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Engine
A-4JB1
Workshop manual
Isuzu A-4JB1 Workshop Manual
Industrial diesel engine
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Table Of Contents
232
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
General Repair Instructions
Notes on the Format of this Manual
General Information
Main Data and Specifications
Standard Bolt
Tightening Torque Specifications
Tightening Torque Specifications
Flanged Head Bolt
Special Parts Fixing Nuts and Bolts
Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
Timing Gear Case, Flywheel Housing, Camshaft, and Timing Gear
Cooling and Lubricating System
Intake and Exhaust Manifold
Engine Electrical
Fuel Injection System
Maintenance
Engine Serial Number
Injection Pump Identification
Lubricating System
Main Oil Filter
Model Identification
Fuel Filter
Fuel System
Air Bleeding
Water Separator (Water Sedimentor)
Injection Nozzle
Injection Nozzle Adjustment
Injection Nozzle Inspection
Spray Condition
Cooling Fan Drive Belt
Cooling System
Operating Test
Thermostat
Valve Clearance Adjustment
In-Line Type Injection Pump
Injection Timing
Injection Timing Confirmation Procedure
Distributor Type Injection Pump
Pump Fixing Bolt
Compression Pressure Measurement
Engine Oil Viscosity Chart
Engine Oil Viscosity Grade – Ambient Temperature
Recommended Lubricants
Engine Repair Kit
Section 3. Engine Assembly (1)
Engine Assembly (1)
Disassembly
Fuel Injection Pipe with Clip
Injection Pump
Exhaust Manifold
Injection Nozzle Holder
Rocker Arm Shaft and Rocker Arm
Cylinder Head
Crankshaft Damper Pulley with Dust Seal
Idler Gear
Timing Gear Backlash Measurement
Idler Gear “A” End Play Measurement
Piston and Connecting Rod with Upper Bearing
Connecting Rod Cap with Lower Bearing
Camshaft with Camshaft Timing Gear and Thrust Plate
Flywheel
Crankshaft Bearing Cap with Lower Bearing
Crankshaft Upper Bearing
Tappet
Crankshaft Rear Oil Seal
Single Unit
Rocker Arm Shaft Bracket
Rocker Arm Shaft Snap Ring
Split Collar
Intake and Exhaust Valve
Piston and Connecting Rod
Connecting Rod Bearing
Piston Ring
Piston Pin Snap Ring
Piston Pin
Camshaft, Camshaft Timing Gear, and Thrust Plate
Camshaft Timing Gear
Thrust Plate
Engine Assembly (2)
Cylinder Head Lower Face Warpage
Exhaust Manifold Fitting Face Warpage
Cylinder Head Height (Reference)
Inspection and Repair
Valve Guide
Manifold Fitting Face Warpage
Valve Stem and Valve Guide Clearance
Valve Guide Replacement
Valve and Valve Seat Insert
Valve Guide Installation
Valve Stem Outside Diameter
Valve Thickness
Valve Seat Insert Removal
Valve Seat Insert Replacement
Valve Depression
Valve Contact Width
Valve Seat Insert Installation
Valve Seat Insert Correction
Valve Spring
Valve Spring Free Height
Valve Spring Inclination
Valve Spring Tension
Rocker Arm Shaft and Rocker Arm Clearance
Rocker Arm Shaft Run-Out
Rocker Arm Shaft Outside Diameter
Rocker Arm Correction
Cylinder Body
Cylinder Body Upper Face Warpage
Cylinder Liner Bore Measurement
Cylinder Liner Projection Inspection
Cylinder Body Bore Measurement
Cylinder Liner Removal
Cylinder Liner Grade Selection
Cylinder Liner Replacement
Cylinder Liner Installation
Piston Selection
Piston Grade Selection
Piston Grade
Cylinder Liner and Piston Clearance
Tappet and Push Rod
Tappet Outside Diameter
Push Rod Curvature
Tappet and Cylinder Body Clearance
Camshaft
Camshaft Journal Diameter
Camshaft and Camshaft Bearing
Camshaft Bearing Replacement
Camshaft Run-Out
Cam Height
Camshaft Bearing Installation
Camshaft End Play
Thrust Plate Replacement
Thrust Plate Removal
Crankshaft and Bearing
Crankshaft Tufftriding Inspection
Judgment
Crankshaft Journal and Crankpin Diameter
Crankshaft Run-Out
Bearing Tension
Crankshaft Journal and Bearing Clearance
Connecting Rod Bearing Inside Diameter
Crankpin and Bearing Clearance
Crankshaft Timing Gear Replacement
Crankshaft Timing Gear Removal
Crankshaft Timing Gear Installation
Crankshaft Pilot Bearing Installation
Crankshaft Pilot Bearing Replacement
Crankshaft Pilot Bearing
Flywheel and Ring Gear
Ring Gear
Ring Gear Installation
Piston
Piston Ring Gap
