remove the flyweight assembly and the cam gear. Camshaft Remove the snap ring which holds down the front Crankshaft...
  • Page 46 ENGINE Piston and Connecting Rod Piston ring (4) Snap ring (5) Piston Bush (The drawing-out of the bush must Piston pin (6) be limited to only when replaced.) Con'rod bolt (The drawing-out of the con'rod bolt must be limited to only when replaced.) Connecting rod (7) Cap (2) Bearing (3)
  • Page 47 ENGINE 41 Piston ring Remove the piston ring with a ring pliers. Pliers: piston ring 1-85221-029-0 Fig. 56 Piston pin Brass bar Remove the snap rings with a commercially avail- able tool. With a brass bar attached to the piston pin, push it out by hammering it lightly.
  • Page 48 Measurement position: 13mm below the top (Measure in X-X and Y-Y directions.) (Near the No. 1 compression ring) mm (in.) Engine Limit Repair method 4LB1 Perform boring and Fig. 59 honing of the inner 4LC1 0.2 (0.0079) diameter. 4LE1 Cylinder bore diameter and grade mark...
  • Page 49 ENGINE mm (in.) Engine Bore Diameter Grade 77.400 – 77.410 (3.0472 – 3.0476) 4LB1 77.411 – 77.420 4LC1 (3.0476 – 3.0480) 77.421 – 77.430 (3.0480 – 3.0484) 85.000 – 85.010 (3.3464 – 3.3468) 85.011 – 85.020 4LE1 (3.3468 – 3.3472) 85.021 –...
  • Page 50 0.075 (0.0029) 0.15 (0.0059) 0.3 (0.0118) Fig. 66 Cylinder Head Height H (Reference) mm (in.) Engine Standard 4LB1 63.90 – 64.10 4LC1 (2.515 – 2.523) 4LE1 Note: If the cylinder head lower face is reground, valve depression must be checked.
  • Page 51 ENGINE HOT PLUG Hot Plug Depression Clean the cylinder head lower face, taking care not to damage the hot plug surfaces. Use a straight edge and a feeler gauge to measure the hot plug depression in a straight line from the No.
  • Page 52 ENGINE Hot Plug Installation Align the hot plug knock ball 1 with the cylinder head groove 2 and tap it temporarily into position with a plastic hammer. Fig. 71 Place a metal plate 3 approximately 25 mm (1 in) thick over the hot plug upper surface 4. Use a bench press 5 to exert a pressure of 4,000 –...
  • Page 53 ENGINE Heat Shield Installation Install the heat shield to the cylinder head from the noz- zle holder installation hole side. Lightly tap the heat shield flange into place with a hammer and a brass bar. The heat shield flange side must be facing up. Note: Always install a new heat shield.
  • Page 54 ENGINE Valve Seat Insert Replacement Valve Seat Insert Removal Arc weld the entire inside circumference 1 of the valve seat insert 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.
  • Page 55 ENGINE Apply abrasive compound to the valve seat insert surface. Insert the valve into the valve guide. Apply light pressure to the valve while turning it to fit the valve seat insert. Check that the valve contact width is correct. Check that the valve seat insert surface is in contact with the entire circumference of the valve.
  • Page 56 ENGINE 5. TAPPET (Cam Follower or Valve Lifter) AND PUSH ROD TAPPET Inspect the tappets for excessive wear, damage and any abnormalities. Use a micrometer to measure the tappet diameter. mm (in.) Standard 20.967 – 20.980 Tappet Diameter (0.82547 – 0.82598) Fig.
  • Page 57 ENGINE 6. CAM SHAFT Inspection of cam shaft Check the journal and the cam for evidence of wear, Camshaft damage or any other defect. Note: With the front and rear parts of camshaft pressed in with ball bearings, and with the cylinder block pressed in with roller bearings as the center bearing, check to see if the camshaft rotates smoothly with no play at each bearing.
  • Page 58 ENGINE 7. ROCKER ARM SHAFT AND ROCKER ARM Inspect all disassembled parts for wear, damage and any abnormalities. Fig. 94 Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm outside diameter. If the measured value is less than the specified limit, the shaft must be replaced.
  • Page 59 Grade mark (Stamped) piston. mm (in.) Model Outside diameter of piston Grade 77.375 – 77.385 (3.0462 – 3.0466) 4LB1 77.386 – 77.395 4LC1 (3.0467 – 3.0470) Fig. 99 77.396 – 77.405 (3.470 – 3.0474) 84.975 – 84.985 (3.3454 – 3.3458) 84.986 –...
  • Page 60 Clearance between piston pin and piston pin hole mm (in.) Standard 0.002 – 0.012 4LB1, 4LC1, 4LE1 (0.00008 – 0.00047) Piston ring gap With the ring inserted into the cylinder bore, push it in with the piston head so that it becomes a right angle to the cylinder, and then measure the gap of the piston ring.
  • Page 61 ENGINE 4LE1 mm (in.) Standard Limit 0.085 – 0.105 compression ring (0.0033 – 0.0041) (0.0078) 0.050 – 0.085 compression ring (0.0020 – 0.0033) 0.15 0.030 – 0.070 (0.0059) Oil ring (0.0011 – 0.0027)
