Isuzu 4ja1 Manuals

Isuzu 4ja1 Manuals

Manuals and User Guides for Isuzu 4ja1. We have 2 Isuzu 4ja1 manuals available for free PDF download: Workshop Manual

Isuzu 4ja1 Workshop Manual

Isuzu 4ja1 Workshop Manual (564 pages)

Brand: Isuzu | Category: Engine | Size: 10.51 MB

Table of Contents

Section 6A Engine Mechanical

23
- Table of Contents
  23
- Main Data and Specifications
  26
- Torque Specification
  30
  - Standard Bolts
    30
  - Special Parts Fixing Nuts and Bolts
    31
- Recommended Liquid Gasket
  44
- LOCTITE Application Procedure
  45
- Servicing
  46
  - Model Identification
    46
  - Air Cleaner
    46
  - Lubricating System
    46
  - Fuel System
    47
  - Cooling System
    49
  - Valve Clearance Adjustment
    53
  - Compression Pressure Measurement
    54
- General Description
  58
- Removal and Installation
  59
  - Removal
    59
  - Installation
    62
    
    Coolant Replenishment
    63
    
    Engine Warm-Up
    63
- Engine Repair Kit
  64
- Engine Overhaul
  65
  - Removal
    65
    
    External Parts
    65
  - Disassembly
    69
    
    Internal Parts
    69
    
    Major Components
    69
    
    Minor Components
    78
    
    Rocker Arm Shaft and Rocker Arm
    78
    
    Cylinder Head
    79
    
    Piston and Connecting Rod
    81
  - Inspection and Repair
    83
    
    Cylinder Head
    83
    
    Rocker Arm Shaft and Rocker Arm
    90
    
    Cylinder Body
    91
    
    Camshaft
    99
    
    Crankshaft and Bearing
    101
    
    Crankshaft Bearing Selection
    105
    
    Crankshaft Pilot Bearing
    107
    
    Flywheel and Ring Gear
    107
    
    Piston
    108
    
    Cylinder Head Gasket Selection
    110
    
    Connecting Rod
    112
    
    Idler Gear Shaft and Idler Gear
    113
    
    Timing Gear Case Cover
    113
  - Reassembly
    115
    
    Internal Parts
    115
    
    Minor Component
    115
    
    Rocker Arm Shaft and Rocker Arm
    115
    
    Cylinder Head
    116
    
    Piston and Connecting Rod
    118
    
    Positive Crankcase Ventilation (PCV) Valve
    121
    
    Major Component
    123
  - Installation
    140
    
    External Parts
    140
- Lubrication System
  148
  - Lubricating Flow
    148
  - Oil Pump and Oil Filter
    149
  - Oil Pump
    150
    
    Disassembly
    150
    
    Inspection and Repair
    151
    
    Reassembly
    152
  - Oil Filter and Oil Cooler
    153
    
    Disassembly
    153
    
    Inspection and Repair
    154
    
    Reassembly
    155
- Inter Cooler
  157
  - Removal
    158
  - Installation
    158
- Special Tools
  159
Section 6B Engine Cooling

163
- Main Data and Specifications
  165
  - General Description
    166
  - Coolant Flow
    166
  - Water Pump
    167
  - Thermostat
    167
  - Radiator
    168
- Diagnosis
  169
- Draining and Refilling Cooling System
  170
- Water Pump
  172
  - Removal and Installation
    172
  - Removal
    172
  - Inspection and Repair
    173
  - Installation
    173
- Thermostat
  175
  - Removal and Installation
    175
  - Removal
    175
  - Inspection and Repair
    175
  - Installation
    176
- Radiator
  177
  - Removal and Installation
    177
  - Radiator and Associated Parts
    177
  - Removal
    178
  - Inspection and Repair
    179
  - Installation
    180
Section 6C Fuel System

183
- Main Data and Specifications
  184
- General Description
  185
  - Fuel Flow
    185
  - Fuel Filter and Water Separator
    186
  - Injection Pump
    188
  - Injection Nozzle
    189
- Fuel Tank
  190
  - Removal
    191
  - Installation
    191
- Fuel Gauge Unit
  193
  - Removal
    194
  - Installation
    194
- Fuel Tube / Quick - Connector Fittings
  196
- Filler Neck
  198
  - Removal
    198
  - Installation
    198
- Fuel Filler Cap
  199
- Injection Pump
  200
  - Removal and Installation
    200
  - Removal
    200
  - Installation
    203
- Injection Nozzle (4JA1L)
  207
  - Disassembly
    207
  - Reassembly
    208
- Special Tools
  219
Section 6D Engine Electrical