Piston Ring and Piston Ring Groove Clearance
Piston Ring and Piston Ring Groove
Piston Pin Diameter
Piston Pin and Piston Clearance
Connecting Rod Bushing Removal
Connecting Rod Bushing Installation
Connecting Rod Alignment
Idler Gear Shaft and Idler Gear
Connecting Rod Side Face Clearance
Idler Gear Shaft Outside Diameter
Crankshaft Front Oil Seal Replacement
Idler Gear “A” Inside Diameter
Timing Gear Case Cover
Oil Seal Installation
Engine Assembly (3)
Reassembly
Rocker Arm Shaft
Valve Stem Oil Seal
Crankcase
Oil Pump with Oil Pipe
Flywheel Housing
Flywheel Housing Bolt Torque
Oil Pan
Intake Manifold
Lubricating System
Item
Main Data and Specifications
General Description
Lubricating Oil Flow
Oil Pump
Vane and Pump Body Clearance
Oil Filter with Built-In Oil Cooler
Rotor and Vane Clearance
Vane, Rotor, and Cover Clearance
Relief Valve
Oil Cooler
Relief Vale
Cooling System
Item
Main Data and Specifications
Coolant Flow
General Description
Water Pump
Water Pump
Bearing Unit
Cooling Fan Center
Impeller and Seal Unit
Set Screw
Thermostat
Fuel System
Item
Main Data and Specifications
General Description
Fuel Filter and Water Separator
Injection Nozzle
Injection Nozzle Needle Inspection
Nozzle Body and Needle Valve Inspection
Nozzle Lapping Procedure
Injection Pump Data
Injection Volume Adjustment
Governor Adjustment
Injection Quantity
Full Adjustment
Speed Lever Angle
Section 9. Engine Electricals
Engine Electricals
Starter Identification
Armature
Armature Short Circuit Test
Armature Winding Ground Test
Armature Winding Continuity Test
Commutator Run-Out Test
Commutator Outside Diameter Measurement
Commutator Outside Diameter
Segment Mica Depth Measurement
Field Winding Continuity Test
Brush and Brush Holder
Field Winding Ground Test
Yoke
Brush Spring Inspection
Brush Holder Insulation Test
Pinion Clutch
Pinion Inspection
Pinion
Dust Cover
Shift Lever
Torsion Spring
Through Bolt
Lead Wire
Inspection after Reassembly
When Pinion Gap Deviates from Specified Value
Alternator
Alternator Identification
Rectifier with Brush Holder
Rotor and Bearing
Front Cover
Pulley and Fan
Ball Bearing
Rotor Coil Continuity Test
Rotor Coil Ground Test
Stator Coil Continuity Test
Stator Coil Ground Test
Rectifier (Positive Diode) Continuity Test
Rectifier (Negative Diode) Continuity Test
Rectifier Assembly Replacement Procedure
Brush
Section 10. Troubleshooting
Hard Starting
Starter Inoperative
Starter Operates but Engine Does Not Turn over
Engine Turns over but Does Not Start
Fuel Is Not Being Delivered to the Injection Pump
Fuel Is Being Delivered to the Injection Pump
Unstable Idling
Unstable Idling
Insufficient Power
Excessive Fuel Consumption
Excessive Oil Consumption
Overheating
White Exhaust Smoke
Dark Exhaust Smoke
Oil Pressure Does Not Rise
Abnormal Engine Noise
Engine Knocking
Continuous Noise
Gas Leakage Noise
Slapping Noise
Section 11. Special Tool List
Special Tool List
General Rules
Section 12. Repair Standards
Millimeters to Inches
Inches to Millimeters
Section 13. Conversion Table
Feet to Meters
Length
Meters to Feet
Miles to Kilometers
Area
Cubic Centimeters to Cubic Inches
Cubic Inches to Cubic Centimeters
Square Centimeters to Square Inches
Square Inches to Square Centimeters
Volume
Gallons (Imp.) to Liters
Gallons (U.s.) to Liters
Liters to Gallons (Imp.)
Liters to Gallons (U.s.)
Kilograms to Newton
Kilograms to Pounds
Mass
Newton to Kilograms
Pounds to Kilograms
Kilo Pascal to Kilograms Per Square Centimeters
Kilograms Per Square Centimeters to Kilo Pascal
Kilograms Per Square Centimeters to Pounds Per Square Inches
Pounds Per Square Inches to Kilograms Per Square Centimeters
Pressure
Foot Pounds to Kilogrammeters
Kilogrammeters to Foot Pounds
Kilogrammeters to Newtonmeters
Torque
Temperature
Fahrenheit to Centigrade
Centigrade to Fahrenheit
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Quick Links
1
Tightening Torque Specifications
2
Valve Clearance Adjustment
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INDUSTRIAL
DIESEL ENGINE
A-4JA1, A-4JB1
MODELS
WORKSHOP MANUAL
©
2003 ISUZU MOTORS LIMITED
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