  • Page 62 If the tension is insufficient, the bearing must be replaced. Tighten the connecting rod and the bearing cap to the specified torque. kg·m (ft. lbs.) Fig. 105 3.8 – 4.2 4LB1, 4LB1T (27 – 30) 2.3 – 2.7 Tightening (17 – 20) 4LC1 torque ↓...
  • Page 63 ENGINE 10.CRANKSHAFT AND CRANKSHAFT BEARING Outside diameters of journal and pin If worn beyond the limits-replace Crank journal mm (in.) Standard Limit 4LB1 56.0 (2.2047) 55.86 (2.1992) 4LC1 4LE1 60.0 (2.3622) 59.86 (2.3567) Crank pin mm (in.) Fig. 107 Standard...
  • Page 64 ENGINE Oil seal Timing gear case When the lip of an oil seal is found defective, replace it with a new one. Installation Use the crankshaft front oil seal installer to install the Front oil seal crankshaft front oil seal. Fig.
  • Page 65 ENGINE REASSEMBLY 1. CYLINDER HEAD ASSEMBLY Glow plug (7) Connector (8) Seat valve (1) Split cillar (5) Spring seat (4) Apply Locktite No.262 Valve spring (3) to this portion. (5 locations) Nozzle holder (6) Valve (2) Hot plug Seat; Valve insert Fig.
  • Page 66 ENGINE Intake and Exhaust Valve Springs Install the valve springs with their painted end (the close pitched end) facing down. Painted potion Fig. 119 Spring Seat Split Collar Spring compressor Split collar Use a spring compressor to push the valve spring into position.
  • Page 67 Install the connecting rod to the piston with setting the marks as illustrated. Install the piston pin into the piston and the connect- ing rod bushing. Fig. 124 Grade mark (Hot plug side) Front mark Engine front direction Isuzu mark Cylinder number stamped side Fig. 125...
  • Page 68 ENGINE Piston Pin Snap Ring Use a pair of snap ring pliers to install the piston pin snap ring. Check that the piston moves smoothly on the piston pin. Fig. 126 Piston Ring 1 st Use a piston ring installer to install the three piston rings.
  • Page 69 ENGINE 3. INTERNAL PARTS Reassembly Steps (1) Crankshaft (2) Piston Assembly (3) Rear Seal Retainer (4) Camshaft (5) Cam Gear (6) Idler gear and Shaft (7) Oil Pump Assembly (8) Timing Gear Case (Without PTO) (9) Flywheel Housing (10) Flywheel (11) Crank Pulley (12) Oil Pipe (13) Oil Strainer...
  • Page 70 ENGINE Internal Parts (1/3) (13) ※ (10) (12) (11) (14) Fig. 128...
  • Page 71 ENGINE Internal Parts (2/3) (19) (20) (18) (17) (15) (20) (16) Fig. 129...
  • Page 72 ENGINE Internal Parts (3/3) (8-1) (8-2) Fig. 130...
  • Page 73 ENGINE Crankshaft bearing With oil hole Fit correctry and groove Note that there is an oil hole and an oil groove in the (Upper) upper bearing (on the block side), but not in the lower bearing (on the bearing cap side). Fit the bearing tang firmly into the slot machined on the cylinder body bearing arches.
  • Page 74 Set the bearing cap cylinder number marks and the con- necting rod cylinder number marks. The marks must be facing the injection pump side. kg·m (ft. lbs.) 3.8 – 4.2 Cylinder No. 4LB1 (27 – 30) 2.3 – 2.7 Tightening (17 – 20) 4LC1 torque ↓...
  • Page 75 ENGINE Camshaft assembly Apply engine oil to the inside of the bearing of the cylinder block, and then install the camshaft assembly. Note: When installing the assembly, care should be taken not to damage the bearing. After installation of the snap ring to the outside of the front bearing, check to see if the camshaft rotates smoothly.
  • Page 76 ENGINE Oil pump assembly When PTO is not provided, install the oil pump Cylinder block assembly to the cylinder block. PTO not provided kg·m (ft. lbs.) Tightening torque 1.9 – 2.9 (14.0 – 21.0) Fig. 142 When PTO is provided, install the oil pump to the front plate.
  • Page 77 ENGINE Timing gear case (with governor) Governor cover When not provided with PTO, install the timing gear case to the cylinder block. When provided with PTO, install it to the front plate. Timing gear case Put the link plate of the governor incorporated in the gear case through the connecting hole of the injection pump in advance.
  • Page 78 ENGINE Crank pulley Lubricate the lip of the front, seal with oil Install the crank pulley, lock the crankshaft and tighten Crankshaft the front bolt. kg·m (ft. lbs.) Crank pulley Tightening torque 17.0 – 19.0 (123.0 – 137.0) Washer Front oil seal Fig.
  • Page 79 ENGINE Cylinder head assembly Lubricate the bolts with oil. Tighten the bolts in the sequence shown in the illustra- tion to the specified torque. kg·m (ft. lbs.) Bolt size Tightening torque M12 × 1.5 8.5 – 9.5 60°〜90° (8 each) (61 –...
  • Page 80 ENGINE Adjustment of valve clearance Refer to Section “General Information – Maintenance” (on page 21). Front hanger and rear hanger Rear hanger Tighten them to the specified torque shown below. kg·m (ft. lbs.) Tightening torque 1.9 – 2.9 (14.0 – 21.0) Front hanger Fig.