221
- Main Data and Specifications
  222
- General Description
  223
- Torque Specifications
  225
- Generator
  227
  - Removal and Installation
    227
  - Disassembly
    229
  - Inspection and Repair
    232
  - Reassembly
    238
- Starter Motor
  242
  - Removal and Installation
    242
  - Disassembly
    243
  - Inspection and Repair
    246
  - Reassembly
    249
- Pre-Heating System
  253
  - Inspection and Repair
    253
  - Glow Relay
    253
  - Glow Plug
    253
  - EGR System
    253
Section 6F Exhaust System

537
- Main Data and Specifications
  538
- General Description
  539
- Removal and Installation
  540
- Inspection and Repair
  542
- General Description
  543
- EGR System Diagram
  545
- Inspection
  547
- EGR Cooler (4JA1TC/4JH1TC Euro-III Model)
  548
- Main Data and Specifications
  551
- Turbocharger
  551
- General Description
  552
- Inspection and Repair
  553
- Special Tools
  555
- IHI Service Network
  556
  - Removal and Installation
    558
    
    Inspection
    562
    
    Installation
    562
    
    Removal
    562

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Isuzu 4ja1 Workshop Manual

Isuzu 4ja1 Workshop Manual (232 pages)

INDUSTRIAL DIESEL ENGINE

Brand: Isuzu | Category: Engine | Size: 5.91 MB

Table of Contents

Table of Contents
3
General Information
4
General Repair Instructions
5
Notes on the Format of this Manual
5
General Information
7
Main Data and Specifications
9
Standard Bolt
10
Tightening Torque Specifications
10
Maintenance
20
- Engine Serial Number
  21
- Injection Pump Identification
  21
- Lubricating System
  21
- Main Oil Filter
  21
- Model Identification
  21
- Fuel Filter
  22
- Fuel System
  22
  - Air Bleeding
    23
  - Water Separator (Water Sedimentor)
    23
  - Injection Nozzle
    24
  - Injection Nozzle Adjustment
    24
  - Injection Nozzle Inspection
    24
  - Spray Condition
    24
  - Cooling Fan Drive Belt
    25
- Cooling System
  25
  - Operating Test
    25
  - Thermostat
    25
- Valve Clearance Adjustment
  26
- In-Line Type Injection Pump
  27
- Injection Timing
  27
- Compression Pressure Measurement
  29
  - Engine Oil Viscosity Chart
    30
  - Engine Oil Viscosity Grade – Ambient Temperature
    30
- Recommended Lubricants
  30
- Engine Repair Kit
  31
Section 3. Engine Assembly (1)
32
Engine Assembly (1)
32
Disassembly
34
- Fuel Injection Pipe with Clip
  35
- Injection Pump
  35
- Exhaust Manifold
  35
- Injection Nozzle Holder
  38
- Rocker Arm Shaft and Rocker Arm
  38
- Cylinder Head
  38
- Crankshaft Damper Pulley with Dust Seal
  39
- Idler Gear
  39
- Timing Gear Backlash Measurement
  39
- Idler Gear “A” End Play Measurement
  39
- Piston and Connecting Rod with Upper Bearing
  40
- Connecting Rod Cap with Lower Bearing
  40
- Camshaft with Camshaft Timing Gear and Thrust Plate
  40
- Flywheel
  40
- Crankshaft Bearing Cap with Lower Bearing
  41
- Crankshaft Upper Bearing
  41
- Tappet
  41
- Crankshaft Rear Oil Seal
  41
- Single Unit
  42
- Rocker Arm Shaft Bracket
  43
- Rocker Arm Shaft Snap Ring
  43
- Split Collar
  45
- Intake and Exhaust Valve
  45
- Piston and Connecting Rod
  46
- Connecting Rod Bearing
  47
- Piston Ring
  47
- Piston Pin Snap Ring
  47
- Piston Pin
  47
- Camshaft, Camshaft Timing Gear, and Thrust Plate
  48
- Camshaft Timing Gear
