Isuzu 4JH1 Manuals

Manuals and User Guides for Isuzu 4JH1. We have 1 Isuzu 4JH1 manual available for free PDF download: Workshop Manual

Isuzu 4JH1 Workshop Manual

Isuzu 4JH1 Workshop Manual (564 pages)

Brand: Isuzu | Category: Engine | Size: 10 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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