  • Page 81 ENGINE 4. EXTERNAL PARTS (Right-hand Side) Fig. 157 (1) Dipstick (2) Oil Filter (3) Injection Pump (4) Injection Pump Housing Cover (5) Fuel Pipe (6) Leak Off Pipe (7) Fuel Hose (8) Injection Pipe...
  • Page 82 ENGINE 5. EXTERNAL PARTS (Left-hand Side) (11) (10) (17) (12) (16) (16) (13) (14) Fig. 158 (9) Water Pump (10) Thermostat and Water Outlet Pipe (11) Cylinder Head Cover (12) Exhaust Manifold (13) Starter (14) Generator (15) Fan Pulley (16) Fan Belt (17) Cooling Fan...
  • Page 83 ENGINE Dipstick Dipstick Oil filter (cartridge) Cartridge Insert the dipstick. Install the cartridge with a filter wrench (commer- cially available). (1) Apply engine oil thinly to the gasket of the cartridge. (2) Screw in the cartridge until the gasket comes into contact with the seal, and then tighten it by giving it about 3/4 turns.
  • Page 84 ENGINE Injection pump housing cover After applying sealant (TB1207C) to the housing cover, Housing cover install it to the cylinder block by the side of the injection pump. kg·m (ft. lbs.) Tightening torque 0.8 – 1.2 (6.0 – 9.0) Note: The areas of the housing cover to which liquid gasket is applied are about 4 mm in width from the cover edge Fig.
  • Page 85 ENGINE Fuel pipe Leak off pipe Leak off pipe Install the fuel pipe to the injection pump and then tighten it to the specified torque. Install the leak off pipe to the nozzle holder and then Fuel pipe tighten it to the specified torque. kg·m (ft.
  • Page 86 ENGINE Adjustment of valve clearance (Refer to Section “GENERAL INFORMATION – MAINTE- NANCE.”) Cylinder head cover Cylinder cover Install the gasket to the cylinder head cover. Notes: Gasket Much care should be taken for the gasket not to get dislocated or twisted when installing the head cover.
  • Page 87 ENGINE Generator Water pump Tighten the adjust plate together with the water pump, and then install them temporarily. Adjusting plate Install the bottom of the generator to the timing gear case, and then tighten it temporarily with bolts and nuts. Install the fixing bolts onto the top of the generator through the adjusting plate.
  • Page 88 LUBRICATING SYSTEM SECTION 3 LUBRICATING SYSTEM TABLE OF CONTENTS CONTENTS PAGE LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM ........84 OIL PUMP.
  • Page 89 LUBRICATING SYSTEM LUBRICATING OIL CIRCULATION DIAGRAM Valve opening pressure 1kg/cm (14.0 PSI) Oil filter Oil gallery Main bearing Idle gear bush Cylinder head Valve opening Rocker arm pressure Crankshaft Timing gear bracket 4.5kg/cm (64.0 PSI) Connecting rod Governor Rocker shaft Rocker arm Oil pump Injection pump...
  • Page 90 LUBRICATING SYSTEM OIL PUMP With PTO Body; Oil pump Front plate (Body; integral structure) Pin (common) Without PTO Rotor; outer Roter; inner O-ring (common) Relief valve Pump gear Spring Plug Common Oil pump (common) Fig. 180 Inspection and replacement When there is wear, damages or any other defects found, repair or replace the rotor.
  • Page 91 COOLING SYSTEM SECTION 4 COOLING SYSTEM TABLE OF CONTENTS CONTENTS PAGE COOLING WATER CIRCULATION SYSTEM DIAGRAM ........88 WATER PUMP .
  • Page 92 COOLING SYSTEM COOLING WATER CIRCULATION SYSTEM DIAGRAM Bottom bypass type thermostat Cyliner head Cylinder block bypass circuit) Water pump Radiator Fig. 181...
  • Page 93 COOLING SYSTEM WATER PUMP DISASSEMBLY Seal unit Impeller Bearing unit Fan center Cover Body Setscrew Fig. 182 Fan center Cover Cover Loosen the set screw. Remove the cover. Note: The cover is applied with sealant (TB1207B). When re- moving the cover, much care should be taken not to Setscrew Fan center deform it by applying an excessive force to it.
  • Page 94 COOLING SYSTEM REASSEMBLY Bearing unit With a hole in the bearing unit set in line with one in the Align holes body, lock the bearing unit with a setscrew. Body Bearing unit kg·m (ft. lbs.) Set screw tightening torque 0.8 – 1.2 (6.0 – 9.0) Fan center Setscrew Fig.
  • Page 95 COOLING SYSTEM THERMOSTAT Inspection and replacement Replace the thermostat when there is wear, damages or any other defects found. Opening temp. 74.5 – 78.5°C (166 – 174°F) Thermometer 8mm or more at 90°C Valve lift mm (in.) (0.315 inch or more at 194°F) Agitating rod Thermostat Wooden piece...
  • Page 96 FUEL SYSTEM SECTION 5 FUEL SYSTEM TABLE OF CONTENTS CONTENTS PAGE FUEL CIRCULATION SYSTEM DIAGRAM ..........94 GOVERNOR .
  • Page 97 FUEL SYSTEM FUEL CIRCULATION SYSTEM DIAGRAM Fuel tank Nozzle holder Injection pump Nozzle Fuel filter Fig. 189...