  49
- Thrust Plate
  49
Engine Assembly (2)
50
Inspection and Repair
51
- Valve Guide
  52
- Manifold Fitting Face Warpage
  52
- Valve Stem and Valve Guide Clearance
  52
- Valve Guide Replacement
  52
- Valve and Valve Seat Insert
  53
- Valve Guide Installation
  53
- Valve Stem Outside Diameter
  53
- Valve Thickness
  53
- Valve Seat Insert Removal
  54
- Valve Seat Insert Replacement
  54
- Valve Depression
  54
- Valve Contact Width
  54
- Valve Seat Insert Installation
  55
- Valve Seat Insert Correction
  55
- Valve Spring
  56
- Valve Spring Free Height
  56
- Valve Spring Inclination
  56
- Valve Spring Tension
  56
- Rocker Arm Shaft and Rocker Arm Clearance
  57
- Rocker Arm Shaft Run-Out
  57
- Rocker Arm Shaft Outside Diameter
  57
- Rocker Arm Correction
  58
- Cylinder Body
  58
- Cylinder Body Upper Face Warpage
  58
- Cylinder Liner Bore Measurement
  59
- Cylinder Liner Projection Inspection
  59
- Cylinder Body Bore Measurement
  60
- Cylinder Liner Removal
  60
- Cylinder Liner Grade Selection
  60
- Cylinder Liner Replacement
  60
- Cylinder Liner Installation
  61
- Piston Selection
  62
- Piston Grade Selection
  63
- Piston Grade
  63
- Cylinder Liner and Piston Clearance
  63
- Tappet and Push Rod
  64
- Tappet Outside Diameter
  64
- Push Rod Curvature
  65
- Tappet and Cylinder Body Clearance
  65
- Camshaft
  65
- Camshaft Journal Diameter
  65
- Camshaft and Camshaft Bearing
  66
- Camshaft Bearing Replacement
  66
- Camshaft Run-Out
  66
- Cam Height
  66
- Camshaft Bearing Installation
  67
- Camshaft End Play
  67
- Thrust Plate Replacement
  67
- Thrust Plate Removal
  67
- Crankshaft and Bearing
  68
- Crankshaft Tufftriding Inspection
  68
- Judgment
  68
- Crankshaft Journal and Crankpin Diameter
  69
- Crankshaft Run-Out
  69
- Bearing Tension
  69
- Crankshaft Journal and Bearing Clearance
  70
- Connecting Rod Bearing Inside Diameter
  70
- Crankpin and Bearing Clearance
  71
- Crankshaft Timing Gear Replacement
  73
- Crankshaft Timing Gear Removal
  73
- Crankshaft Timing Gear Installation
  73
- Crankshaft Pilot Bearing Installation
  74
- Crankshaft Pilot Bearing Replacement
  74
- Crankshaft Pilot Bearing
  74
- Flywheel and Ring Gear
  75
- Ring Gear
  75
- Ring Gear Installation
  76
- Piston
  76
- Piston Ring Gap
  76
- Piston Ring and Piston Ring Groove Clearance
  77
- Piston Ring and Piston Ring Groove
  77
- Piston Pin Diameter
  78
- Piston Pin and Piston Clearance
  78
- Connecting Rod Bushing Removal
  78
- Connecting Rod Bushing Installation
  79
- Connecting Rod Alignment
  79
- Idler Gear Shaft and Idler Gear
  80
- Connecting Rod Side Face Clearance
  80
- Idler Gear Shaft Outside Diameter
  80
- Crankshaft Front Oil Seal Replacement
  81
- Idler Gear “A” Inside Diameter
  81
- Timing Gear Case Cover
  81
- Oil Seal Installation
  82
Engine Assembly (3)
84
Reassembly
85
- Rocker Arm Shaft
  86
- Valve Stem Oil Seal
  88
- Crankcase
  100
- Oil Pump with Oil Pipe
  101
- Flywheel Housing
  101
- Flywheel Housing Bolt Torque
  101
- Oil Pan
  102
- Intake Manifold
  108
Lubricating System
112
- Item
  113
- Main Data and Specifications
  113
- General Description
  114
- Lubricating Oil Flow
  114
- Oil Pump
  117
- Vane and Pump Body Clearance
  118
- Oil Filter with Built-In Oil Cooler
  120