  • Page 98 FUEL SYSTEM GOVERNOR The adjustments of the governor-related parts require the engine performance test. Before disassembling the governor, measure the dimensions “A” and “B” given in the structural drawing to ensure the same dimensions in reassembly. Do not disassemble the governor when the performance test cannot be conducted after reassembly. 1.
  • Page 99 FUEL SYSTEM 2. STRUCTURAL DRAWING OF GOVERNOR (2) Start spring Control link Set spring Snap pin Guide lever Floating lever Link plate Cap nut Guide piece Shifter Setscrew Shaft (floating) Main Fuel cut lever Fuel cut shaft spring Return spring Shifter shaft Tensioner O-ring...
  • Page 100 FUEL SYSTEM 3. REASSEMBLY OF CONTROL LEVER RELATED PARTS (1) Put the lever (main spring) through the hole of the timing gear case lever. Note: Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case lever respectively.
  • Page 101 FUEL SYSTEM (6) Assemble the control lever. Assemble the O-ring to the groove of the bushes (control lever) first, and then assemble the washers and the control lever before tightening up the control lever with a nut. kg·m (ft. lbs.) Control lever tightening torque 1.2 –...
  • Page 102 FUEL SYSTEM 4. Reassembly of shifter (1) Assemble the shifter to the guide lever, put the shaft through it, and then assemble the snap ring. (2) After assembly, confirm that the shaft moves smoothly. (3) Also, confirm that the shifter shakes smoothly. Guide lever Shifter Snap ring...
  • Page 103 FUEL SYSTEM 5. Reassembly of governor cover Assemble the related parts such as the fuel cut lever and the idle spring to the governor cover. [Stop] [Operate] Governor cover Return spring Governor (Bent-up part) Thrust washer Idle spring O-ring Shaft Spring washer (Notched groove) Fuel cut lever...
  • Page 104 FUEL SYSTEM 6. Reassembly of full-load stopper Install the full-load stopper to the timing gear case, and then tighten it with a nut temporarily. Timing gear case Full load stopper Nut; setscrew Fig. 197...
  • Page 105 FUEL SYSTEM 7. Reassembly of governor lever related components Assemble each lever and spring to the timing gear case. Main spring lever Lever shaft Tensioner lever Link plate Main spring Eye; start spring Set spring Guide piece Start spring Guide lever Snap pin Plug Floating lever...
  • Page 106 FUEL SYSTEM NOZZLE HOLDER ASSEMBLY DISASSEMBLY Injection pipe Leak off pipe Nozzle holder ASM Spring Packing Body seat Spacer ｝ Shim Nozzle Corrugated Nozzle washer spring Retairing Heat shield Injection pump Gasket Fig. 199 NOZZLE ASSEMBLY Inspection and replacement Place the removed nozzle in the clean light oil, disas- semble it into the nozzle body and the needle valve and clean them thoroughly.
  • Page 107 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING Engine does not start Starter does not run Engine starts but Starter runs but does does not run not start continuously. Check battery Fuel system Fuel injected Engine Air mixed in fuel pump Battery in discharging Check (Charge) compression...
  • Page 108 TROUBLESHOOTING Unstable engine rotation Unstable rotation at Engine does not Unstable engine Idling speed Unstable rotation at medium speed change from high to idling too high high speed (Hunting) low rotation Defective idling Defective control Check fuel for air Check accelerator Governor spring adjustment lever adjustment...
  • Page 109 TROUBLESHOOTING Insufficient output Overheat Fuel system Cooling system Handling Mechanical system Check fuel for air Check cooling Check fan belt Check if oil used mixing water level for slip is inferior quality, Check engine or engine oil is control too much Insufficient Slipping Air mixed...
  • Page 110 TROUBLESHOOTING Abnormal exhaust gas White smoke too much Black smoke too much Air cleaner clogged Check nozzle Check if fuel used is of Check fuel for water inferior quality mixing Replace air Defective cleaner element (Repair or replace) Change fuel Water mixed (Change fuel) Check air hose for crash...
  • Page 111 TROUBLESHOOTING Oil pressure too low Oil consumption too much Oil consumption too much Check oil level Check for oil leakage Check for oil leakage Low (Replenish) Leaking (Retighten, Leaking (Retighten, replace packing seal) replace packing seal) Check cooling water temperature Check nozzle Check oil quality High...
  • Page 112 SPECIAL TOOLS SECTION 7 SPECIAL TOOLS The alphanumeric codes in parentheses “( )” are part numbers assigned by special tool manufacturers. Illustration Part Number Part Name Page 5-8840-2675-0 Compression gauge 5-8840-9026-0 Compression gauge adapter 5-8840-9016-0 Nozzle tester (J-28829) 5-8840-9015-0 Oil filter wrench —...
  • Page 113 CONVERSION TABLE SECTION 8 CONVERSION TABLE TABLE OF CONTENTS ITEM PAGE LENGTH ............... 113 AREA .

  • Page 114: Length

    CONVERSION TABLE LENGTH FEET TO METERS ––– –––0 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 ––– 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 9.144 9.449 9.754 10.058 10.363...

  • Page 115: Area

    CONVERSION TABLE AREA SQUARE INCHES TO SQUARE CENTIMETERS ––– –––00 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 ––– 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 193.548 200.000 206.451...
  • Page 116 CONVERSION TABLE VOLUME GALLONS (U.S.) TO LITERS U.S. gal. U.S.gal. liters liters liters liters liters liters liters liters liters liters ––– –––00 3.7854 7.5709 11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688 ––– 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 75.7085...

  • Page 117: Mass

    CONVERSION TABLE MASS POUNDS TO KILOGRAMS lbs. lbs. ––– –––0 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 ––– 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 13.608 14.061 14.515...

  • Page 118: Pressure

    CONVERSION TABLE PRESSURE POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS lb/in lb/in (psi) kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm (psi) ––– –––0 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 ––– 0.7031 0.7734 0.8437 0.9140 0.9843...

  • Page 119: Torque

    CONVERSION TABLE TORQUE FOOT POUNDS TO KILOGRAMMETERS ft. lbs. ft lbs. kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m ––– –––0 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244 ––– 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627...

  • Page 120: Temperature

    CONVERSION TABLE TEMPERATURE FAHRENHEIT TO CENTIGRADE °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C -51.1 -18.9 13.3 45.6 77.8 110.0 142.2 174.4 -50.0 -17.8 14.4 46.7 78.9 111.1 143.3 175.6 -48.9 -16.7 15.6 47.8 80.0...
  • Page 121 Copyright reserved for this manual may not be reproduced or copied, in whole or in part, without the written consent of ISUZU MOTORS LIMITED. WORKSHOP MANUAL (INDUSTRIAL) 4LB1, 4LC1, 4LE1 (IDE-2270) Issued by ISUZU MOTORS LIMITED ENGINE SALES PLANNING OFFICE...
  • Page 122 IDE-2270 PRINTED IN JAPAN...

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