- Rotor and Vane Clearance
  118
- Vane, Rotor, and Cover Clearance
  118
- Relief Valve
  121
- Oil Cooler
  121
- Relief Vale
  123
Cooling System
124
- Item
  125
- Main Data and Specifications
  125
- Coolant Flow
  126
- General Description
  126
- Water Pump
  127
- Water Pump
  128
  - Bearing Unit
    130
  - Cooling Fan Center
    132
  - Impeller and Seal Unit
    132
  - Set Screw
    132
- Thermostat
  134
Fuel System
136
- Item
  137
- Main Data and Specifications
  137
- General Description
  138
- Fuel Filter and Water Separator
  140
- Injection Nozzle
  141
- Injection Pump Data
  146
- Injection Volume Adjustment
  146
- Governor Adjustment
  147
- Injection Quantity
  147
- Full Adjustment
  147
- Speed Lever Angle
  148
- Section 9. Engine Electricals
  150
Engine Electricals
150
- Starter Identification
  151
- Armature
  157
- Armature Short Circuit Test
  157
- Armature Winding Ground Test
  157
- Armature Winding Continuity Test
  157
- Commutator Run-Out Test
  158
- Commutator Outside Diameter Measurement
  158
- Commutator Outside Diameter
  158
- Segment Mica Depth Measurement
  158
- Field Winding Continuity Test
  159
- Brush and Brush Holder
  159
- Field Winding Ground Test
  159
- Yoke
  159
- Brush Spring Inspection
  160
- Brush Holder Insulation Test
  160
- Pinion Clutch
  160
- Pinion Inspection
  160
- Pinion
  163
- Dust Cover
  163
- Shift Lever
  163
- Torsion Spring
  163
- Through Bolt
  164
- Lead Wire
  164
- Inspection after Reassembly
  164
- When Pinion Gap Deviates from Specified Value
  164
- Alternator
  165
- Alternator Identification
  165
- Rectifier with Brush Holder
  169
- Rotor and Bearing
  169
- Front Cover
  169
- Pulley and Fan
  169
- Ball Bearing
  170
- Rotor Coil Continuity Test
  171
- Rotor Coil Ground Test
  171
- Stator Coil Continuity Test
  171
- Stator Coil Ground Test
  172
- Rectifier (Positive Diode) Continuity Test
  172
- Rectifier (Negative Diode) Continuity Test
  173
- Rectifier Assembly Replacement Procedure
  173
- Brush
  174
Section 10. Troubleshooting
178
- Hard Starting
  180
- Unstable Idling
  184
- Unstable Idling
  186
- Insufficient Power
  187
- Excessive Fuel Consumption
  191
- Excessive Oil Consumption
  193
- Overheating
  194
- White Exhaust Smoke
  196
- Dark Exhaust Smoke
  197
- Oil Pressure Does Not Rise
  198
- Abnormal Engine Noise
  200
- Engine Knocking
  200
- Continuous Noise
  201
- Gas Leakage Noise
  201
- Slapping Noise
  202
Section 11. Special Tool List
204
- Special Tool List
  205
- General Rules
  208
Section 12. Repair Standards
208
- Millimeters to Inches
  222
- Inches to Millimeters
  222
Section 13. Conversion Table
222
- Feet to Meters
  223
- Length
  223
  - Meters to Feet
    223
  - Miles to Kilometers
    223
- Area
  224
- Volume
  224
  - Gallons (Imp.) to Liters
    225
  - Gallons (U.s.) to Liters
    225
  - Liters to Gallons (Imp.)
    225
  - Liters to Gallons (U.s.)
    225
  - Kilograms to Newton
    226
  - Kilograms to Pounds
    226
- Mass
  226
- Pressure
  227
  - Foot Pounds to Kilogrammeters
    228
  - Kilogrammeters to Foot Pounds
    228
  - Kilogrammeters to Newtonmeters
    228
- Torque
  228
- Temperature
  229
- Fahrenheit to Centigrade
  229
- Centigrade to Fahrenheit
  229

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